nmac & pe (mechanical & electrical) engineering · mechanical engineering & maintenance...

© 2016 Electric Power Research Institute, Inc. All rights reserved.© 2015 Electric Power Research Institute, Inc. All rights reserved.

Jim Heishman / Chris Wiegand

NMAC & PE Program Managers

Integration Committee Meeting

Tuesday, August 30, 2016

NMAC & PE

(Mechanical & Electrical)

Engineering

August 15, 2016, Rev. 1

2© 2016 Electric Power Research Institute, Inc. All rights reserved.© 2015 Electric Power Research Institute, Inc. All rights reserved.

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Purpose and Objective of the Presentation

Discuss Engineering Themed Research Projects

Elicit advice and recommendations on proposed and future projects

and long term strategy

Solicit input for communications with the ER Action Plan Committee

and Nuclear Power Council


Nuclear Power

Council

Executive

Committee

ER APC

NPC/EC

Equipment

Reliability

Action Plan

Committee

Integration

Committees

Program 65

(Turbine - Generator)

You are here

Engineering Programs

(BOPC)

Mechanical / Electrical

(PE/NMAC)I&C

BOPC – Balance of Plant Corrosion

I&C – Instrumentation & Controls

NMAC – Nuclear Maintenance Application Center

PE – Plant Engineering


PE Chair: Chris Abernathy,

Lead Engineer

NMAC Chair: Andrew Barritt,

Mechanical Engineering & Maintenance Supervision

Combined PE/NMAC Integration Committee Chairs


Integration Committee Member Introductions

Please introduce yourself!

– Name

– Utility

– Position

– How many years have you

been coming to these

meetings?


Agenda – Tuesday (Engineering Focus)


Agenda – Wednesday (Maintenance Focus)


2016 ER Program Metrics, Products, & Schedule

12

45

6

1012

1618

28

38

66

0

10

20

30

40

50

60

70

January February March April May June July August September October November December

ER APC 2016 Product Schedule

Planned Completed


Integration Committee Report Format –(Your Input needed at the end of Tuesday and Wednesday IC meetings)

Research Focus Areas and Inputs for 2017

Budget Summary and Supplemental Changes

ER APC Requests, Issues, or Concerns

Examples of Leveraging ER Products

Items to Report to Executive Committee or NPC General

Session?


Chris Wiegand

Plant Engineering Program Manager, EPRI

Plant Engineering(Electrical Maintenance & Engineering)

Mid-Year Progress Report

NMAC/PE Integration Committee Meeting

August 30, 2016



Discuss Plant Engineering Research Projects

Elicit advice and recommendations on proposed and future projects

and long term strategy

Solicit input for communications with the ER Action Plan Committee

and Nuclear Power Council


Plant Engineering TeamEPRI Staff

Marc Tannenbaum

Principal Technical

Leader

Sam Harvey

Principal Technical

Leader

Drew Mantey

Sr. Technical

Leader

Jim Sharkey

Sr. Technical

Leader

Chris WiegandProgram Manager

Wayne Johnson

Sr. Technical

Leader

Chris Kerr

Principal Technical

Leader

David Knapp

Technical Leader


Engineering Programs

StaffContact Information Technical Areas

Chris Wiegand704-595-2854

[email protected]

Program Manager

Wayne Johnson704-595-2551

[email protected]

AC Power Reliability, Transformers, Switchyards, Motors

Jim Sharkey704-595-2557

[email protected]

Emergency Power Reliability, Circuit Breakers, Diesels

David Knapp704-595-2960

[email protected]

Active Electric Components, Relays

Marc Tannenbaum 704-595-2609

[email protected]

Parts Reliability, Procurement Engineering, CGD, Critical Spares

Sam Harvey 704-595-2637

[email protected]

Integrated Life Cycle Management, Single Point Vulnerabilities, Flood

Seals, Reliability Innovations, Aging Management

Drew Mantey484-467-5864

[email protected]

Passive Electrical Components, Cables

Chris Kerr704-595-2710

[email protected]

Offsite Power Reliability, EQ, Aging Management


Focus Area Components

AC Power Reliability

Large Transformers Switchyard Circuit Breakers

Relays/PTs/CTs Bus work

Disconnects Grid

Emergency Power Reliability

Diesel Generators Gas Turbines

Batteries DC systems

Inverters UPS



Active Electrical Component Reliability

Relays Circuit Breakers

Switches Solenoids

Motors Voltage Regulators

Passive Electrical Component Reliability

Cables Busses

Fuses Electrical Penetrations

Splices Terminations/Connections



Procurement Engineering

Obsolescence Commercial Grade Dedication

Critical Spares Counterfeit/Fraudulent Parts

Knowledge Transfer Collaboration/JUTG

Reliability Innovations

Components Processes

Methods Software

Hardware Life Cycle


Plant Engineering 2016 Mid-Year Statistics

Over 5000 products downloaded so far in 2016

– Single Point Vulnerability (SPV) Process Guide (3002005419) (190)

– Plant Engineering: Guideline for the Acceptance of Commercial-Grade Items in Nuclear Safety-Related Applications: Revision 1 to EPRI NP-5652 and TR-102260 (3002002982) (187)

– Generator Maintenance Guide for Emergency Diesel Generators (3002005014) (77)

Completed Deliverables in 2016 so far

– Service Life Assessment Guide: An Aging Assessment Reliability Process 3002008007

– Plant Engineering: Low-Voltage Cable Susceptibility to Wet Aging 3002007991

– Plant Engineering: Emergency Diesel Generator Turbocharger End-of-Expected-Life Guidance 3002005015

– Investments Portfolio Optimal Planning Technical Manual 3002007445


2016 Remaining Deliverables (All on Track)

Counterfeit/Fraudulent Item CBT 2.0

Plant Engineering: Electrical Penetration Aging Management Guide- Update

Evaluation and Development of Degraded Grid Detection Schemes

Equipment Important to Offsite Power Reliability Scoping Guideline

Integrated Life Cycle Management Revision 1

Likelihood of Replacement Calculator to Support the ILCM Program

Waveshaping Technology for Intake Fouling and Spill Control

Undeclared Digital Content

Motor Cable Insulation Testing – Comparison of Tan Delta/Very Low Frequency Testing (VLF) and High Potential Testing

Guideline for the Inspection and Removal of Moisture from Electric Motors

Low Voltage Motor Repair Specification, Revision


2017 Planning

As you listen to the 2017 projects, keep in mind industry operating experience and your personal/fleet experience and ask yourself:

• Are the projects addressing the industry needs

• Are the projects addressing my Site/Fleet needs

• What gaps exist

• What future concerns are not evident by the operating experience

• What isn't being done

Your role as advisor

Public Benefit


2017 Proposed Projects

Cable Polymer Handbook and Cable Submergence Qualification

Offsite Power Guideline Pilots and Insulator / Bus Advanced Coatings

Biodiesel Research and DG Tune

Critical Spares Implementation and Commercial Grade Dedication Seminar

ILCM and Equipment Reliability Manual

Motor Very Low Frequency Testing and Operating Guidance for Motors during Unbalanced Voltage Conditions

Relay Forensic Aging Analysis and Relay PM Templates


2017 Funding

3 Supplementals going to base in

2017:

Cable Program (no issues)

Cable Submergence (no issues)

Seismic Qualification Reporting and Testing

Standardization (minor issues worked through

do not expect any major issues)

All focus areas funded and no

high priority projects under the

funding line


Examples of Leveraged EPRI Products

Open Phase

– APS

– FENOC

– Southern

ILCM

– Exelon

– Duke

Single Point Vulnerability

Procurement Engineering

EDG Video use at VC Summer


Jim Heishman

NMAC Program Manager

Integration Committee Meeting

August 31, 2016

NMAC & PE

(Mechanical Engineering &

Maintenance)

Integration Committee

August 15, 2016



Staff Introduction

2016 and 2017 Project Discussion (Research Focus Areas)

