NMAC & PE (Mechanical & Electrical Maintenance · 3 © 2016 2015 Electric Power Research Institute, Inc. All rights reserved. Get Connected…

© 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

August 30, 2016

NMAC & PE

(Mechanical & Electrical

Maintenance)

August 15, 2016

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

Emergency Exits: Waldorf Astoria BR (Mezzanine Level)

NOTE: ALL

RED DOORSARE EMERGENCY

EXIT DOORS

WALDORF ASTORIA BALLROOM


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Purpose and Objective of the Presentation

Discuss Maintenance 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 – Wednesday (Maintenance Focus)


Integration Committee Report Format

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?


Together…Shaping the Future of Electricity


Presenter: Heather Feldman

Program Manager, Engineering Programs (BOPC)

Patty Wade

STE Coordinator

NMAC and PE Integration Committee Meeting

August 31, 2016

Standardized Task

Evaluation (STE) Update


Topics

Standardized Task Evaluation Program Foundation

– What is it?

– What is the value?

– Who is in it?

– How does it work?

Standardized Task Evaluation Program Administration

– Utility Implementation

– Workforce Provider Implementation

Standardized Task Evaluation Development

Future Plans


Standardized Task Evaluation Program Foundation


What is the Standardized Task Evaluation (STE) Program?

Standardizing Tasks Across the Industry

Qualification of supplemental maintenance workers

–Tasks include rigging, scaffolding, pump maintenance, valve maintenance

–Over 80 EPRI developed modules currently available

–44 modules on INPO’s NANTeL

“Guidelines for On-The-Job Training and Qualification” INPO’s ACAD 91-006, Rev 1 recognizes STEs as alternate basis for qualification


Value – Standardized Task Evaluation (STE) Program

Photo courtesy of

United Association

FENOC has realized an

improved performance of

supplemental workforce in

critical outage support tasks

by implementation of EPRI’s

Standardized Task

Evaluations.

Source: EPRI Product 1020755

•Easily managed qualification process

•Enables a “work-ready workforce”

•Cuts training time and costs

•Efficient use training resources

Supplemental valve maintenance

at TVA:

“Through cooperation between our

companies, D&Z has trained

numerous personnel onsite and

qualified them using their AP3

program. Because of this we

receive qualified personnel who

we are confident can perform

their tasks safely and

proficiently during our outages.”

Source: EPRI Product 3002006720


Utilities

AEP

APS

Dominion

Duke Energy

Energy Northwest

Entergy

Exelon

First Energy Nuclear Operating Company

Nebraska Public Power District

OPPD

Pacific Gas and Electric Co

Talon Energy

SC Electric and Gas

Southern Nuclear

Tennessee Valley Authority

Wolf Creek Nuclear

CANDU Owners Group (Canada)

TVA Fossil (Non-Nuclear)

Oglethorpe Power Corp (Non-Nuclear)

Workforce Provider Organizations

BHI Energy

Day and Zimmermann

Electrical Training Alliance (IBEW/NJATC)

Instrument Contracting & Engineering Association (ICEA)

International Association of Bridge, Structural, Ornamental and Reinforcing Ironworkers

International Brotherhood of Boilermakers, Iron Ship Builders, Blacksmiths, Forgers & Helpers, AFL-CIO

Westinghouse

UA of Plumbers and Pipefitters (US and Canada)

Areva NP (Canada)

IBEW – Local 804 (Canada)

Infrastructure Health and Safety Assoc (IHSA) (Canada)

Ironworkers Ontario District Council (Canada)

International Brotherhood of Boilermakers (Canada)

Who participates in the EPRI STE Program?


What is a Standardized Task Evaluation?

EPRI tools are used to test a worker’s knowledge and skills

Tools are available from EPRI’s website

Task Analysis

Written Exam

Performance Evaluation


Standardized Task Evaluation Program Administration


Program Administration

Getting Started

– Compare utility tasks with Standardized Task Analysis

– Identify and resolve gaps

Administer Written Exam and Performance Evaluation

– INPO Accredited Training Department

– AP3 (EPRI Administration Protocol for Portable Practicals)

Compliant Organization

Qualification

– Record qualification in EPRI registry, PADS, utility database, and/or

workforce provider database


AP3 Compliant OrganizationsEnables work force providers to administer STEs

• United States

BHI Energy

Day & Zimmermann

United Association of Plumbers and Pipefitters

International Association Bridge, Structural, Ornamental and Reinforcing Iron Workers

• Canada

Bruce Power

Ontario Power

IHSA


STE Task Qualification Registry

• Over 9,000 individuals have successfully completed both a

written and performance standardized task evaluation in

PERFORM INDUSTRIAL RIGGING



PERFORM STANDARD RIGGING



CALIBRATE GENERAL INSTRUMENTATION

Over 15,500 Individuals have successfully completed

both a written and performance standardized task

evaluation in a given task.


