On-line Monitoring and Calibration Techniques in IC On-line Monitoring and Calibration Techniques in Nuclear Power Plants. Prepared by: H.M. Hashemian, President. Analysis and

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  • Advanced I&C

    On-line Monitoring and Calibration Techniques in Nuclear Power Plants

    Prepared by:H.M. Hashemian, President

    Analysis and Measurement Services CorporationAMS Technology Center

    9119 Cross Park DriveKnoxville, Tennessee 37923

    USA

    Presented at:International Conference on

    Opportunities and Challenges for Water Cooled Reactors in 21st Century

    Vienna International CentreInternational Atomic Energy Agency

    Vienna, Austria

    27-30 October 2009

  • Do Not Forget Sensors and Cables

    2H.M. Hashemian

    Process

    Temperature Sensor

    PressureTransmitter

    Cables

    Cables

    Penetration

    I&C Cabinets(Analog or Digital)

    Control Room Area(Mild Environment)

    Containment(Harsh Environment)

    ~150 meters

  • Proper Installation is Critical to Temperature Sensor Performance

    3H.M. Hashemian

    0

    4

    8

    12

    Res

    pons

    e Tim

    e (s

    ec)

    Thermocouple Tag Number

    DWM139B-01A

    0

    1

    0 10 20 30 40 50 60

    Time (Sec)

    Step

    Res

    pons

    e

    Fast - GoodSlow - Bad

    RTD

    Thermocouple

  • Nuclear Power Plant Pressure Transmitter Failure Mode Detected by Pure Luck

    4H.M. Hashemian

    80

    90

    100

    110

    120

    9:30 AM 10:00 AM 10:30 AM 11:00 AM 11:30 AM 12:00 PM 12:30 PM

    RC

    S Fl

    ow (%

    )

    Time

    JPF025B-04

    FT-445

    FT-444

  • Sensing Lines are Critical to the Performance of Pressure Transmitters

    5H.M. Hashemian

    Process Pipe or Vessel

    Condensate Pot

    Vent

    ThermalInsulation

    Rootvalve

    Shield Wall

    Penetration

    Accessible Isolation Valve

    Transmitter

    PrimaryContainment

    Wall

    Restriction Device

    Check Valve

    ~ 50 meters

  • Cable Diagnostics

    1 2 3 4

    RTD

    -0.5

    0

    0.5

    -200 0 200 400 600 800 1000

    1,22,3

    3,4

    Distance (Feet)

    6H.M. Hashemian

  • Signal Problems are Not Always in Cables

    Current MeterN

    eutr

    ons

    Current Voltage Source

    +

    NeutronDetector

    7H.M. Hashemian

    -

    I V Test

  • 10H.M. Hashemian

    MaintenanceClasses

    Predictive Maintenance

    Methods that use Data from Test

    Sensors

    Predictive Maintenance

    Methods that use Data from Existing Process Sensors

    Predictive Maintenance

    Methods Based on Active Measurement

    Signals

    Detection of Fouling of

    Venturi Flow Elements

    Detection of Sensing Line

    Blockages

    Instrument Calibration Verification

    Loose Parts Monitoring

    Leakage Monitoring

    Vibration Measurement

    Sensor Installation Verification

    Sensor Response Time

    Testing

    Cable Condition Monitoring

    Conventional and Advanced Predictive Maintenance Technologies

  • Plant Implementation of On-Line Calibration Monitoring

    H.M. Hashemian 9

    PlantComputer

    Data

    Status of Plant Instrumentation

  • Plant Startup and Shutdown Data

    10H.M. Hashemian

    0

    10

    20

    30

    40

    50

    60

    70

    80

    90

    0 500 1000 1500 2000 2500

    Pres

    sure

    Time (Minutes)

    Startup Data KDL204A-01

    0

    10

    20

    30

    40

    50

    60

    70

    80

    90

    0 300 600 900

    Pres

    sure

    Time (Minutes)

    Shutdown Data KDL204A-02

  • On-Line Calibration Monitoring Results Covering the Full Operating Range of a Transmitter

    11H.M. Hashemian

    -1.0

    -0.5

    0.0

    0.5

    1.0

    7.5 20 30 40 50 60 70Operating Point (%)

    + (ALLOWABLE CALIBRATION LIMIT)

    - (ALLOWABLE CALIBRATION LIMIT)

    CRS038B-01D

    evia

    tion

    (%)

  • Conclusions and Recommendations

    Do not forget the sensors, process-to-sensors interfaces, cables, connectors, and penetration

    The validity, accuracy, and fidelity of process signals depends on proper installation of sensors and flawless cables and connectors

    On-line monitoring techniques and in-situ test methods are now mature enough for ready use in nuclear power plants

    Regulators have approved the OLM concept to verify the calibration of nuclear plant pressure, level, and flow transmitters

    U.S. plants are applying for generic NRC licensing to implement OLM for online calibration monitoring of pressure, level, and for transmitters

    Research is needed to establish the uncertainty of modeling techniques for on-line calibration monitoring applications

    H.M. Hashemian 12

  • Thank You

    13H.M. Hashemian

    Advanced I&COn-line Monitoring and Calibration Techniques in Nuclear Power PlantsDo Not Forget Sensors and CablesProper Installation is Critical to Temperature Sensor PerformanceNuclear Power Plant Pressure Transmitter Failure Mode Detected by Pure LuckSensing Lines are Critical to the Performance of Pressure TransmittersCable DiagnosticsSignal Problems are Not Always in Cables 8Plant Implementation of On-Line Calibration MonitoringPlant Startup and Shutdown DataOn-Line Calibration Monitoring Results Covering the Full Operating Range of a TransmitterConclusions and Recommendations 13

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