2017 Budget changes

2016 Project Updates

User Group Updates


NMAC (Mechanical) Team

Jim Heishman

Program Manager

Ricky Way, Principal Technical Leader

Tom Walker, Principal Technical Leader

Jeff Greene, Senior Technical Leader

Rick Pepin, Senior Technical Leader Bob O’Neill,

Project Manager -Consultant

Nick Camilli,

Senior Technical Leader

Marty Bridges,


Gary Boles, Principal Technical Leader

David Ziebell, Senior Technical Leader


NMAC Personnel

Name Title Phone E-Mail Coverage Area

Jim Heishman Senior Program

Manager, NMAC 704.595.2768 [email protected] Maintenance, Engineering, Operations

Gary Boles Principal

Technical Leader

704.595.2781 [email protected] Component, Component Engineering,

Maintenance Processes, Work Planning, Fluid Leak

Reduction, Bolting

Marty Bridges Senior Technical

Leader

704.595.2672 [email protected]

Preventive Maintenance Programs, Preventive

Maintenance Basis Database, Equipment Reliability,

Maintenance Assessments, Condition Based Maintenance

Programs, Main Condensers, Maintenance Engineering

Nick Camilli Technical Leader 704.595.2594 [email protected]

Mechanical Support, Lubrication, Air Operated Valves

(AOV), Check Valves, Motor-Operated Valves (MOV), Main

Steam Isolation Valves (MSIV), Equipment Reliability,

Power Uprates, Mobile Work Management


NMAC Personnel

Name Title Phone E-Mail Coverage Area

Jeff Greene Technical Leader 704.595.2666 [email protected] Management, Preventive Maintenance Basis

Database, Equipment Prognostics, Radiation Monitors

Bob O’Neill Project Manager -

Consultant

508.539.3301 [email protected] Solenoid Operated Valves (SOVs), Pressure Relief Valves

(PRVs), Air-Operated Valves (AOVs)

Rick Pepin Senior Technical

Leader

704.595.2889 [email protected], Valves, Maintenance, Engineering, Mechanical

Component, Maintenance Processes, Work Planning,

Electronic Work Packages, Condition Based Maintenance

Programs, Fluid Leak Reduction, Maintenance Strategy

Tom Walker Principal Technical

Leader

704-595-2994 [email protected] Mechanical Support of Valves (Air-Operated, Motor-Operated,

Check, and Safety Relief), Terry Turbines and Other Mechanical

Components

Rick Way Principal Technical

Leader

704-595-2679 [email protected] Reliability, Engineering, Maintenance Strategy,

Preventive Maintenance Basis Database

David Ziebell Senior Technical

Leader

404.316.9823 [email protected] Operations & Maintenance (O&M) Processes and Practices,

Clearance and Tagging, Change Management , Foreign

Material Exclusion


NMAC 2016 Mid-Year Statistics

Completed Deliverables in 2016:

Nuclear Maintenance Applications Center: Maintenance Work Package Planning Guidance (3002007020)

EPRI MOV Performance Prediction Program, Addendum 8 and 9 to EPRI TR-103237-R2 (3002007058 & 3002007059)

Pump Virtual Sensors Project: Final Report (3002008038)

Remaining 2016 Deliverables in Progress:

Assembling Gasketed Flanged Bolted Joints: Update of 1015337

Terry Turbine 3D Animated Maintenance Program (TT3D) Version 2.0

Pump Virtual Sensors Project: Final Report


2016 Remaining Deliverables (All on Track)

Valve Specialist Guide

Balanced and Unbalanced Globe Valve Methodology Including Validated Approach for Balanced

Disk Valves

Pump Specialist Guide

Maintenance Rule Implementation Self-Assessment Guidelines for Nuclear Power Plants-Revision 1

Purge Valve Maintenance Guide

Valve Packing Maintenance and Program Practices, Update to 3002005353

AOV Evaluation Guide Rev 2

EDG Technical Advisory Committee; Industry Effort to Improve Emergency Diesel Generator

Performance

Control Rod Drive Pump Maintenance Guide

Controllable Reactor Coolant Pump Seal Prototype: Interim Progress Report


Research Focus Areas – Maintenance Related

NMAC

1.Component Guidance

2. Innovative Technology

3. Maintenance & Engineering

Practices

4. Predictive Maintenance

5. Preventive Maintenance


2016 Research Focus Areas

NMAC




Practices



• MOV PPM Version 4

• Terry Turbine Governor Valve 3D

• MSIV Guide update

• CRD Pump 3D

• AOV Evaluation Guide update

• Purge Valve Maintenance Guide

2017 and beyond

• Circulating Water System

• Air System updates

• New Nuclear Technology

Review



NMAC




Practices



• Virtual Pump Sensors

• Wireless in Power Block

• NDE FLEX Elastomer Hoses

• Controllable Pump Seal

• Machine Verification

2017 and beyond

• Nano-technologies for water

proofing

• Vision Integrated Platform

• Thermography for Leak

Detection



NMAC




Practices



• FLEX Diesel Fuel Testing

• Flood Protection Practices

• Bolting Practices Guide (Update)

• HEPA Failure Modes Analysis

• Mobile Work Management

• Pump Specialist Guide

• Packing Guide (Update)

• Valve Component Specialist

Guide

2017 and beyond

• Maintenance and

Engineering Fundamentals

update

• System Engineering

Handbook update

• Electrical Bus Bolting



NMAC




Practices



• Acoustic and Ultrasonic

Diagnostics Guide

• Alternative Bearing Solutions

2017 and beyond

• Application of sound camera

• Automated IR imaging

• Condition Monitoring Technology

with Tablets



NMAC




Practices



• FLEX Templates

• PMBD Web Services

• PMBD Quick Reference Guide

• ER Process Comparison

• PMBD Expert Elicitation Guide

2017 and beyond

• Failure Mode Severity

classification


NMAC 2017 Budget Changes


2017 Funding

2 Supplementals move to base in 2017:

PMBD UG (no issues)

MOV PPM (no issues)

All Research Focus Areas (RFAs) are

funded and one high priority project

possible under the funding line at

present (PMBD Cost Module to be

discussed in later presentation)


NMAC User Group Report Outs

User Group Focus Areas and Key Take-A-Ways


Focus Areas and Key Take-A-Ways

Work Planners

Continued focus on implementation of Minor

Maintenance and Toolpouch process.

Key contact groups for Mobile Work

Management (mWM) and resolution of

current issues associated with Skill of the

Craft, Wrench Time and Sufficient Technical

Detail issues.

Transformer and Switchyard

EPRI 3002003258, Transformer Sudden

Pressure Device Guide and EPRI

3002005359, Transformer Protective Relay

Guide, are recent products developed from

TSUG Power Transformer Working Group.

EPRI 1026664, Switchyard Maintenance

Guide, was a project that was started out of

the TSUG Switchyard Working Group. This

document was used to develop NANTEL

Switchyard Training Module


Utility engineers shared Terry turbine and

HPCI/RCIC/AFW system operating

experience and lessons learned

EPRI continues to develop 3D animation

tools for the Terry turbine and associated

trip/throttle and governor valves,

to capture industry knowledge

and provide training tools for

utilities.


Terry Turbine Circuit Breaker

Status and resolution of Part 21’s on circuit

breakers

– AZZ-NLI Masterpact circuit breakers; Failure to

close

– Magne-Blast micro-switch failures.

IER L3-15-38: Electrical fault on ground stab.

(Palo Verde)

Saving time and money with alternative

MCCB testing methodology (TVA)

Arc Flash mitigation using protective relays

(Palo Verde)

Numerous tutorials and Workshops



Condition Based Maintenance

Integration of online monitoring into M&D

centers is reducing PM costs

– Reduces manual data collection and allows

more time for analysis and troubleshooting

using APR tools.

New condition monitoring tools and emerging

technology are allowing more efficient use of

staff time

– Ex. Use of on-line 360 degree IR for switchyard

monitoring and use of acoustics in conjunction

with an optical camera to detect equipment

anomalies.

Hoisting Rigging and Crane

Ensuring crane is stabile and proper rigging is used.

