opal reactor “successes and challenges” · – identify suitable equivalent material for fan...
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OPAL Reactor
“Successes and Challenges”
28 May 2014 – Engineers Australia
David Vittorio
OPAL Reactor Manager
Overview
• OPAL – Description
• Technical Challenges and
Improvements
• Practices and Processes
• Utilisation and Operating
Performance
OPAL – Multipurpose
Pneumatic
Transfer
Irradiation
Facilities
Primary
Coolant
Large Volume
Irradiation
Facilities
Cold Neutron
Source
Core
Bulk Irradiation
Facilities
Neutrons – For Health
10,000 hospitals in the
world use radioisotopes
40 million patients per year
Diagnostics (cardiology,
oncology, neurology)
Therapy / palliative care
10%
90%
Neutrons – for Science
Small Angle
Neutron Scattering
High Intensity –
Powder Diffractometer
Reflectometer
High Resolution –
Powder Diffractometer
Laue
Diffractometer
Strain
Scanner
Time Of Flight
Inelastic Scattering
Ultra Small Angle Neutron
Scattering
Back-
Scattering
Crystal
Alignment
Small Angle Neutron
Scattering
Operating instruments
Construction/commissioning
Neutrons – For Industry
Source: Topsil and Yole Development
• High and very high voltage markets• Low volume specialty products
• High and medium voltage markets• Medium volume specialty products
NTD - Silicon
Technical Challenges and Improvements
Cold Neutron Source
• Cryogenic Refrigeration System
• Cold Neutron Source Helium Compressors
• Multiple component failures
– Compressor Bearing Instability
– Compressor Air End Screw Failures
• Consequence
– Failures resulted in unreliable operation of reactor and
CNS supply
– Major maintenance intervention to rectify
– Suspension of CNS science based program
Helium Compressor – Component Failures
2 x 250kW Helium compressors supply high pressure/high flow helium to the Cold Neutron Source cryogenic system
Compressor Screw Air Ends
Root Cause Analysis
• Root Cause Analysis Outcome– Compressor oil degradation resulting in bearing instability
– Compressor oil degradation resulting in air end screw failures
High Oil
Temp.
Low
Viscosity
Screw
Contact
Debris
Filter
Blockage
Reduced
Oil Flow
FAILURE
CNS Compressor Rectification
• Compressor Screw oil
injection temperature
reduced 45oC
11
• Installation of high capacity
plate-and-frame Heat
Exchangers
Performance Indicator Actual Target
CNS Cold Source operations since
18/07/13 to 26 May 2014
- Days at full power in NO mode
- CNS Operational Availability
Reactor days at power
315.0
99.8%
315.0
95.0%
OPAL Full Power Days –
Calendar 2014 to 26 May
122 122
CNS Operational Availability in 2014
(to 26 May)
100% 95.0%
CNS Performance
• Benefits
– Cost effective approach
– Local suppliers
– Lead times reduced from 19
weeks to 4 weeks
– Superior corrosion protection
than original
Cooling Tower Fan Refurbishments
• Aim
– Refurbish fans to extend life and improve
reliability
– Cost effective approach
– Keep installed spare fan operational
– Utilise standard shutdown periods
7 x Al Blades (re-use)
Motor 45 kW (replace)
Gearbox (refurbish), specialist
Support Frame (refurbish), new HDG
Removable Walkway (refurbish), new HDG
All fasteners, (replace), use HDG
14 x hub blocks (refurbish), zinc electroplate
1 Hub (refurbish):
ENECON CeramAlloy CP & ChemClad SC
7 x blade shafts (replace), Bisplate 80 + HDG
Original Fan Assembly New Fan Assembly
• Challenges
– Source local suppliers
– Identify suitable equivalent material for fan blade shaft
replacement
� Chemical analysis
� Physical properties analysis
� Metallographic examination
� Suitability for HDG
Practices and Processes
How do we decide and define an optimum mix of
maintenance tasks ?
Maintenance Strategy Optimisation
• Condition Monitoring Tasks - Surveillances, inspections,
testing, monitoring, trending or analysis tasks
addressing failure modes with a defined P-F interval.
