Implementation of OnLine Monitoring Technologies

1
Implementation of On-Line Monitoring Technologies
The International Atomic Energy Agency Technical
Meeting on Increasing Instrument Calibration
Interval through On-Line Monitoring Technologies

• Brandon Rasmussen
• EPRI Instrumentation Control Center
• September 28, 2004

2
Introduction

• EPRI has been assisting numerous power plants in
  the evaluation, analysis, and implementation of
  On-Line Monitoring (OLM) systems through an
  active multi-year project.
• The experience gained has been well documented in
  a series of reports.
• It is envisioned that the capabilities of OLM
  systems can be exploited for the development of
  Equipment Condition Monitoring (ECM) systems,
  allowing the early warning diagnoses of OLM
  systems regarding individual instrument channels
  to be extended to specific plant components.
• Current and past efforts in pursuing this
  development are gaining momentum.

3
EPRI Experience in On-Line Monitoring

• EPRI initiatives in OLM began in the 1990s with
  the Instrument Calibration and Monitoring Program
  (ICMP) which targeted calibration monitoring of
  redundant sensor installations.
• In 1994, EPRI formed the EPRI/Utility On-Line
  Monitoring Working Group with the goal of
  obtaining NRC approval of on-line monitoring as a
  calibration reduction tool for safety-related
  instruments.
• This effort evolved into two working groups the
  Instrument Monitoring and Calibration Users
  Group and the On-Line Monitoring Implementation
  Users Group.
• Current OLM efforts continue, focusing on
  establishing guidelines for obtaining NRC license
  amendments to increase the calibration intervals
  of technical specification instrumentation.
• Additional efforts continue to support
  implementations carried out under the EPRI OLM
  program initiatives.

4
On-Line Monitoring Reports

• On-Line Monitoring Cost-Benefit Guide, EPRI, Palo
  Alto, CA 2003. 1006777.
• On-Line Monitoring Implementation Guidelines,
  EPRI, Palo Alto, CA 2001. 1003360
• Plant System Modeling Guidelines for Implementing
  On-Line Monitoring, EPRI, Palo Alto, CA 2002.
• Implementation of On-Line Monitoring for
  Technical Specification Instruments, EPRI, Palo
  Alto, CA 2002. 1006833.
• On-Line Predictive Condition Monitoring System
  for Coal Pulverizers Application of Wireless
  Technology. EPRI, Palo Alto, CA SmartSignal
  Corp., Lisle, IL and Dynegy Midwest Plant System
  Modeling Guidelines for Implementing On-Line
  Monitoring 1003661 (1003579)
• Equipment Condition Assessment Application of
  On-Line Monitoring Technology 1003695 2004
  product
• On-Line Monitoring Techniques to Equipment
  Condition Assessment Technical Update 2004
  product

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On-Line Monitoring

• May also be referred to as
• Calibration Monitoring
• Instrument Surveillance
• Calibration Verification
• Sensor Validation
• Signal Validation
• Definition of On-Line Monitoring (OLM)
  Technology
• OLM is an automated method of monitoring
  instrument performance and assessing instrument
  calibration while the plant is operating, without
  disturbing the monitored channels. Plant System
  Modeling Guidelines to Implement On-Line
  Monitoring, EPRI, Palo Alto, CA 2002. 1003661.

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Historical OLM Problem Statement

• Small instrument drifts are difficult to detect.
• Costly in terms of quality and efficiency.
• Can cause incorrect control actions.
• Periodic manual calibrations are the current
  defense.
• Costly in terms of labor, radiation exposure, and
  down time.
• Can cause damage or failures.
• May be unnecessary.

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OLM Systems Brief Overview

• OLM systems utilize empirical models to model a
  set of instrument channels, based on historical
  behavior.
• Continuous statistical analyses of the empirical
  models performance allow for unusual behavior to
  be identified on a channel specific basis.
• Instrument channels of suspect behavior can be
  further evaluated and/or calibrated.
• Instrument channels of usual behavior are
  considered healthy and within calibration.
• The goal of OLM systems as pursued by EPRI was to
  reduce instrument calibrations, especially safety
  related channels.
• While this goal is active, a new parallel goal is
  being pursued to build on the foundation of OLM
  systems for ECM.

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On-Line Monitoring

• The benefits of OLM are
• Information filtering
• Performance monitoring
• Calibration monitoring
• Calibration reduction
• A cost benefit analysis for nuclear power plants
  indicated that the ROI term for sensor validation
  systems, specifically for calibration reductions,
  was approximately 6 years.
• Value of performance monitoring and information
  filtering not included.
• If however sensor validation systems are employed
  for equipment condition monitoring (ECM)
• the suggested ROI term is lt1y, and
• annual benefits are in the range of .0.5M/year
  to 1.0M/year
• Based on cost of unplanned downtime and
  documented equipment failures.