– Disturbing number of incidents recently identified where either the crane tipped or the rigging failed to secure the load due to inadequate supervision of on-site contractors.

The lack of uniform training standards and testing plus overly burdened processes increase the cost of rigging and lifting activities. – Committed to supporting “Delivering the Nuclear

Promise, the HRCUG seeks to assemble an advisory group of members, vendors, NEIL, and INPO to find ways to streamline processes and reduce costs while actually increasing safety.



Preventive Maintenance Basis Database Japan RCM-CBM

Key development and implementation group

for implementation of Condition Based vs.

Time Based Maintenance process.

Implementing continuous improvement in the

Predictive Maintenance process and interface

with international peers and exchange of best

practices

Next meeting on September 21, 2016, in

conjunction with the ERWG and PMWG

meetings in Charlotte. Attendees will learn

how to better use and apply this web-based

tool and review work planned on improving

the tool over the next 5 years.

With the PMBD Project moving into base

funding in 2017, the PMBDUG will be

replaced in following years by Technical

Advisory Group (TAG) Meetings as

needed based on PMBD project efforts.



Large Electric Motor

Workshop Topics that address recent industry

events such as Field Cable and Motor

Testing and Termination Issues which led to

EPRI project to evaluate the application of

Very Low Frequency Testing to Electric

Motors

Developed criteria for evaluation of in-

process inspection of motor windings, EPRI

3002003261, Sample Coil Inspection Guide.

This document has drawn the attention of the

IEEE Dielectric Committee for possible

collaboration.

Maintenance Rule

Provide information exchange between

utilities and EPRI to resolve technical issues

from the baseline inspections and the

ongoing revisions to the rule.

Develop technical guides and documentation

of good practices that can reduce costs of

implementation, increase consistency among

utilities, leverage rule activities to improve

plant performance, or reduce vulnerability to

regulatory compliance issues.


Template for ER APC Report Outs

Your input is needed for next slide


Utility Success Story Applying EPRI Products for ER APC,

Information for other members to consider

Company – Title

Existing EPRI Products recently used to benefit your utility/plant– Including Product IDs

Activities (in applying the products)– Example-Program development and implementation

Benefits (from the overall application)– system vulnerability evaluations – terry turbine guide was used to

better understand performance


2016 Nuclear Sector

Member Satisfaction


Member Satisfaction - Background

EPRI has captured member satisfaction

feedback in various forms for many years

Current member satisfaction survey

adopted by Board in 2006

Results reviewed regularly with Board

– one of Corporate Performance Indices (CPIs)

Member feedback used to drive

continuous improvement across EPRI

Helps prioritize efforts

– focus on areas with greatest impact on

satisfaction


Nuclear Member Satisfaction Survey Results

Overall Performance

Ease of Doing Business

Technical Program Value

Overall Satisfaction

2015 Results

2010-2015 Trend

92.3%

Overall

PerformanceEase of Doing

BusinessTechnical

Program Value

86.1%

93.2%

92.4%

75%

80%

85%

90%

95%

100%

2010 2011 2012 2013 2014 2015

• Impact of research on improving my business

• The program's strategic priorities and directions

• Quality of research results

• Relevance of research carried out by the program

• Technical staff expertise

Top ranked aspects of EPRI Experience

Who completed the Survey


Category Initiative Timeframe

Research and

Development

• Research Focus Areas

• Project Overview Forms

• Quality Management ProgramImplemented 2016

Tech Transfer

• Executive Summary

• Onsite EPRI updates/regional meetings

• International workshops

• International NPC

• Digital Strategy (ongoing)

Implemented 2016

Simplification

• On-line Pricing

• Invoice Review

• New Pricing Model

Implemented 2016

Website• New Search Engine

• Member Center ImprovementsImplemented 2016

Improvement Initiatives

Listening and Responding to the Feedback of our Members


Digital Delivery Enhancements

Becomes


Becomes

Digital Delivery Enhancements


New Search Engine

The search engine gets smarter over

time based on use.

It tracks what people search and where

they go with the results.

The more the search engine is used, the

faster it learns.

As it learns, features such as relevance

and search term recognition will

dramatically improve, and as a result

improve your search experience.

You make the search engine better by

using it!


Survey instrument

Key components …

1. Who you arewithout a name and organization, we can’t

count your input!

2. Number of years you have been an Advisor

3. How we’re doing

4. How you assess EPRI value

5. Key improvement in ease of doing business

6. Value you have received from this Program


Survey instrument

Key components

7. Rate each statement based on how

satisfied you are

8. Rank the top 5 statements as

indicated in the instructions

9. Would you recommend EPRI

10.If you are not satisfied with us in any

area, please tell us why

9

10

7

8


2015 Nuclear Member Satisfaction Scores, By Area≤86% 87%-90% ≥91%

Program AreaSurveyed

Co's% Response

Overall

Performance

Technical

Program Value

Ease of Doing

Business

Overall

SatisfactionTotal

Nuclear Sector Council 19/39 48.7% 94.4% 96.6% 81.1% 93.3% 91.3%

Materials Degradation / Aging 18/40 45.0% 91.5% 92.1% 84.2% 92.1% 90.0%

Fuel Reliability 15/40 37.5% 89.5% 91.4% 89.5% 89.5% 90.0%

Used Fuel and High-Level Waste Management 16/40 40.0% 96.8% 96.0% 90.5% 97.8% 95.3%

Nondestructive Evaluation 13/40 32.5% 90.0% 92.7% 81.8% 90.0% 88.6%

Equipment Reliability 30/40 75.0% 91.0% 91.2% 83.8% 90.7% 89.2%

Risk and Safety Management 16/40 40.0% 92.2% 94.4% 91.1% 91.1% 92.2%

Strategic Initiatives (ANT and LTO) 20/40 50.0% 95.0% 95.7% 90.7% 95.7% 94.2%

Chemistry, Low-Level Waste and Radiation

Management15/40 37.5% 94.4% 94.4% 88.8% 95.8% 93.3%

Total 92.3% 93.2% 86.1% 92.4% 91.0%


Chris Wiegand

Plant Engineering Program Manager,

EPRI

EPRI NMAC/PE Projects Related to

Delivering the Nuclear Promise (DNP)

NMAC/PE Integration Committee Meeting

August 30, 2016



Review the DNP initiative

Discuss NMAC/PE input and involvement with DNP

Discuss NMAC/PE projects supporting DNP

Elicit advice and recommendations on proposed DNP projects and

involvement


What is the Nuclear Promise

The “Nuclear Promise” goes back to post World War 2 and President Eisenhower’s Atoms for Peace Speech.

– https://www.youtube.com/watch?v=LWMZZqsnMHk&list=PLQwSHgzejer-nFvOqUr2WsPqc-nNlhvfX&index=7

– https://www.youtube.com/watch?v=7dDNoFQ2bzc&list=PLQwSHgzejer-nFvOqUr2WsPqc-nNlhvfX&index=8

– https://www.youtube.com/watch?v=_0P9S4F4KpQ&list=PLQwSHgzejer-nFvOqUr2WsPqc-nNlhvfX&index=6

– Safe, Reliable, and Economic Electricity Production

https://www.youtube.com/watch?v=LWMZZqsnMHk&list=PLQwSHgzejer-nFvOqUr2WsPqc-nNlhvfX&index=7

https://www.youtube.com/watch?v=7dDNoFQ2bzc&list=PLQwSHgzejer-nFvOqUr2WsPqc-nNlhvfX&index=8

https://www.youtube.com/watch?v=_0P9S4F4KpQ&list=PLQwSHgzejer-nFvOqUr2WsPqc-nNlhvfX&index=6


The Three Promises

Safe: Promise delivered

Reliable: Promise delivered; Post TMI INPO creation leading to operational gains and incredible performance metrics

Economic: Promise not met

Burdensome regulatory issues

Inefficiencies

Failure to integrate technology

Fallen Plants


The DNP Initiative

Goals:

Enable plants to achieve 30 percent cost reduction by 2018

Sustain strong safety performance, as measured by INPO index or other safety metrics