• Fixed Time Tasks - Fixed time overhaul, restoration or
replacement tasks addressing failure modes that exhibit
a wear-out failure pattern.
• Corrective Maintenance Tasks – Correct expected or
unexpected failures.
Condition
Based Task
3
Failure will
always be a
breakdown
(Expected
failure)4
Fixed Time Task
1 Fixed Time Task
Condition Based Task
OR
2
Pa
tte
rn o
f F
ail
ure
Rate of Deterioration
Age-Related (Wear-Out)
Random
Sudden
Gra
dualP
F
P-F interval(Potential to Functional failure)
P
F
P-F interval(Potential to Functional failure)
Safe or Economic Life
4%
2%
5%
7%
14%
68%
Quadrant 1
Fixed Time Strategy is the only option
Task interval is set by the safe or economic life (or
MTBF)
(Eg – Limit switches in a hot cell)
Quadrant 3
Condition Based Strategy is the only option
Task interval is set by the P-F interval
For the task to be feasible there must be:�A clearly defined P condition that the task is able to reliably detect
�A fairly consistent P-F interval
�A P-F interval that is long enough to be of practical use
Quadrant 4
Run to Fail strategy is the only option
(Eg Lighting)
Quadrant 2
Either Fixed Time or Condition Based
Strategy is an option
First look for a Condition Based Task (Quadrant 3)
Then look for a Fixed Time Task (Quadrant 1)
Maintenance Strategy Optimisation
Condition Monitoring
• Condition Monitoring fits into quadrant 2 & 3 of
the Maintenance Feasibility & Effective Analysis
Random
Condition
Based Task
3
Failure will
always be a
breakdown
(Expected
failure)4
Fixed Time
Task
1 Fixed Time
Task
Condition
Based Task
OR
2
Pa
tte
rn o
f F
ail
ure
Rate of Deterioration
Age-Related
Sudden
Gra
dual
Quadrant 3 & 2
Condition Based Task is the only option
Task interval is set by the P-F interval
For the task to be effective there must be:
�A clearly defined P condition that the task is able to
reliably detect
�A fairly consistent P-F interval
�A P-F interval that is long enough to be of some use,
i.e. it is practical to monitor within the P-F interval
and there is sufficient time to plan and take action
before reaching the F condition
Condition Monitoring for Safety and Reliability
• Vibration Monitoring (VA)
• Thermography
• Oil Analysis & Lubrication Management
• Chemistry Control
• Process Data review and trending
CM Techniques
Bearings & Couplings (pump and fly- wheel):• Temperature• On-line VA• Handheld VA
Process:• Measurement of
inlet & outlet pressures (efficiency)
• Flow trending
Mechanical Seals:• Trending of
leakage rates
Oil Analysis of bearings
Thickness testing of pipes
Motor:• Bearings (VA)• Thermography• Insulation/winding
resistanceProcess:• Chemistry control
and monitoring
Condition Monitoring - Example
• 129 Hz fault plus harmonics and the trend of worsening
condition.
Condition Monitoring - Example
CM -Thermography
• Switchboards
• MotorsOVERLOADS
Utilisation and Operating Performance
Status of Mo99 Supply
Australia
< 5%
ANSTO
Canada
40%
Netherlands
30%
Belgium
10-15%
South Africa
10-15%
SAFARI
HFR
NRU
Poland
5%
Maria
BR-2
France
10-15%
OSIRIS
Performance – Operating days
0
50
100
150
200
250
300
2006 2007 2008 2009 2010 2011 2012 2013 2014
39
94
128
248
286282
270
296
108 108
294
Total Power
Days (Calendar Years)
Ta
rge
t D
ay
s
Target - 300
Safe Days
OPAL critial
on 12 August 2006
2014 Status at:
Tuesday 28/4/14
Fo
reca
stP
ow
er
Da
ys
Act
ua
l P
ow
er
Da
ys
2012 – Planned
Long Shutdown (42 days)
Performance – Availability to Plan
60
65
70
75
80
85
90
95
100
2008 2009 2010 2011 2012 2013 2014
72
91
9392
97
94
98
Availability to
Planned Schedule (%)
OPAL critial
on 12 August
2006
2014 Status (current): From 1/1/14 to 28/4/14
98% - Target Availability to Plan