Uses – Examples

Site Usage

• Utility administers STE and enters qualification into utility system

• Workforce provider administers STE and enters qualification into EPRI registry and utility accepts qualification

Industry Usage

• Registry used to enable portability and work ready workforce


Standardized Task Evaluation Development


Working Groups

Purpose

– Periodic meetings to review and revise existing STEs or to create

new STEs

EPRI acknowledges utility and workforce provider support at the working groups.


STE Task Listing

Task listing is available at:

– https://membercenter.epri.com/programs/065756/Lists/Attachments/Unique%20Pages/ebc69b

482cac40a3ac2aab68222a270c/STE%20Task%20Listing.pdf

Task listing reviewed on August 3-4, 2016

https://membercenter.epri.com/programs/065756/Lists/Attachments/Unique Pages/ebc69b482cac40a3ac2aab68222a270c/STE Task Listing.pdf


EPRI Standardized Task Evaluation Program

• Sample Evaluations Include:

EM01.05 Electrical Safety for Qualified Worker

EM01.06 Clean & Maintain Electrical Cabinets, MCC, Load Center and

Switchgear

IC04.01 Calibrate General Instrumentation

IC06.01 Maintain Air Operated Positioners

MM03.01 General Valve Maintenance

MM05.06 Maintain Centrifugal Pumps


Evaluations Developed Using the Systematic Approach to

Training (SAT) Process

Source: EPRI Product

3002006470


Future Plans


Future Plans

Support existing STEs as broader implementation occurs

Continue to refine task list

Potentially expand to areas beyond maintenance tasks

– Radiation protection tasks

– Alignment of STEs with standardized training and procedures

– Chemistry tasks

– Engineering tasks




EPRI Standardized Task Evaluation Program Resources

EPRI STE Program Brochure (2015) Product: 3002004945

http://www.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002004945

Success Story 3002006720, Standardized Task Evaluation Program Enables Workforce Providers to

Accelerate Qualification Efforts, Reduce Training Costs – (2015)


EPRI Standardized Task Evaluation Program Implementation Guide, Revision 1 Updated 7/2015 - Product:

3002006470


Administration Protocol for Portable Practicals (AP3) – Product1015074


Success Story – Dominion – Product 1024815


Success Story – First Energy – Product 1020755









Nick Camilli

Sr. Technical Leader

Nuclear Power Council – NMAC IC

August 31, 2016

NMAC Valve Update2016 Deliverables


Refresher – Key Drivers of Valve Projects

Operating Experience

– Valve events continue to be the most prevalent in OE reviews

Technology Changes/Knowledge Transfer

– Guides are updated to keep up with technology changes and to

facilitate knowledge transfer at utilities/plants

Regulatory Changes

– Guides are updated to reflect changes in NRC and code

requirements

Gaps in existing product catalogue

– New guides are developed to address specific needs


2016 Valve Products

3002008055Evaluation Guide for Valve Thrust and Torque Requirements

3002008045Motor-Operated Valve Application Guide Vol:1


3002008056

Air-Operated Valve Application Guide

3002007696Valve Specialist Guide

3002007711Purge Valve Maintenance Guide

#1


Issue

1) There is significant overlap between the AOV and MOV

application guides with regard to Section 5 – methods for

determining required thrust or torque.

2) Based on current EPRI internal QA guidance, these

required thrust/torque methods need to be published in a

QA document.


Current Situation

Overlap


Resolution

Separate AOV Evaluation Guide content into two documents:– Evaluation Guide for Valve Thrust and Torque Requirements

Single source document covering all valve types for determining valve required thrust/torque, independent of actuator

Includes new balanced disk globe valve research

– AOV Application Guide

How to calculate actuator capability and margin (valve requirements removed)

Revise the MOV Application Guide, Two Volumes – Remove Section 5 (valve requirements) and replace it with a reference

to the new valve evaluation guide

– Make all documents QA


Resolution – What this looks like big picture

Evaluation Guide for Valve

Thrust and Torque

Requirements

(How to determine

thrust/torque

requirements)

AOV

Application

Guide

MOV Application

GuideEPRI

Test

Reports

Future

Application

Guides?