Build on success to date in gaining monetary recognition of nuclear value attributes

Activities:

Cost Center Evaluation

Establish Teams and Sponsors

Create Efficiency Bulletins (actions to take)


The Largest Cost Centers

Cost Centers:– Maintenance/site services

– Operations

– Licensing

– Security

– Engineering

– Radiation Protection

Top activities comprise approximately 50% of all work time:– Work management planning and execution (27%)

– Corrective action (11%)

– Training (11%)


The DNP Committees

Nine Original Committees:

Work Management

Work Execution

Corrective Action

Training

Engineering

Security

Radiation Protection

Regulatory Efficiency

PM Process

Combined Committees

Component Classification

Supply Chain

Transform the Organization

Oversight & Assessment


EPRI DNP Projects

PM changes– Costs addition to PMBD

– FLEX Database

– Vulnerability Tool Training

Reverse Engineering Process

Component Improvements

Wired Worker and Electronic Packages

Standard Test Evaluation Program

Training Modules

Radiation Protection


Together…Shaping the Future of Electricity


Sam Harvey

Principal Technical Leader

NMAC & Plant Engineering Integration

Committee Meeting

August 30, 2016

Integrated Life Cycle Management

(ILCM) – Update


Current Developments of ILCM

Quick Review

Likelihood of Replacement

Heat Exchanger Capabilities

Web Application

ILCM Future Opportunities


What is ILCM Address asset management decisions for long term operations.

Integrated Life Cycle Management (ILCM) combines asset failure

likelihood with economic impact to quantify the financial risks of operating

plants (IPOP module).

This combination offers the possibility of defining an optimum long-term

operating and financial strategy that reduces plant operating risks and

improves financial performance.


What is ILCM

The ILCM software links scientifically developed component and structure

degradation algorithms with plant-specific financials to enable better-

informed decisions about the control of capital spending.

The software platform provides a consistent basis for making decisions

about multiple major plant components and making decisions across

multiple plants.


ILCM Components

Limited to high cost and high consequence assets for Life Extension Evaluations.

Plant specific algorithms based on:– Dominant material aging characteristics

– Modified by plant operating stressors

– Modified by maintenance stressors

Components– Turbine, Generator, large pumps, condensers, transformers

feed water heater, steam generator, pressurizer

Structures– Spent fuel pool, containment, torus


The ILCM program utilizes a Likelihood of Failure (LoF) curve to calculate

an optimum replacement time.

The original LoF curves were developed using “Physics of Failure”

methods.

It is desirable to simplify the calculation of the LoF curve to calculate the

likelihood that a component will have to be replaced either for failure or for

other reasons like obsolescence.

The likelihood of replacement for failure and/or obsolescence is referred to

as Likelihood of Replacement (LoR).

This is expected to greatly increase the usability of ILCM to any

component or system that a utility is evaluating.

ILCM – LoF vs LoR


Likelihood of Replacement (LoR)

“Expert elicitation” methods are used to develop an LoR curve.

Expert elicitation can be used by plant personnel on any

component or structure whether or not it is already explicitly

included in ILCM.

Methodology allows input from one or several “experts”.

An LOR curve will be used in ILCM.

The rest of the ILCM calculations can proceed normally.


The LoR Methodology Approach

• Identify Component

• Identify Background Information

Scope

• Industry and plant performance

• EOL guidance

OE • Expert Elicitation

• Likelihood

• Variability

• Timing

• Comparative Ranking

Probabilistic

Evaluation

• LoR curve

Results


An Excel workbook is provided to those being elicited.

It is expected to require approximately 30 minutes to fill out the

workbook.

The workbook from each person elicited is sent to an Elicitation

Coordinator.

Another Excel workbook is used by the Elicitation Coordinator to

combine the responses and to provide an LoR curve – the

likelihood of replacement being required versus time.

This has been piloted with Duke and Exelon.

Updates to the workbooks are being performed based on

feedback from the pilots.

LoR Process


Identify a component or system and categorize it into one of

the following groups:

– I&C

– Structural

– Active Mechanical

– Passive Mechanical

– Active Electrical

– Passive Electrical

LoR Process


Elicit input from one or several personnel that are familiar with the

system.

Identify component or system.

Identify failure mechanisms and stressors.

Identify previous failures that have occurred.

Will the degradation/obsolescence be recognized well before a

failure will occur in the field?

Identify whether replacement is controlled by likelihood of failure or

obsolescence (or both)

Process


The component

failure probability

(black line) is input

to ILCM.

The colored bands

are confidence

intervals.

Likelihood of Replacement


Heat Exchanger Module

The ILCM software Version 2.1 contains a feedwater heater module to

estimate the Likelihood of Replacement (LOR) of feedwater heaters in

nuclear power plants.

The feedwater heat exchanger module has been expanded to include

many more heat exchangers, including CCW, RHR, Turbine Oil,

Diesel Jacket Water, Fuel Pool Cooling, Containment Fan Coolers,

and others.

The fluid conditions will be expanded to include:

o Sea Water

o Brackish Water

o Open Cycle Fresh Water

o Closed Cycle Fresh Water

o Oil

o Air

o Closed Cooling Water

o Primary Water


Heat Exchanger Degradation Mechanisms Considered

Degradation mechanisms considered for the shell include:

– Flow Accelerated Corrosion (FAC)

– Microbiologic Influenced Corrosion (MIC)

Degradation mechanisms considered for the tubes include:

– Microbiologic Influenced Corrosion (MIC)

– Erosion

– Stress Corrosion Cracking (SCC)

– Wear (vibration, fretting, etc.)

Degradation mechanisms considered for the internals (baffle plates,

tie rods, etc.) include:

– Steam damage


Potential Capabilities of ILCM – PM Decisions

ILCM currently evaluates long-term replace/refurbish decisions

based on likelihood of failure, consequences, and cost.

This can be extended to short-term decisions on PMs.

An evaluation of the following items will allow input to a PM

decision to be made:

– The likelihood of failure change for a longer PM frequency

– The consequences/undesirability of a failure during operation

– The cost is maintenance time, cost of plant operation time if a

downpower is required, and availability of parts

Such an evaluation may be possible with collaboration between

the PMDB and ILCM.


Potential Capabilities of ILCM – Other Applications

Many ILCM likelihood of failure curves are developed using

“physics of failure” techniques.

This method creates algorithms that are based on the

physics of how the degradation occurs and effects the

material capability.

These methods can be extended to other degradation

issues, like baffle bolt cracking, and other MRP and

BWRVIP issues.

Degradation algorithms can be inserted into ILCM to provide

insight for repair/replace decisions.


Potential Capabilities of ILCM – LTAM/LCMP Integration

ILCM currently provides stand-alone input to

replace/refurbish decisions on components.

Many utilities are using similar Life Cycle Management Plan

(LCMP) and Long Term Aging Management (LTAM)

formats.

ILCM can be adapted to provide easily-integrated output in a

LCMP or LTAM program.

This could reduce the work required to develop and update

long term plans.


ILCM - 2016

Completed IPOP Technical Manual 3002007455

Develop Web Application

Update LoF algorithm for different Steam Generator materials/types

Add Likelihood of Replacement Module

Add Heat Exchangers

Potential Applications

https://membercenter.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002007455


The Future of ILCMContinue Technical deployment through workshops

Initial Interest Group Meeting 8/15-16/2016 in Charlotte

Interest Group to Determine and Drive Future Enhancements and Additional Components

Software downloadable at EPRI Member Center 3002006645, Technical Report 3002003010




Jeff Greene


8/30/16

Integration Committee Meeting Engineering Day

Flood Protection

Project Updates


Topics

Highlights: 2015 EPRI Flood Protection Systems Guide

Scope of 2016-17 Flood Design Basis Best Practices Guideline

Timeline for Development of Guideline

Sample of 2016 Survey Questions


Flood Protection Systems Guide – Available to Members

12 Utilities Involved in TAG

Good Initial Industry Feedback

Significant Product Downloads

Since Publication 11/24/15

Product ID: 3002005423


Flood Protection Systems Guide – 2015 Technical Report

Immediate response to assist members by

providing flood protection feature guidance.

