Presentations Session6 6.3 Naser

8/3/2019 Presentations Session6 6.3 Naser

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Next Step: On-Line Early Fault

Detection, Diagnostics, andPrognostics

Joseph Naser Ramesh Shankar EPRI

IAEA Technical Meeting on "Increasing Instrument CalibrationInterval Through On-line Monitoring Technologies

September 27-29, 2004Halden, Norway


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Prog 2 Copyright 2004 Electric Power Research Institute, Inc. All rights reserved.

Objectives

Demonstrate on-line monitoring technology inoperating nuclear plants for real-time diagnosisof high-value/high-impact plant equipment(e.g., turbines, feedpumps, condensatesystem)

Increase equipment reliability and availabilityand reduce unplanned outages

Reduce maintenance costs by moving tocondition-based predictive maintenanceSupport successful integration into enterprisebusiness process


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On-Line Monitoring Background

EPRI obtained an NRC SER in 2000 after adecade of research (TR-104965-R NRC SER)

The TR considered two approaches: Channel parametric techniques (redundant

instruments) and Advanced pattern recognition (MSET, neural

networks, etc.) for non-redundant channels

Plant implementation commenced soonafterwards, with goals (2001-present): Demonstrate plant reliability improvements Demonstrate cost benefits Develop guidelines for modeling and implementation


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Costs of Downtime

Reduced reliability/availability

Increased challenges to safety systems

Negative revenue impact

Increased corrective maintenance costs

Shutdown/startup costs, equipment damageand stresses, reduced life expectancy of equipment


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On-Line MonitoringApplications

NASA Shuttle main engine monitoring

Railroad industry

Commercial airlines Delta in-flight engine monitoring

Power Industry

Double blind test for feedwater flow sensor evaluation Instrument calibration reduction Equipment condition monitoring

applications


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Condition-Based PredictiveMaintenance

Need to minimize corrective maintenanceNeed to minimize costly preventative maintenancewhich often replaces good equipment and is costly

Base decisions on actual condition of equipmentNeed early fault detection and diagnosticcapabilities to minimize likelihood of forced outagesand equipment damage

Need highly accurate predictive capabilities basedon actual equipment condition and status of failureprecursors for reliable estimate of time to failure

Select the best time to perform maintenance


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ECM System Diagram


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An Integrated Future

On-LineMonitoring

and Assessment

System

MaintenancePlanning &Procedures

ExistingEquipment

Maintenance Approaches

Data

Integration

IntegratedMonitoring &Diagnostics &Prognostics Application

SmartSensor

1st PrinciplesModels


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Fleet-wide EnterpriseArchitecture

Sensor Data Feeds

eCM Server

SQL OPCCustom

Plant Operations

Component Maintenance

Expert

SystemsEngineer

Plant 1

Plant 3 Plant 2

CorporateFleet

Monitoring Center

Sensor Data

E PRI Add l Mod el

Development/ Oversight


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Sensor Needs

Ability to capture failure modes may point toadditional sensor needs

Wireless sensor solutions Cost of wiring: $1,000 to $2,000/ft Wireless technology penetration into the consumer

and industrial markets Wireless technology provides an as-yet unexplored

degree of sensing and control for the electric power industry

Paradigm shift in sensing Multi-process, multi-functional capabilities


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On-Line Monitoring TechnologyRoadmap

2004-52004-5

20092009

20052005

Submitted TR for NRCSE R of OLM Technology

Demonstration of On-Line

Monitoring & WirelessTechnology

E arly Anomaly Detection andAutomated Diagnostics

Decision Support Systems (DSS)Installed (Early AnomalyDetection and AutomatedDiagnostics)

Condition-BasedMaintenance Decisions

(Prognostics)

1

2

3

4

5

20032003

1990s1990s

20072007

Instrument Monitoring andCalibration Reduction

Pilot Study for Fleet-Wide E CMcompleted ( E nterprise wide)

On-Line Monitoring

ImplementationWireless Technology Ev aluations

Decision Support Systems Installed(Complete E CM/DSS Demos andModeling Guidelines)

Lessons Learned for Integrationof DSS Installations from (3)and (4) with Prognostic Tools


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W hat is Needed to be Done?

Use risk-informed insights, as well asdeterministic approaches, to determine a list of critical equipment that can cause significantnegative economic consequences if they fail;

list would be the candidates for on-line earlyfault detection, diagnostics, and prognostics

Take existing on-line monitoring capabilities,which have been previously developed for instrument calibration reduction, for the caseswhere there are redundant sensors and wherethere are non-redundant sensors, and expandto on-line monitoring of critical equipment


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W hat is Needed to be Done? (Contd)Research and determine applicable existingearly fault detection technology for criticalequipment

Research to address any gaps in the early fault

detection technology that is needed to beovercome for critical equipment

Research and determine existing diagnostictools in an on-line, automatic mode of operationfor critical equipmentResearch to address any gaps in diagnostictechnology that is needed to be overcome for

critical equipment


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W hat is Needed to be Done? (Contd)

Create new diagnostic models for a significantsubset of critical equipment that has higheconomic consequences of failure, leveragingtechnology development from other industries,

these models will take multiple inputs to look atmultiple failure mechanisms to deduce moreinformation than currently routinely used

Determine the sensor needs to detect anddiagnose precursors to the failure modes in thesubset of critical equipment selected


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W hat is Needed to be Done? (Contd)

Identify causes of data quality issues that willimpact early fault detection and diagnosticssuch as missing, invalid, or noisy data fromvarious plant data sources and develop

technology for overcoming themIdentify existing prognostic tools and ongoingresearch on prognostic capabilities for accurate prediction of time-to-failure

Research to address any gaps in prognostictechnology that is needed to be overcome for critical equipment


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ConclusionsOn-line monitoring addresses the strategic needs for

the power industryNeed for sensors other than process measurement Remaining life Damage accumulation

Synergy between wireless technology and on-linemonitoring

Fleet-based diagnostics/prognostics capabilities

Still a lot to do in order to achieve the benefitspossible from equipment condition-based predictivemaintenance Requires research, development, and application activities

Collaboration and information sharing needed

Documents

Presentations Session6 6.3 Naser