Valve Requirements

(How to determine thrust/torque

requirements for all valves)

Actuator Capability

(How to determine actuator capability

and margin independent of valve)

Advantages

Eliminate duplication

QA

Design Basis Package for

Calculation Support

(ASME Appendix III & IV)


New Research – Balanced Globe Investigation

Sideloading

Likely not an issue for most applications

Limiting case for most is at closed position

Need better prediction technique and

screening criteria

Imbalance Area

Understand “area upon which DP Acts” effect

for unbalanced/caged valves

Previous work focused on uncaged valves

Current guidance uses guide area for T-

pattern caged valves

Goal: Remove conservatism! More accurate predictions = better resource allocation

Understanding the Need


Approach for Sideloading/Imbalance Area Investigation

Scope: T pattern, Cage Guided,

Balanced Plug

Test Specimen 1

– Fisher 4” 150 lb Model ED

Test Specimen 2

– Masoneilan 4” 150 lb Model 41611

Development

CFD Model

CFD

Analysis

Flow Loop

Testing

Develop

Sideloading

Methodology

Validation

Apply

Methodology

to Specimen

Validate with

Flow Loop

Results

Apply

Methodology

to Specimen

#2

Test Specimen

#2 in Flow

Loop

Validate

Methodology

to Specimen

#2

Selected based on

review of TAG globe

valve population


Test Matrix

Fisher

Quick Open Cage

– Flow Under – 3 flow rates (up to 45

ft/s)

– Flow Over – 3 flow rates

– Hot Water Tests – 3 flow rates >

150°F

– Upstream Elbow Testing

3 configurations/3 flow rates

Flow Under/Flow Over

Linear Cage

– Flow Under – 3 flow rates


Masoneilan

Linear Cage

– Flow Under – 3 flow rates


Added scope due to

discussions with

Fisher & Masoneilan


Results – Step 1: Screening to Use Validated Model

𝑟𝑏−𝑟𝑐 ℎ

𝜋𝑟𝑠2 > 0.12

Control Type?

Cage Controlled

Use Generalized Model with user-defined CDPT

Coefficients

Port Controlled

Cage-to-Body

Clearance?

Clearance is Narrow or unknown

Use Generalized Model with user-defined CDPT

Coefficients

Clearance is WideUse Validated FDPT Model Screening-Two Point Model-Multi-Point Model (Disk Bands)

Clearance Check


Results – Step 2: Screening for FDPT Approach

Close Stroke –

Two Point Model

Open Stroke –

Multi-Point Model

Flow Over Flow Under

Notes(1, 6)

Notes(2, 5)

Opening Stroke

Closing Stroke

Notes(1, 7 )

Notes(2, 3, 7 )

Opening Stroke

Closing Stroke

QuickOpening

Linear & Equal Percentage

Notes(1, 7)

Notes(2, 3, 7 )

Opening Stroke

Closing Stroke

QuickOpening

Linear & Equal Percentage

Notes(1, 7)

Notes(2, 3, 7)

Opening Stroke

Closing Stroke

Disk Style BSection 8.2.5 &

Section 10.2

Notes:

1. Evaluation requires multi-point model (effective area band model)

2. Evaluation using two-point method is generallly acceptable for the closing stroke. The two-point model is non-conservative at the full open position; however, the actuator output is much greater at the start of trave (at the open position) and the non-conservatism in the model does not affect margin predictions.

3. The most conservative evaluation is based on static running friction with line pressure and no DP (if this condition is applicable).

4. Acceptable evaluation method depends on normalized velocity.

5. The most conservative analysis is based on two-phase conditions. Two-phase conditions decreases the self-closing FDP just off the seat (5% to 25%). If sufficient back pressure is not present to suppress cavitation, the most conservative evaluation is based on static running friction with line pressure only unless (if this condition is applicable).

6. The most conservative analysis is based on Single-phase conditions. Single-Phase conditions increases the self-closing FDP just off the seat (5% to 25%).

7. Validation performed against test data over a range of Vp numbers


Results – Step 3: Implementing Validated Multi-Point FDPT

Model

vsDPDFDPT PdCCF 2

4

DPTSRUSwtPR FFFFFF

For open direction, need to calculate FR at four

positions

• Closed

• 40% open

• 55% open

• Full Open


330 –> 187 pages

Gate and globe –> Rising stem

Valve requirements removed

Enhanced figures

QA compliant

MOV Application Guides

Volume 1: Rising Stem Volume 2: Quarter Turn Valves

308 –> 65 pages

Butterfly –> Quarter Turn


Enhanced figures

QA compliant


AOV Application Guide

Objective

– Provide evaluation techniques to verify the proper AOV actuator

sizing and set point establishment for normal and accident

conditions


Enhanced figures

QA compliant


2016 Valve Products




3002008056




#2

Refurbishment

Suppliers

Valve

Manufacturers

Valve

Specialist

• Valve-Specific Design Information

• Valve Performance Specifications

• Recommended Spare/Replacement Items

• Industry Performance Data

• Design/Procurement Specifications

• Installation Specifications

• Plant Design Parameters

• Feedback on Refurbishment Specification & Requirements

• Refurbished Valves

• Refurbishment Work Scope Definition

• Specifications and Work Instructions

• Testing/Verification Recommendations

• Performance & Testing Acceptance Criteria

Users Groups

• Industry Valve Performance Issues

• Plant-Specific Performance Experience


Valve Specialist Guide

The Need

As experienced personnel leave or retire and new personnel come into the industry, it is important to plan for the transfer of knowledge to maintain reliable operation of valve systems and components.