Focused on feature descriptions, design

criteria, inspections, and available testing

methods.


Flood Protection Systems Guide – Section Overview

Section 2: Types of Flood Barriers Used in Nuclear Power Plant Applications

Section 3: Current Testing Methods and Acceptance Criteria

Section 4: Design Considerations Associated with Flood Protection Components

Section 5: In-service Inspection, Testing, and Maintenance Recommendations

Section 6: Industry Performance Analysis

Section 7: Establishing and Managing Flood Bases Requirements


Flood Protection Systems Guide Overview

Section 2: Types of Flood Barriers

Sections of Guide Structured by

Categories and Components Initially

Defined in Section 2:

– Passive Components

– Active Components

Flood Barrier Penetration Seal (FBPS) – A material, combination of materials, or

pre-manufactured device installed inside a penetration through a flood barrier to seal

the opening and maintain the flood rating of the barrier. Typical penetrations include

openings to accommodate the passage of pipe, tubes, conduits, cable trays, cables

and ventilation ducts.


Flood Protection Systems Guide Overview Section 3: Current Testing Methods and Acceptance Criteria

– Summary of Historic Penetration Seal Testing Methods

– Primer for follow-on work related to test criteria development



Section 4: Design Considerations

– Focus on Flood Barrier Penetration Seals (FBPS)

Mechanical Penetrations

Electrical Penetrations

Ventilation Penetrations

Combination Penetrations



Section 5: In-service Inspection, Testing, and Maintenance Recommendations



Section 7: Establishing and Managing a Flood Bases

– Best practices from within TAG outlined

– Primer for Design Basis Best Practices Guideline focused more on “programmatic” aspects


2016/2017: Best Practices Guideline - Design/Licensing Basis

NSAIC requested that EPRI develop guidance by end of 2017.

Document Purpose: Collect best practices from the industry for

maintaining an external flooding design/licensing basis.

Focused on External Flooding but will acknowledge overlap

between external and internal flooding.


Design/Licensing Basis Best Practices Guideline - Outline

Design (Method)

Qualification (QA Requirements)

Maintenance (Procedures)

Modification (Design Change Process)

Inspection (Flooding Design Basis Walk downs)

Testing (Periodic Surveillance of Flood Protection Features)

Mitigation (Mitigating Strategies)

Training

Reevaluations

Integrated Assessment

Documentation and Reporting


Best Practices Guideline – Section Outlines

Design (Method)– Identification of features

– Acceptable methods

– Consolidated documents

– PRA

Qualification (QA Requirements) – Appendix B controls for back up

– Augmented quality requirements or something else

– Attributes

Maintenance (Procedures) – Plant Configuration for Full Range of Operation

– Work Management Procedures

– Risk assessment during maintenance and aggregate risk

– Maintenance Rule

– PMs

– Installation and Testing


Best Practices Guideline - Design/Licensing Basis

Modification (Design Change Process) – Requirements for Flooding Design Basis

– New Seal Type Qualification for Design Basis

Inspection (Flooding Design Basis Walkdowns) – Lessons Learned from NEI 12-07

– Additional Requirements

– Sampling of Flood Protection Features

Testing (Periodic Surveillance of Flood Protection Features) – WCAP 17700-NP

– Barrier Surveillance

– Active / Passive / Temporary

Mitigation (Mitigating Strategies) – Procedures in place and time requirements

– Compliment FLEX Guidance without Duplication

– Capture Lessons Learned from 50.54(f) Response


Best Practices Guideline - Design/Licensing Basis

Training– Periodic Training

– Reasonable Simulation

– Validate Assumed Time Requirements

– Qualifications

Reevaluations– NUREG/CR 7046

– Triggers

– Computer Software

– Vulnerability Determination Process

Integrated Assessment (IA)– Pending Content from Appendix G and IA Document

Documentation and Reporting– Walkdown Forms from NEI 12-07 may be used

– Testing Results

– Existing Engineering Evaluations or Calculations


Best Practices Guideline – Next Steps

– Survey sent to 51 Utility Contacts on June 14th, 2016

– Survey ends September 20, 2016

– Begin Assembling Content for Guide Q3 2016

– First Draft for TAG Review Q1 2017

– Publication Q4 2017


Detailed Web-Based Survey Developed

Independent specialty firm conducting survey.

Detailed Industry TAG Review of Questions:

– Only 1 opportunity to collect this information.

– Common titles for utility contacts:

Flood (External and/or Internal) Protection Program Managers

External Hazards Program Managers

Fukushima Task Force Managers

Civil Design Engineers

Fire Protection Program Managers


Data Collection Process for Survey

Web-based methodology– Invitation and up to five reminders to non-respondents

– Branded by EPRI and invitation “signed” by Ken Canavan (Director Plant Technology, EPRI)

– Questionnaire format

Multi-page questionnaire

Skip patterns/auto fills programmed and transparent to respondent

View contains progress bar

Functionality to stop survey and resume (with previous responses saved) at a later time

Ability to upload documents

– Final “call to action” at this meeting

Initial

InvitationReminder

#1Reminder

#2

Two weeksafter initial invitation

Two weeksafter Reminder #1

Reminder

#3


Reminder

#4

Two weeks after Reminder #3

Reminder

#5


Advance

Letters

~30 and ~7 days before field opens


Examples of Survey Questions

What is the maximum D/P your flood protection features are

required to withstand?

Do you have an External Flood Protection Program?

Which departments are involved in management and support

of this program?

Are routine external periodic flood protection self-

assessments being performed?

What are configuration control methods being used for

various features?

What training / qualifications are required?


Last Call for Survey Participation

Thank you so far for significant site completion both within the US and from our international members.

Jeff Greene ([email protected]) – 704-595-2666

mailto:[email protected]


Jeff Greene


Integration Committee Meeting Tuesday, August 30, 2016

Engineering Day

Equipment

Reliability Matrix 1.6


What is the Equipment Reliability (ER) Matrix?

ermatrix.epri.com


What is the Equipment Reliability (ER) Matrix?

ermatrix.epri.com

AP-913 Categories

Co

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on

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ts


Matrix ViewMobile View


ermatrix.epri.com


ermatrix.epri.com

First Example


ermatrix.epri.com


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Second Example


ermatrix.epri.com


Questions / Comments?

[email protected] / 704-595-2666

mailto:[email protected]


Christopher Kerr


Nuclear Power Council ER IC

August 30, 2016

Nuclear Power Plant Offsite

Power Reliability InitiativesStatus of EPRI R&D Plans

Date: August 12, 2016


Agenda

Background

– Industry data and trends

Roadmap Development

– Process and results

2016 Projects

– Nuclear & PDU T&S

Next Steps


Background: Industry Data & Trends

EPRI Trend Data 2005-2014(EPRI 3002005291)

Median LOOP Duration and Event Frequency



EPRI Trend Data 2006-2015(EPRI 3002008101)

Median LOOP Duration and Event FrequencyCategory I.a and I.b Ten-Year Event Summary

0

1

2

3

4

5

6

7

2009 2010 2011 2012 2013 2014 2015

Year Reported

Med

ian Ev

ent D

urati

on, h

ours

0.02

0.022

0.024

0.026

0.028

0.03

0.032

0.034

Even

ts pe

r 10 y

ears

Ten YearMedianEventDuration

Eventsper 10years



Date and Category Plant NameDuration(hr:min) Summary

4/7/2015 /I.b (two

events)

Calvert Cliffs Units 1 and

2

0:00:47

(47

seconds)

A fault on an offsite transmission

line resulted in an undervoltage

(approximately 11% drop)

condition at the plant, causing all

four safety busses to isolate due

to degraded grid relay actuation

and both units to trip. Offsite

power was not available to the

buses due to the undervoltage

condition. The faulted line was

isolated from the plant and offsite

power was available in about 47

seconds, though not restored

until 20 minutes later.



