“Preserving Competiveness in Today’s Economic Preserving Competiveness in Today’s...

Clinton E. Carter

DallasJanuary 13, 2017

“Advanced Monitoring & Diagnostics”

“Preserving Competiveness in Today’s Economic Reality”

The Imperative for Digital Transformation

The Revolution

“We stand on the brink of a technological revolution that will fundamentallyalter the way we live, work and relate to one another.

In its scale, scope and complexity, the transformation will be unlike anythinghumankind has experienced before…”

“The 4th Industrial Revolution”

https://www.youtube.com/watch?v=6ZOkoRuV1R0

Klaus SchwabFounder and Executive Chairman, World Economic Forum

4th Industrial Revolution –

1st Industrial RevolutionMechanization

> Water <> Steam <

2nd Industrial RevolutionMass Production

> Electric Energy <> Division of Labor <

3nd Industrial RevolutionComputer & Automation

> Electronics <> Information Technology <

1800 1900 1970 2000 2016

4th Industrial RevolutionCyber Physical Systems> Cyber Intelligence <

> Physical Production Systems <

Linear to Exponential Evolution

Sputnik to Uber

Industry transformation has become a matter of survival..!

DisruptiveTechnologies are

nowDemonetizing

theElectric Utility

Industry…

$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$...

...................................

Analog

Digital

Condition BasedMaintenance

PredictiveMaintenance

MachineLearning

Broke/Fix

PreventiveMaintenance

Fault SignatureAnalytics

Pattern Recognition& Codification

AutonomousOperation

Fleet WideInternet

National

Global CooperationThe Cloud

Social Media

Main Frame Computing

Personal Computing

Standards

Legislation

Industry Self-Regulation

Regulation

SCADA

BroadbandWireless

Nano-Technologies

Microwave

Satellite

The “Industrial Internet of Things” – is enabling a new age of Operational Excellenceacross the electric utility industry

Prognostics

Advanced Monitoring& Diagnostics

Alarm /Response

Evolution & Convergence

Semi-AutomatedData Collection &

Control

Drone/RoboticData Collection

Manual DataCollection

Cyber-BasedOperators

Manual PlantControl

http://2.bp.blogspot.com/_ynOO15XuGnc/SgySzwJMbaI/AAAAAAAABQs/XfhT3c_Nswc/s400/1+caveman.jpg

Power Optimization Center

State-of-the-Art Advanced Monitoring & Diagnostics

…while enabling real-time Operations Support and meaningful Cost Reductions

Advanced Monitoring & Diagnostics drives Fleet Performance improvements…

Plants We Serve:Type Units MWCoal 20 11,000Gas 26 3,400Nuclear 2 2,340

16,740

11 Years Experience

Operations

Maintenance

Engineering

BigData

ActionableIntelligence

AdvancedMonitoring & Diagnostics


Nuclear

Coal

Natural Gas

Increase Generation

Optimize Performance

Reduce Cost

Circulating Water Pumps

Heater Drain Pumps

Condensate Pumps

Turbine / Generator

The system is expanded to monitor emerging equipment challenges

Reactor

SteamGenerators

MainCondenser

ReactorContainment

Heater DrainTanks

EHC Motors

Turbine Plant CoolingWater Pumps

Control RodDrive M/G

Sets

POC also deploys highly flexible wireless monitoring solutions…

Main Feedwater Pumps


Recent Success Stories

POWER OPTIMIZATION CENTER: SUCCESS STORIES

Primary Air FanComponent

“The shot heard ‘round the world…”


