COMSY - A Software Tool for Aging and Plant Life Management

COMSY - A Software Tool for Aging and Plant Life Management

André Zander AREVA NP GmbH, PTCMT-G

3th Plant Life Management Conference May 14th – 17th, 2012; Salt Lake City, USA

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All rights are reserved, see liability notice.

3th PLIM Conference - COMSY – AM/PLIM Surveillance Software - Salt Lake City; May 14th - 17th, 2012 - AREVA NP GmbH

Proprietary - © AREVA NP - p.2

Content

Introduction

AREVA NP Expertise in Aging (AM) and Plant Life Management (PLIM)

Approach, Objectives and Requirements on AM and PLIM

AREVA Concept in the scope of Aging Management for Plants in Operation

Scoping and Screening

Modeling of relevant SSCs

Degradation assessment

Review and/or specification of preventive measures

Examination data management

Verification of transferability reported events

Summary

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AREVA NP GmbH Expertise in Aging / Plant Life Management

AREVA NP GmbH

Aging and Plant Life Management

Plant

Status

Analysis (PStA)

Aging

Management:

New Builds

(PLIM, SAMP)

Aging

Management: Plants in

Operation

(AM, PLIM)

Aging Management

Review for

Long-Term

Operation

(AMR for LTO)

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Aging and Lifetime Management

► The process of aging management (AM) has the objective to

monitor and control degradation effects which may compromise

safety functions of the plant. Steps are:

Identification of possible degradation mechanisms for safety

relevant Systems, Structures and Components (SSCs)

Ensure, that testing and maintenance programs sufficiently

provide preventive measures to control degradation effects

► The Plant life management (PLIM) methodology also includes

aging surveillance for availability relevant SSCs (optional)

► AM and PLIM cover mechanical components, electrical and I&C

systems and civil structures

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Aging management requirements

► The aging management process is described in national and

international rules (IAEA guidelines, AP-913, KTA-1403, etc.)

► All aging management rules call for a comprehensive approach,

requiring the systematic collection of various aging and safety

relevant data on a plant-wide basis. This data needs to be

periodically updated and evaluated.

► Due to the complexity of the process, this activity needs to be

supported by a dedicated software tool for

the management of aging relevant data and associated

documents (approx. 30 000 SSCs)

analytical functions for the periodic assessment of

degradation effects resembling the state of science and

technology

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AREVA NP Concept for Aging Management

Implementation

Important modules of the

AREVA NP Aging Management (AM) Concept are:

Definition of safety relevant Systems, Structures & Components (SSCs)

Categorization into Aging management-groups (SCs)

Collecting of aging-relevant parameters for relevant SSCs

Assessment of relevant degradation mechanisms on system level

Preparation of lifetime assessment reports for major components

Crosscheck between expected degradation modes and existing inspection

and maintenance programs

Assessment, whether existing preventive measures are adequate

Final report + knowledge base for periodic aging surveillance process

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Safety relevance

evaluation

Degradation

assessment

Optimized ISI and

maintenance scope

Aging and Lifetime Management Basic process

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►assessed and reviewed according relevance and transferability ►AM classification, determine of preventive measures

►degradation assessment

and remaining life

►updating based on state

of science and technology

Determine of SSCs within the

scope of AM

Identification of relevant

degradation mechanism

Verification of transferability

reported events

COMSY Condition Oriented ageing

and plant life Monitoring

SYstem Review and/or

specification of preventive measures

►trending of NDE results

►improvement of scope and intervals ►updating of condition prognosis

►system requirements ►specification of scope ►modeling of relevant SSCs

AREVA concept for the surveillance of

aging effects


scope of AM

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COMSY Software for Aging and Plant Life Management

Features: ► comprehensive plant model for components and their interactions

► management of aging relevant parameters for SSCs

► engineering tools and material libraries

► degradation models for relevant degradation mechanisms

► integrated inspection and maintenance management module

► events from nuclear reporting system

► technical documentation functions

► interfaces and import functions Next to PLIM, COMSY is applied for lifetime design activities within the scope of new builds, modernization projects and power uprates.

COMSY is a software tool for aging and plant life management in power plants.

The tool enables the design and setup of a knowledge-based power plant model

compatible to the requirements of international and national rules

(e.g. IAEA Safety Guide NS-G-2.12, KTA 1403).

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Scoping of safety relevant SSCs

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SSCs Category M1

Mechanical SSCs in category M1:

Reactor pressure vessel

RWCU system to second isolation valve

Core spray system

Residual heat removal system

Main steam line to second isolation valve

etc.

Assessment

of major

components

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Typical mechanical SSCs in

category M2:

Emergency cooling system

Low pressure injection system

High pressure injection system

Safety injection system

Reactor water cleaning system

Emergency diesels

Emergency cooling water system

etc.

SSCs Category M2

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Step 1:

For each relevant pipe or component a material specific representative component will be specified and all corresponding valves will be determine.

Step 2:

Depending on the evaluated degradation mechanism a more detailed modeling on a component by component basis will be performed.