Calvert Cliffs Event



Surge Arrestor Failure at Ryceville substation



Voltage Depression at Calvert Cliffs



Initiating events causes for Category I.a and I.b events in U.S. Nuclear Plants

(2006 through 2015)



LOOP Events by Initiating Situation (2006-2015)



- Causes of LOOP and Partial LOOP Events (2004-mid 2015)



OE Data Breakdown– 164 Domestic events evaluated / International OE used for

confirmation

External events: weather, grid, wildlife

Events by Category

Equip HP External

Human Performance Events

by Location

PLANT

SWYD

GRID

SUMMARY OF EVENTS BY LOCATION

PLANT SWYD GRID



2015-2016 Events LOOPs: 1

Offsite Power Related Events: 40 (includes Tech Spec LCOs)

Cause Categories

– Human Performance: 11**

– Transformer / Auxiliaries: 9

– Grid (Voltage Control): 7 (5 events at 1 site/ 2 at 2nd)

– Weather: 6**

– Insulators: 5

– PT/ CT / Instrument Cables: 5

– HV Circuit Breaker: 3

– Grid (Other): 3 (line faults)

– Grid/Switchyard Relaying: 2

– Plant Relaying: 1

– Plant Cable: 1

** Combination of causes for event (i.e., Human Performance and Equipment Failure, Weather and Equipment Failure)



Recent Large Power Transformer (LPT) Failures



Summary:

– Last 4 Category I (Ia or Ib) LOOP events (2014/2015) caused by

equipment issues on the associated transmission system.

– Though no Category I events from weather in 2015, there was a

significant Category II event due to a winter storm; weather remains

#1 cause of LOOP events over 10 year rolling average.

– Human performance issues at the plant contribute to many “near

misses”, i.e. Category II, IVa events.

– Failures of Large Power Transformers (LPTs) contributing to

Category II events.


Roadmap Development

EPRI 3002008002, December 2016

Key Sections

• Assessment (as-is versus desired state)

• Planning (required R&D projects)

• Implementation

As-Is based on Operational Experience (OE) Collection

• Domestic 2004-2015

• International: IAEA, EPRI Member surveys

Technical Advisory Council (TAC) support


Roadmap Development

As-Is Assessment: Existing EPRI Guidance for LPTs– Combination of EPRI Transmission & Substation (T&S) and Nuclear sector products


Roadmap Development

Operational

Experience -

NRC

Existing EPRI

Guidance and

R&D

EPRI Nuclear and

T&S Workshops

Operational

Experience -

INPO

Operational

Experience –

T&S

2016 Projects Scope

Roadmap Update Publish roadmap to highlight existing EPRI products, capture preliminary

R&D results, and identify any additional R&D that may be required to improve

NPP offsite power reliability.

Offsite Power Critical

Equipment Scoping

Guideline

Develop guidance to identify equipment within the plant, NPP switchyard, and

Grid that is critical to offsite power reliability. Utilize results of process to

ensure condition monitoring and preventative maintenance of critical

equipment is consistent with its importance.

Advanced Coatings for

Insulators*

Guidance for application of advanced coatings on switchyard insulators and

overhead conductors (i.e., transmission lines, buses), to reduce flashover

events due to contamination and moisture buildup.

Improving

Contamination

Flashover Performance

of Substation

Insulation*

Guidance for evaluation of contamination of substation insulation, monitoring

technologies and maintenance schedule and techniques for optimum

performance.

Utilization of PTX for

NPP GSUs and SATs*

Research to evaluate usage of the T&S Power Transformer eXpert (PTX)

software tool for asset management of NPP GSUs and SATs.

Evaluation of PTX, PHM

and ILCM Transformer

Asset Management

Software*

Evaluate three different large power transformer asset management tools for

NPP GSUs and SATs and determine if and how they may be integrated to

provide improved tools to assess current health.

HV Circuit Breaker

Maintenance and

Condition Monitoring *

Improve performance on NPP HV circuit breakers through enhanced

condition monitoring and maintenance. The initial phase will be to review

existing Nuclear and PDU T&S guidance and develop an interim guideline to

include best practices.

Notes * Joint EPRI Transmission & Substation (T&S) and Nuclear projects


Offsite Power Critical Equipment Scoping Guideline

(EPRI 3002008004, December 2016)


Offsite Power Critical Equipment Scoping Guideline (EPRI 3002008004,

December 2016)


Offsite Power Equipment Scoping Guideline

Review Results Existing Condition

Monitoring / Mnt

Additional Condition

Monitoring / Mnt (Appendix

A)

Required R&D?

5. Transmission Network Component Review (Normal Path)

345 kV Aerial Line to

Substation 1

Overhead Conductor

Management Guide (EPRI

1019943)

Overhead Transmission

Inspection, Assessment, and

Asset Management

Reference Guide-2015 (EPRI

3002005611)

Advanced Coatings

Transmission towers /

insulators / static wires

Field Guide: Visual Inspection

of Steel Structures (EPRI

3002005630)

Advanced Coatings

Substation Circuit Breaker

345-1 (345 kV)

EPRI PMBD for Substation

- SF6 Dual Pressure CB

HV Circuit Breaker

Maintenance and

Condition

Monitoring Guide

345 kV Line 1 Protective

Relaying (CTs, PTs, relays)

NERC PRC-005 Protection

System Maintenance

N/A N/A


Advanced Coatings for Insulators/Conductors/Structures

EPRI 3002004487 September 2014

– Super-hydrophobic and icephobic coatings may improve performance of

insulators/conductors/structures by reducing:

Insulator, conductor and structure icing

Insulator contamination

Conductor corona

– Test Plan

Tier 1: small scale testing on coated samples

Tier 2: Lab testing on coated components

– 11 vendors (8 advanced/3 RTV)

Tier 3: Field demonstration at utility sites*



EPRI 3002004487 Insulator Test Results

– Two key performance properties are Ice Adhesion and Self Cleaning (Artificial

Contamination test) / Inclined Plane test checks for carbon tracking (arcing)

– 3 coatings identified for field testing (A, B, E)

•“++”: Much better than uncoated or greatly

improved property after test

•“+”: Better than uncoated or improves initial

property after test

•“0”: Same as uncoated or retains initial

property after test

•“-“: Worse than uncoated or loses some

initial properties after test

•“- - “: Much worse than uncoated or has

lost initial properties after test

• “n/a”: Sample not available from vendor for

test



EPRI 3002007817 December 2016

– Field demo’s underway

Conductor icing

– 345kV 2 conductor bundle - T2 (twisted pair) (installed)

– 345kV 2 conductor bundle - Drake Round

Insulators

– Road salt / icing (installed)

– Cooling Tower Contamination (installed)

Realtime monitored & regular inspections, final assessment

– 2016 report Covers results of lab testing of aged components / repeat testing

Covers field demo project installation and monitoring

Results of field tests in 2017


Improving Contamination Flashover Performance of Substation

Insulation

EPRI 3002007813 December 2016

– Key Research Question

Reliability of substations impacted by flashovers due to insulator

contamination from road salt, marine salt, and industrial pollution. Need for

remediation;

– How best address contamination?

– Technical basis for implementing or timing of maintenance actions?

2017 scope for comparison of methods and washing frequency

Manual washing Re-InsulationSpray washing


Utilization of PTX for NPP GSUs and SATs

EPRI T&S Software

– Evaluation of Dissolved Gas in Oil Analytics (3002005979)

– PTX Transformer Fleet Management Software Version 2.0 (3002005971)

EPRI

PTX

Algorithms

(Rule-based)

Measurements

• DGA

• Oil Quality

• Furans

• Routine Electrical

• LTC DGA & Oil Quality

• LTC Operation Count

Design

Information

• Manufacturer

• Vintage

• Nameplate Data

Readily

Available DataTransformer

Fleet Risks –

Short

Term/Long Term

Belief & Likelihood

of Fault Conditions

Present

Basis for Asset Management

Decisions

Integrates decades of expert knowledge in a rule-based framework.