The Outcome

This report provides a road map for

the development of component

expertise.


Valve Specialist Guide Skills Chart


Valve Specialist Guide Layout

The guide uses a color coded approach (shown in the

previous slide) for entry, intermediate and expert levels

The format of skills, training and industry information is

maintained through the guide.

The Technical Advisory Group comprised of many

international members


2016 Valve Products




3002008056




#3


Purge Valve Guide

Purge Valves have created significant impacts to Nuclear

Plant Operations

Purge Valve Design and Maintenance is unique and requires

specific guidance

Keys to maintenance such as

the graphic figures support

field work


Purge Valve Content

The Purge Valve Guide outline:

– Design Information (Section 2)

– Troubleshooting (Section 3)

– Condition Monitoring/Preventive Maintenance

(Section 4)

– References (Section 5)


A small additional pressure drop can cause tremendous

additional bearing loads for large valves. A 10 psid (69 kPa)

drop across a 72-in. (DN 1800) valve can result in a torque

requirement of 5125 ft-lbs (6920 N-m).

Testing of purge valve is direction dependent. Information

Notice 88-73[4] concerning leak rate testing is addressed in

this guide and ways to ensure testing is correct.

Temperature is the largest contributor to seat accelerated

aging, followed closely by oxidation in HVAC systems.

Purge Valve Key Take-A-Ways


Purge Valve Key Take-A-Ways

Some plants have found that ultrasonic examination (UT) can

be used effectively to detect cracking.

Once an optimum point is reached that minimizes leakage, it

is important to effectively lock the valve in the correct closed

position. The use of a gag is very effective. If this is not

possible, match marks should be used as a minimum. The

valve mechanical stops should be reset if available.


Product Schedule

Product ID Title Deliverable Date

3002008055 Evaluation Guide for Valve Thrust and Torque Requirements August 31, 2016

3002008045 Motor-Operated Valve Application Guide Vol:1 November 15, 2016

3002008047 Motor-Operated Valve Application Guide Vol:2 November 15, 2016

3002008056 Air-Operated Valve Application Guide November 18, 2016

3002007696 Valve Specialist Guide October 12, 2016

3002007711 Purge Valve Maintenance Guide November 11, 2016


Potential Work for 2017/2018

Support request from PWR Owner’s Group

– Quarter Turn valve testing

Potentially revise diagnostic testing guide (1022954) for further

guidance

– Quarter Turn valve bearing COF

PWROG has identified Nylon and NiResist as additional materials

to be tested

– Diaphragm valves

Development of thrust prediction model




Rick WayPrincipal Technical Leader

NMAC-PE Integration Committee

Wednesday, August 31, 2016

Maintenance Projects

and Discussion on

“Delivering the

Nuclear Promise”


Agenda

A Brief Review of “Delivering the

Nuclear Promise”

EPRI NMAC/ PE activities in

support of DNP

Discussion on PMBD and

Maintenance Activities



Process for review of new improvement opportunities


EPRI NMAC and PE Activities






Future of PM Basis Database

PMBD

Data

EPRI User Interface

Vulnerability Tool

Cost Module

PM Templates

Industry Data

Work Order Information

Equipment Failure Data

Online Monitoring Data

PMBD Web Services

Integration with:

Utility ER Tools

3rd Party Software

Additional EPRI Products

Data Integrity

Regular Template Reviews

Internally and with Industry

Groups


NMAC and PE a very involved in the solutions to many of the

Nuclear Promise initiatives

– Work Management

– Preventive Maintenance

– Component Classification

– Supply Chain

PMBD Future: Provide a tool that integrates with other ER

software tools and provide a next generation set of analysis

tools which integrate cost and other aspects of reliability.

Key Take Away Points


IC Meeting Summary and Discussion


IC Meeting Summary and Discussion

Solicited Feedback of IC meeting

Template and Input for ER APC Report

Closing Thoughts


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


Maintenance Focused IC Meeting Closing

Comments and Critique



Documents

NMAC & PE (Mechanical & Electrical Maintenance · 3 © 2016 2015 Electric Power Research Institute, Inc. All rights reserved. Get Connected…