Modeling of systems, sub-systems and components

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Categorization of SSCs in respect to

safety and availability requirements

flexible specification of key-

parameters for the assessment of

safety and availability

requirements

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Information relevant for AM mechanical components

Safety and

availability category

Design and

geometry data

Material

specifications

Thermal hydraulic

operating data

Load cycle

catalogue

Material

as-build data

NDE

examination records

Technical

documentation

Inspection /main-

tenance manual

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Scoping of relevant electrical and I&C components using functional chains

Generation of component data sheets for the relevant elements of functional chains

Determination of degradation mechanisms (thermal, radiological, electrical, mechanical)

Specification of testing concept and techniques

Function test

Visual test

Partial discharge -, insulation resistance measurements, etc.

Condition assessment for each component

Recording and assessment of relevant events from reporting systems

Documentation of results

Information relevant for AM electrical and I&C components

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Roma Skalsky Description of the component

If required, divided into sub-components

Specification of materials.

thermal behavior

dose rate

Operation conditions are linked via ‚room climate pools‘

Testing results and monitoring data are linked to the component

Integrated documentation function

Electrical and I&C components - Element Data Sheet

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Scoping of civil structures depending on safety requirements

Generation of element data sheets

Determination of element specific degradation mechanisms

Specification of testing concept and techniques

Visual inspection

Component testing techniques

Laboratory tests

Condition assessment for each component

Recording and assessment of relevant events from reporting systems

Linking of relevant documents

Information relevant for AM civil structures

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Description of the function

Design criteria and design standards

Materials and reinforcements

Normal operation conditions are linked via ‚room climate pools‘

Off-normal operation conditions

earthquake, flooding, etc.

Allowable loads

Testing results and monitoring data are linked to the component

Integrated documentation function

The element data sheet for civil structures comprises the following

information:

Civil structures - element data sheet

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For each relevant room, a

so called ‚room climate‘

pool is being generated.

This pool indicates

conditions like temperature,

moisture, local dose rate,

etc.

This pool is used for the

degradation assessment of

electrical, I&C and civil

components, if associated

with the pool structure.

Modelling of the ‚room climate‘ using pool structures

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Management of inspection and

maintenance manual

COMSY manages and evaluates

Inspection and maintenance

manual

The scope of activities and

inspection techniques applied are

itemized and assessed.

This pool is used for the validation

of inspection concepts of

mechanical-, electrical-, I&C and

civil components

Activities specified in the

maintenance and inspection

manual are associated with

systems, sub-systems and

components.

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and remaining life




scope of AM




reported events









aging effects

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Relevant degradation mechanisms for mechanical components

NPP degradation statistics BMU 2007

Ni-SCC

10.3%

FAC

39.3%

IGSCC

15.7%

corrosion

misc.

13%

MIC

6.3%

TGSCC

13.4%

IGSCC

sensitized

0.2% contact corr.

13%

Hydrogen ind.

0.2%

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Scope of Degradation Mechanisms

► Stress corrosion cracking

pitting

crevice corrosion

uniform corrosion

thermal transient fatigue, thermal cycling

fatigue, thermal stratification fatigue

FAC - erosion corrosion

cavitation erosion

droplet impingement erosion

MIC

Strain induced corrosion cracking

► General corrosion

► Localized corrosion

► Microbiological corrosion

► Flow - induced corrosion

IGSCC intergranular stress corrosion cacking

TGSCC transgranular stress corrosion cacking

Ni-SCC Ni-base stress corrosion cacking

► Fatigue

► Corrosion fatigue

Solid particle erosion ► Erosion

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Relevant degradation mechanisms for electrical and I&C components

Electrical and I&C components may experience the following stress factors

Depending on the material groups applied (polymers, metals, glass,

ceramics, etc.) and the operating conditions, a possible degradation

mechanism is determined for the following degradation groups:

►Thermal aging, ThA

►Radiological aging, RA

►Electrical aging, EA

►Mechanical aging, MA

►Thermal loads thermal aging, Hot Spots

►Chemical loads oxidation, material decomposition

►radiation embitterment, discoloring

►moisture „water trees“

►Electrical fields partial discharge

►Mechanical loads vibrations, tensile- and bending loads

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Relevant degradation mechanisms for civil structures

Civil structures may experience the following degradation modes

►Elevated temperatures

►Low temperatures

►Irradiation

►Aggressive chemicals

►Loss of material

►Freeze thaw

►Abrasion or cavitation

►Corrosion of embedded steel

►Cracking

►Shrinkage

►Creep

►Settlement

►Fatigue

Stress factors are e.g.:

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Sensitivity

low

high

Degradation mode specific

information

Degradation Assessment for Passive Components

Reporting

system

assess

not relevant

geometry material operating conditions

Degradation mechanism

water chemistry

Relevan

t

(x) material

behavior

flow situation

geometry

specification

operation

parameters

(x)

no

yes

A

B

C

chemistry

NDE

results

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Combinations between Wt, Cf, Lc and Wr are possible!