Utilization of PTX for NPP GSUs and SATs

Evaluation of NPP GSU DGA data in progress


Evaluation of PTX, PHM and ILCM Transformer Asset

Management Software

Fleet-Wide Prognostics & Health Monitor (FW-PHM)

– On-Line Monitoring Diagnostic Analysis for Large Power Transformers

(3002000753)

– Fleet-wide Prognostic and Health Management Suite (FW-PHM Suite) v1.2

(3002002762)

DGA

Oil

Analysis

Over-

Temperature

History

AFS

Database

Winding Insulation

Degradation

F(x)

Signature

Similarity Algorithm


Integrated Life Cycle Management (ILCM)

– Integrated Life Cycle Management (3002003010)

– ILCM Version 2.1 (3002006645)

Utilizes a Likelihood of Failure (LoF) curve to calculate

an optimum replacement time.

Evaluation of PTX, PHM and ILCM

Transformer Asset Management Software


Evaluation of PTX, PHM and ILCM Transformer Asset

Management Software

Results to Date– PTX

Strengths: Accurate LPT present condition assessment

Area for Improvement: : Can be interfaced/integrated with financial analysis engines if desired by users / work underway to enhance analytics to handle data from online monitors

– FW-PHM Strengths: Integrates online with monitoring and other data

sources. Creates and maintains up-to-date health histories for individual assets.

Areas for Improvement: New software with pilot users in generation; no current applications in T&D.

– ILCM Strengths: Strong financial tool

Area for Improvement: asset condition based algorithm for failure prediction


HV Circuit Breaker Maintenance and Condition Monitoring

Why– Loss of subject matter expertise

– Lack of comprehensive guidance

– To cover all aspects of lifecycle management

How– Use same process as for Power Transformer Guidebook (aka The

Copper Book)

– Multi-year effort

– Develop chapter by chapter

– Continuous member guidance and review



1. Fundamentals

2. Selection

3. Specification Development

4. Design Reviews

5. Factory Testing & Inspection

6. Shipping & Installation

7. Operation

8. Monitoring & Diagnostics*

9. Maintenance

10. Failures, Problems & Investigations*

11. Asset Management

12. Recent Industry Research Results

13. References

14. Index

15. Glossary

* Complete and Available For Review

* Focus for 2016

Circuit Breaker Reference Guide (3002007763) December 2016

The individual chapters of

the Guidebook are laid out

in a natural order in terms

of when activities would

occur in the life of a circuit

breaker.

Because of this,

information on any

particular subject could be

spread out over several

different chapters.


Roadmap Summary

Purpose– Identify methodologies and technologies to improve NPP

offsite power reliability.

Results– R&D Focus Methodology to identify critical equipment for NPP offsite power

reliability (Scoping Guideline)

Effective monitoring and prognostic technologies for critical equipment that will minimize unplanned failures (PTX)

Identification of design changes to critical equipment that will improve offsite power reliability (Insulator Coatings)

Identification of recommended PM practices for critical equipment(HVCB Guide)


Next Steps

Scoping Guideline pilot at St. Lucie results incorporation

Complete Evaluation of Transformer Asset Management Tools (Fall 2016)

Nuclear site GSU PTX Evaluations

Updated Road Map draft and review

2nd TAC Meeting (October 6, 2016)

Publish Scoping Guideline and Road Map in December 2016

Review and publication of PDU T&S reports (insulators and circuit breakers)

2017 Project Development


Wayne Johnson

Principle Technical Leader

NMAC / Plant Engineering Integration

Committee

August 30,2016

Transformer and Motor

Research

Date: August 15, 2016


Transformer Research

Recent Focus Areas and Reports

Transformer and Switchyard Users Group

Cross Sector Interactions

Future Efforts


Transformer Research

EPRI has a long history of addressing issues related to

power transformers

Transformer Research and Development is primarily done in

the Power Delivery and Utilization (PDU) Sector

Nuclear Sector has been involved in product development

related to power transformers



Recent Large Power Transformer (LPT) Failures



Copper Book– The Cooper Book is a living resource document for utility personnel

responsible for power transformers

– The Cooper Book is updated periodically

– The development of the Copper Book was a cross-sector endeavor that included PDU, Nuclear, and Generation

– The involvement of these sectors represent the major usages of power transformers in the utility industry

Generating Stations

– Nuclear

– All other forms of Generation

Transmission and Distribution



Generating Stations– 1002019, Power Transformer Maintenance and Applications Guide

Fundamentals

Design & Construction

Operation

Failures & Maintenance Problems

Tests

Maintenance Recommendations

– 1015077, Guidance for Planned Replacement of Large Power Transformers at Nuclear Power Plants

To support nuclear utilities in their efforts to replace large power transformers

Source of knowledge to increase staff awareness and appreciation of the major design, procurement, installation, and operational issues that must be considered when replacing a large power transformer



Generating Stations cont’d

– 1022956, Nuclear Maintenance Applications Center: Dry-Type

Transformer and Reactor Application and Maintenance Guide

Focused on dry-type transformers used in unit secondary

substations

Dry-type power transformer design, construction,

Installation

Maintenance

– Preventive Maintenance Basis Database

Templates for transformer maintenance program


Recent Focus Area and Reports

Open Phase Detection Issue

– Identified difficulty in detecting event during a low or no-load level state

– Developed and tested a prototype system

– Licensed system to commercializer

– OPD system based on EPRI technology being used extensively across nuclear industry

– Several international utilities have expressed interest

Released 5 publicly available documents on the open-

phase issue since the 2012.


Recent Focus and Reports

EPRI 3002005360, Application Guide for Performing Open-

Phase Analysis Using an Electromagnetic Transients

Program, Revised Version

– Developed system modeling guidelines to perform open phase

analysis

– Provides criteria (scenarios) that should be evaluated in an open

phase analysis

– Provides a user friendly application guide that details the steps

necessary to accurately perform an open phase analysis using the

restructured version of the electromagnetic transients program

(EMTP-RV)



Focus has been on Transformer Protection since many main

power transformers were being replaced

Effort to reduce single point vulnerabilities had also been

applied to power transformers

Issue with protection philosophy for sudden pressure relays

arose

Reports to address protection issue



EPRI 3002003258, Industry Practices Related to the Application of Sudden Pressure Devices for Large Power Transformers– Trend toward SPDs being placed in alarm only without understanding

the purpose of SPDs

– Sudden Pressure Devices sense and respond to oil or gas interactions from an internal transformer fault.

– sudden pressure relays (SPRs)

– rate-of-rise relays

– rapid-rise relays

– fault pressure relays

– Buchholz principle relays (sudden flow)

– Considered high speed transformer protection devices for internal faults and main protection for some faults in transformer windings and tanks



EPRI 3002005359, Industry Practices Related to the Application of Protective Relaying for Large Power Transformers at Nuclear Power Stations, 2015– Covers present NPP Large Power Transformer Protection

– Transformer protection reliability considerations

Have at least two independent protection schemes.

Sufficient redundancy in the high speed protection for each applicable transformer failure mode (e.g. current differential, SPD)

Protection scheme design enhancements to improve reliability.

– Separate and dedicated CTs.

– Independent PCB trip coils, DC control power, LORs, etc.

– Use of redundant protective functions with both primary and back up protective functions



Industry Group which acts as forum for utility and industry

participants

– Chair: Samson DeBass, Exelon Corp.

– Vice Chair: William “Bill” Duge, First Energy Corp.