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Cost Recovery from OLM Program for Calibration
Reductions
10
Summary of Lost Power Incidents at Selected U.S.
Nuclear Units 2000-2003
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Lost Power Incidents at Selected U.S. Nuclear
Units 2000-2003

1 Low Dollar Estimate 250,000/day Mean
Dollar Estimate 600,000/day High Dollar
Estimate 2,500,000/day
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ECM Program Requirements

• ECM can be achieved through applying logic
  processing to the anomalies output from an OLM
  system.
• A successful ECM program will provide a
  diagnostic system according the definition
  provided in EPRI NP-3652 (1984) Diagnostic
  systems are designed to detect equipment failures
  early enough to warn operators in advance of
  impending failures and to inform maintenance
  personnel about the nature of the failure.
• Successful condition monitoring must
• Have a clear understanding of failure modes
• Have installed instrumentation capable of
  detecting each failure
• Instrument signatures must be definable for each
  failure mode
• Failure mode must progress slowly enough to allow
  early detection

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EPRI Experience in Equipment Condition Monitoring
- Nuclear

• Nuclear sector project initiated in 2003 with
  Exelon and continues in 2004 with the addition of
  TVA.
• In 2003 a vendor evaluation was completed, and
  an implementation undertaken to include data
  integration.
• Current objectives
• Documentation of the procedure for developing
  ECM models
• Results will be provided for a system or
  component at TVAs Sequoyah, Watts Barr, and
  Browns Ferry NPPs
• Incorporation of vibration data will be
  investigated and reported where applicable.
• The ability of the ECM models to correctly
  diagnose the observed equipment degradations or
  failures will be evaluated.

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EPRI Experience in Equipment Condition Monitoring
- Fossil

• Finalizing scope for supplemental project with
  Progress Energy to provide guidance and model
  support for a plant-wide ECM implementation.
• Guidance will focus on model tweaking for
  enhanced diagnostic capabilities and determining
  action plans based on ECM model predictions.
• Both process data and vibration magnitude data
  will be incorporated into the models.

15
ECM Implementation Issues

• While commercial OLM and ECM software systems
  have been demonstrated, there are several issues
  that must be addressed before their full
  potential can be realized for power plant
  applications
• Adequacy of existing instrumentation for
  detecting equipment failure modes.
• Identifying additional sensor types and emerging
  technologies that can provide enhanced
  capabilities.
• Incorporating qualitative information as well as
  numerical data collected at random intervals.
• Integrating the diagnostic outputs from ECM
  systems into existing plant information systems
  to make efficient use of the technology while
  limiting additional unnecessary maintenance.
• Defining critical equipment and the financial
  impact of degradation or failure to develop
  supporting business case.

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Current EPRI Project Goals and Scope - OLM

• Assist in on-site implementations of OLM systems
  and software training.
• Complete updates to OLM reports for 2004 covering
  modeling guidelines, implementation guidelines,
  and technical specification instrument related
  issues (e.g. uncertainty analysis)
• Continued support in model development and
  evaluation at participating plants.
• Further support to plants applying for NRC
  license amendments for increasing calibration
  intervals.

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Current EPRI Project Goals and Scope - ECM

• Demonstrate ECM capabilities for critical plant
  equipment.
• Define failure modes, and failure signature
  charts.
• Identify ability to detect failure modes.
• Implement novel Similarity Based Modeling (SBM)
  methodology for on-line vibration monitoring and
  component assessment.
• Document results and lessons learned.
• Provide on-site implementation support and
  guidance in model development and anomaly
  interpretation.
• Address the issues stated for successful ECM
  implementations in the power industry.

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Contributions of EPRI Experience and Knowledge
for ECM

• Collaborative project structure with multiple
  participants allows for a greater learning
  potential than independent initiatives.
• Broad and expansive base of knowledge with
  respect to component failure that can be mined
  for the development of interpretive diagnostic
  rule bases.
• Integration of ECM systems and their diagnoses
  into existing and future EPRI products related to
  predictive and preventative maintenance will be
  supported.
• Investigations into new sensor technologies
  through other programs can be exploited to
  enhance the diagnostic capabilities of ECM
  implementations.
• Parallel efforts in wireless security will assist
  in bringing new wireless-based technologies into
  power plants as quickly as possible.

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Monitoring System Diagram
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Current Information Flow
On-Line Monitoring and Assessment System
Integrated Monitoring Diagnostics Application
Existing Equipment Maintenance Approaches
On-Line Plant Data
Off-Line Plant Data
1st Principles Models
Smart Sensor
21
An Integrated Future
1st Principles Models
Smart Sensor
Existing Equipment Maintenance Approaches
Integrated Monitoring Diagnostics Application
Data Integration
On-Line Monitoring and Assessment System
Maintenance Planning Procedures
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Final Words

• EPRI has completed several technical documents in
  support of OLM for calibration reduction.
• Continuous support of these documents will
  continue as the OLM project moves forward.
• Over the past several years, the capabilities of
  OLM systems to monitor instrument calibrations
  has been documented.
• Assistance in acquiring license amendments is the
  logical next step, and EPRI plans to support this
  effort where applicable, e.g. tools for
  quantifying model uncertainty.
• EPRI is currently collaborating with vendors and
  participating utilities to promote ECM
  technologies in the power industry.
• Current efforts are building on these experiences
  through extensions into condition monitoring
  applications, to achieve greater benefits, while
  maintaining support for the initiative of
  acquiring calibration interval extensions.