Degradation Mechanism Impact

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and remaining life




scope of AM




reported events









aging effects

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Assessment of the preventive maintenance concept for safety

relevant SCCs

For safety relevant SSCs it needs to be

demonstrated, that adequate preventive

measures exist to manage degradation

mechanisms possibly affecting the SSC

Preventive

maintenance

Degradation

mechanism

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Surveillance Concept

PDCA – Cycle

SSC

Safety relevant?

degradation

mechanism,

degradation rate?

SSC SSC SSCs

preventive-

measure

sufficient?

yes

yes

no

Failure-

oriented

additional

measures

no

M3 M1 / M2

plan do

check act

Aging

surveillance

program

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Inspection and

maintenance

guidelines

Aging relevant

information

SSCs

Safety and

availability

requirements

SSCs

Degradation

mechanisms

Inspection dates

and inspection

results

Software guided validation of

preventive measures

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Software support for implementation of

the aging management process

Safety and

availability

requirements

SSCs

Aging relevant

information

SSCs

Degradation

mechanisms

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Examination data management for mechanical components

Non destructive test procedure

Examination of the surface Volume examination General condition

MT-magnetic particle test

LPT-liquid penetrant test

VT-visual inspection

RT-radiographic test

UT-flaw detection

ET-eddy current test

UT-wall thickness test

RT-radiographic test

GT-general inspection

i

An efficient plant life management process

is based on degradation predictions, which

are validated and optimized through the

performance target inspections.

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COMSY acquires and assesses

examination records from :

► Visual inspection,

► Partial discharge measuring,

► Dissipation factor test,

►VLF Hi-Pot

Durchschlagsprüfung

► Chemical Analysis

► Reflektometrie, Polarization

A structured acquisition allows a

trending of the results.

Examination data management for electrical and I&C components

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Civil Structures

Lifetime

prediction

► Examination results from non destructive testing

(NDT) are fed back into the COMSY program.

► The results are used for further optimization of

service life predictions

to reduce the conservative margin

to optimize the inspection scope

► The evaluation of NDT data is automatically

performed by the COMSY program.

► Based on the NDT evaluation results, a

calibration of lifetime predictions can be

performed.

This process increases the accuracy

of future service life predictions

Evaluation of

examination

results

COMSY Condition Oriented aging


SYstem

Calibration of lifetime prediction

Prediction NDT update

Mechanical component

Electrical / I&C

component

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and remaining life




scope of AM




reported events









aging effects

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Verification of transferability reported events (1)

Within the scope of aging management an event assessment based on

messages from nuclear reporting systems has to be performed.

The evaluation for each event includes:

Check for AM-relevance

If the component affected is not a expendable part, than it is relevant for the AM.

Is there an aging mechanism?

Is this a new effect?

Is it a common mode error?

Check for assignability

Can it also happen on similar components?

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The table gives a general overview for all reports of a specific type.


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►Internal and external events

will be storage in the COMSY

database

►The events will be assessed in

the scope of aging

management and reviewed

according here relevance and

transferability on other SSCs

►If relevant the following steps

will be applied:

Classification in AM classes

Determine of preventive

measures

The transferability on other

SSCs will be supported by a

search function


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AREVA NP Strategy for Aging Surveillance Periodic Activities for the Aging surveillance program

Implementation of an Aging management closed loop (PDCA-circle)

Periodic assessment of inspection results and maintenance experience

feedback

Periodic assessment of industry experience and feedback from nuclear

reporting systems

Re-assessment of degradation potential for relevant SCCs

Validation / optimization of inspection and maintenance programs

Annual progress reports to compile aging management related activities for

authorities

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COMSY – References

Service application

Germany: Brokdorf

Biblis A+B

Brunsbüttel

Grohnde

Gundremmingen B

Isar 1+2

Krümmel

Philippsburg 1+2

Unterweser

Switzerland: Beznau 1

Gösgen

Leibstadt

Spain: Almaraz 1+2

Sweden: Forsmark 1+2

Oskarshamn 2+3

Japan: Fukushima 2-1

China: Chinshan 1

OL3 lifetime design services

EPR 1700 turbine house assistance

Software licenses

Belgium: 9 fossil fired plants

Brazil : Angra 1+2

Bulgaria : Kozloduy 1 to 4

Finland : Loviisa 1+2

Hungary : Paks 1 to 4

Japan : Tomari 1+2

Spain : Asco 1+2

Almaraz 1+2

Cofrentes

St. Maria de Garona

Sweden : Forsmark 1 to 3

Netherlands : Borsele

Argentina : Embalse

Atucha 1 & 2

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COMSY Aging Management Benefit

COMSY compiles aging and reliability relevant information on a plant-wide basis for SSCs important to safety

Integrated engineering analysis functions and comprehensive material libraries effectively support the data handling

Provides degradation assessment functions and optimization of inspection programs by focusing activities on priority components

Assessment of industry experience feedback via nuclear reporting systems, generation of aging status reports

The integrated documentation function provides quick access to technical details and helps to conserve know-how

Proactive Aging Management improves long-term performance of the plant

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COMSY - A Software Tool for Aging and Plant Life Management

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