Primary Air Fan

High Vibration

Component

POC Indication



Primary Air Fan

High Vibration

Plant notification and subsequent investigation

Component

POC Indication

Action Taken



Primary Air Fan

High Vibration


Added oil, replaced bearing during planned outage

Component

POC Indication

Action Taken

Corrective Action



Primary Air Fan

High Vibration


Added oil, replaced bearing during planned outage

Plant Derate: 50% load, 48 hours

Component

POC Indication

Action Taken

Corrective Action

Consequence Avoided



Component Main Power Transformer


Component

POC Indication

Main Power Transformer

High Winding Temperatures


Component

POC Indication

Action Taken





Component

POC Indication

Action Taken

Corrective Action




Cooling pumps and fans returned to service


Component

POC Indication

Action Taken

Corrective Action

Consequence Avoided




Cooling pumps and fans returned to service

Catastrophic Failure / Major Internal Inspection

136.04°F98.194°F117.05°FCLOSE

OPEN

HDP 1 OUTBD BRG TEMPHDP 2 INBD BRG TEMPHDP 2 OUTBD BRG TEMPHDP 1 BKRHDP 2 BKR

1/6/2014 6:00:00 PM1/5/2014 6:00:00 PM 24.00 hours

Heater Drain Pump Reverse Flow

0

100150

200250

350

Event: Unplanned HDP trip and Unit Runback• POC operators identified rapidly increasing bearing temperatures on the tripped HDP.• The POC notified the Control Room.• Operators dispatched discovered the pump rotating backwards due to a stuck open discharge check valve resulting in a loss of

bearing lubrication.• Check valve isolated. Without the assist from the POC, pump damage would have been far more extensive.

A “second set of eyes” enables mitigation of damage following power planttransients

Mitigating Consequences of Single Point Vulnerabilities with AdvancedMonitoring & Diagnostics

EventManual Reactor Trip due to Loss of S/G Level Control

Root Cause: Flow Control Valve Positioner Failure

Codification of Operating ExperienceThis Single Point Vulnerability led to new modeling and alarmsbeing established in support of all FCVs across nuclear units.

Identification & InterventionAdvanced Monitoring identifies similar issue on another FCV

months prior to failure, mitigating risk of inadvertent Reactor Trip.

Feedwater FCV PositionerFailure (October 2015)

Early Identification of FCV Issue(May 2016)

Start Up and Coast Down Reviews Identify Issues During TransientScenarios

Main Turbine Bearing Wipe (January 2016)

Identified during routine Coast Down Review

� Bearing temperatures never exceeded plantalarm set points

� Plant unaware of the issue

� Prevented further damage and avoidedadditional downtime

Bearing Wipe

Plant Request - Uncontrolled Main Feedwater Pump Oscillations

Wireless Crash Carts enable expanded real time monitoring and triage of adverseequipment conditions

POC deployed a wireless system tomonitor the condition. Thisinstallation included mountingvibration transducers on the MFPcontrol valve’s rocker arm in order tomeasure rocker arm movement.

Alarms were configured to identifychanges in behavior. This capabilitywas maintained for a number ofmonths until the machine could betaken offline and repaired.

Strategic Considerations – Deployment of Advanced Monitoring & DiagnosticTechnologies

Essential System Design Attributes:• Highly Scalable – Benefits Compounded with Fleet Expansion• Standardized Platform, Advanced Modeling & Alarming• Automated Data Collection, Analytics and Reporting

Practical Scope of Initial Monitoring Platform:• Safety-Related & Generation Critical Equipment• Integrated Plant Performance• Instrumentation and Process Controls• Single Point Vulnerabilities• Targeted Solutions based upon Individual Plant Needs• Dynamic Integration of Industry Operating Experience into Monitoring Strategies

OptimizedUtility

Operation=

DistributedEnergy

ResourcesTransmission & Distribution Demand+ +

Smart Grid

Optimizing Supply & Demand

Optimizing Equipment Reliability & Performance

Smart Generation

Optimizing Utility Value

Technological advancements combined with economic realities are bringingabout a radical transformation of the electric utility industry.

Through our leadership, the nuclear power industry can be a key contributorto meeting these challenges enabling the continued prosperity of allmankind…

… this is our destiny.

More Info:Clinton E. CarterDirector, Advanced Monitoring & Diagnostic [email protected]

mailto:[email protected]

“Preserving Competiveness in Today’s Economic Preserving Competiveness in Today’s...

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