Group is composed of three working groups

– Power Transformer: Chair – Rod Sorrell, Luminant

– Switchyard Equipment: Chair – Ken Caldwell, Duke

– Grid Reliability – Raey Yohannes, Entergy



Meets once per year in July timeframe

Workshop on Transformer and/or Switchyard topics

Reviews industry issues and proposes topics for further

research

2016 Meeting was held July 25 -28 in Boston, MA

– Workshop on Transformer Testing

– Tour of Doble Labs


Cross Sector Interactions

Active Research Tasks

1. Improved diagnostics of transformers

2. PTLOAD

3. Transformer inspection robot

4. Novel Optical Sensors

5. EPRI Copper Book

6. Membranes for on-line dehydration

7. Transformer Forensics Library

8. Transformer remaining life research


Future Efforts

Application Review of Degraded Voltage Relays

Geomagnetically Induced Current (GIC) Monitoring for Large

Power Transformers Using EPRI Open Phase Detection

System

Acquiring Transformer Data

– Updating Plant Transformer Data

– Collecting Transformer DGA Data up upgrade PTX


Future Efforts

Bushing Issues

– Bushing Monitors

– Bushing Monitoring

Oil Analysis

Other Tests

– Experience with New Bushing Types

Grounding – Design, Equipment, Selection and Maintenance

Switchyard Equipment Maintenance

– Switchyard Maintenance Guide published in 2012

– Review industry implementation of guidance


Motor Research


Large Electric Motor Users Group

Future Efforts


Motor Research

EPRI has been involved with various aspects of electric

motor usage in the nuclear industry

EPRI electric motor guidance covers topics from motor

maintenance, skill development, and component

management


Existing Reports

3002000644, Nuclear Maintenance Applications Center: Motor Management Guide Supporting Plant License Renewal Including Environmental Qualification Considerations

3002000809, Guide for the Specification of Replacement and Spare AC Squirrel-Cage Induction Motors Having Voltage Ratings Up to 600V

1021396, Guidance for Developing an Electrical Motor Specialist: Plant Support Engineering

1020625, Guidance for the Replacement of Large Electric Motors at Nuclear Power Plants

1019161, Proactive Obsolescence Management

1016680, Nuclear Maintenance Applications Center: Guide for the Performance of On-site and Vendor Shop Inspections of Electric Motors


Existing Reports

1016679, Repair and Reconditioning Specification Guidance for AC Squirrel-Cage and Salient Pole Synchronous Motors with Voltage Ratings of 2.3 to 13.2 kV: Revision 1 of 1000897

1015076, Plant Support Engineering: Large Motor End of Expected Life and Planning Considerations

1011894, Motor Repair versus Motor Replacement

1011892, Guideline for the Specification of Replacement and Spare AC Squirrel-Cage Induction Motors Having Voltage ratings of 2,300 V to 13,200V

1009699, Guide for Increasing the Capacity of Induction Motors

1009698, Shipping and Storage of Electric Motors

1003095, Electric Motor Tiered Maintenance Program

1000968, Troubleshooting of Electric Motors: 1000968

NP-7502, Electric Motor Predictive and Preventive Maintenance Guide



EPRI 3002003261, Guide for Sample Stator Coil Inspection

and Testing During Motor Rewinds and Manufacturing:

Sample Coil Inspection Guide

– Stator windings of motors and generators are made up of

individual, treated coils

– Report provides recommendations for testing and inspection of

sample coils

To obtain a better quality form-wound stator winding

To retreat in process coils if proper penetration of resin has not

been achieved



EPRI 3002005357, Nuclear Maintenance Applications Center: Squirrel-Cage Rotor Inspection, Testing, Repair, and Replacement Considerations– Rotor inspections are important for the power industry because many

large motors have been in service for 30-plus years

– Because of this time in service, rotor aging and degradation issues have been found during motor refurbishments

– Guidance to detect and correct degraded conditions, minimize in-service failures, and maximize the life of the rotor

– In addition, many nuclear plants have been approved for plant life extension up to 20 years, which will also demand extended design life for the power plant motors

– New rotors are also covered to provide the motor program owner information on proper rotor material selection, assembly processes, and final testing


Recent Focus Area and Results

EPRI 3002005358, Guidance for Operating Motors Under

Unbalanced Voltage Conditions

– Initial literature search to determine how motors behave under

unbalanced voltage conditions

– The search became necessary to address issues around motor

impact due to plant open phase condition

– Additional analysis and/or testing may be required to fully address

this issue

– Currently reviewing proposed testing to determine additional

guidance



Industry Group which acts as forum for utility and industry

participants

– Chair: Harry Smith, Exelon

– Vice Chair: Rick Locke, TVA

Group is composed of three working groups

– Applications: Chair – Russ Randolph, Duke

– Information: Chair – Henry Johnson, Arizona Public Service

– Maintenance: Chair – Clifford Both, PSE&G Services



Meets twice per year in January and August timeframe

Workshop on Electric Motor topics

Reviews industry issues and proposes topics for further research

2016 Meetings– January 2016 meeting was held Jan 25 -28 in Glendale, Arizona

Workshop on DC Motors

No Tour at this meeting

– August 2016 meeting was held August 22 – 25 in Roanoke, Virginia

Workshop on Motor Testing

Tour of AREVA Motor Repair and Technology Facility


Future Efforts

Moisture Management for Electric Motors: Moisture

Prevention, Detection, and Restoration Guidance

Very Low Frequency (VLF) Testing of Motors and Cables

Revision of Low Voltage Motor Repair Spec.

Revision of Low Voltage Motor Replacement and/or Spare

Spec.


Questions


Afternoon Break


Sam Harvey


NMAC & Plant Engineering Integration Committee Meeting

August 30, 2016

Single Point Vulnerabilities - Update


Agenda

History

Progress

Future


Single Point Vulnerability - Schedule

Phase 1 – Dec 2014

– Establish EPRI SPV Collaboration website

– Populate with industry SPV processes and results (SPV lists) – ERWG request

– Revise ICES to add/enhance SPV tagging of events

Phase 2 – 2015

– Work with ERWG and IEWRG to develop an SPV Process Guide for universal application

– Publish SPV Process Guide 3002005419

– Develop working prototype application for hosting SPVs and mitigation/elimination strategies

– Develop standardized input datasheet for SPV application

Phase 3 – 2016

– Develop Industry SPV Application for comparing identification and strategies for dealing with SPVs

Goal – Reduce industry SCRAMs through sharing of industry SPV processes and results

https://membercenter.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002005419&Mode=download


Single Point Vulnerability – Risk Factors Risk Assessment of SPVs

– Graded Indicator

– Elements

SPV Maintenance Design Modifications Maintenance Strategies On-line Work Management Vulnerability Identification Timeliness of Mitigation Planning and Scheduling Protected Equipment Engineering Monitoring Effectiveness Causal Analyses Work Practices Life Cycle Management


Single Point Vulnerability Application Create Industry Collaborative SPV Database

− Fields

Reactor type (i.e. BWR 4 or 5, PWR CE or B&W, etc.)

Turbine type (Siemens, GE, etc.)

A/E

Elementary Function

System

Component type (relay, AOV, etc.)

Technical bases

Mitigation strategy or Elimination strategy if eliminated

Classification (EPRI PMBD)

Point of contact


Single Point Vulnerability Application

Create Industry Collaborative SPV Application

− Uniform Input Format

− Standardize to EPRI PMBD Names and Features



Uniform Input Format


Single Point Vulnerability Application – Opening Screen


Single Point Vulnerability Application - Distribution


Single Point Vulnerability Application – Site Search


Single Point Vulnerability Application – Industry Search


Single Point Vulnerability Application – Search Results


Single Point Vulnerability Application – Sortable Search Results


SPV Database Application



Developing beta pre-production application

– Common input format

– EPRI standard approach (PMBD)

– Standardize common system names

– Some unique fields (On-line refueling path delays)

– Ease of Use

Beta application testing in September 2016


SPV Database Application

Lessons Learned

− Inconsistent entry requires detailed review

− Opportunity to further improve SPV performance by

Better component characterization of duty cycle and environment

Helps determine appropriate failure modes

Complete understanding of technical basis of classification

Will ensure mitigation aligns with failure mode

Align mitigation strategies to failure modes according to component characterization


Current Needs

Solicit input sheets

Need quality data to start testing

Load application with member information

Deploy for Beta pre-production testing (Data Cleanup)


The Future

Pursue production version of application

Data quality improvement and alignment

Deploy Beta production application in 2016


Review of “Engineering Day”

Actions and Summary of Meeting

Chris Wiegand

nmac & pe (mechanical & electrical) engineering · mechanical engineering & maintenance...

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