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Development and Testing of Work Package …...Light Water Reactor Sustainability R&D Program...
Transcript of Development and Testing of Work Package …...Light Water Reactor Sustainability R&D Program...
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LightWaterReactorSustainabilityR&DProgram
Development and Testing of Work Package Automation for Plant
Modernization Ahmad Al Rashdan, Ph. D.Idaho National Laboratory
Presented to: Advanced Sensors and Instrumentation, 2017 NE I&C Review.
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Acknowledgement
• DepartmentofEnergyLightWaterReactorSustainabilityProgramforfundingthiseffort.
• XcelEnergyInc.forcollaboratingonpartsofthiseffortunderCRADA17-CR-05.
• OtherINLcontributors:– KennethThomas,Vivek Agarwal,RonaldBoring,ShawnStGermain,JohannaOxstrand,ThomasUlrich,andBrandonRice.
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Work PackageWork
Package
Worker Order
Documents References
…
Group of Steps/ Task
Material list, equipment
list, ...
StepGroup of
Steps/ Task
Step Step
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Electronic Work
Package
Automation Technologies
Work Process Deficiencies
Automated Work Package
Development of Work PackagesPaperWP
ScannedWP
FormsWP
InteractiveWP
IntelligentWP
AutomatedWP
eWPPWP AWP
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Automation of Work Packages
InitiationofWorkRequest
(5functions)
ScreenWorkRequest(1functions)
WorkPackageCreationandScheduling(7functions)
Pre-ImplementationWalkDown(2functions)
SupervisorAssignsWorkPackagetoCraft(3functions)
HoldsandPre-JobBrief(5functions)
MeasurementandTestEquipment,Tools,and
SpareParts(4functions)
WalkDownClearance(TagOut)and
OperationsPermissiontoStart
(6functions)
PerformWorkActivity(13functions)
Sign-OffClearanceandReview
(1function)
QualityAssuranceandArchiving
(3functions)
• Fiftyfunctionsenvisioned targetingallphasesoftheworkprocess.
-AlRashdan etal,2016,AutomatedWorkPackage:ConceptualDesignandDataArchitecture,INL/EXT-16-38809.IdahoFalls-EPRI,2015,ImprovingtheExecutionandProductivityofMaintenancewithElectronicWorkPackages:AMobileWorkManagementInitiative,3002005363,ElectricPowerResearchInstitute.
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Survey
0% 10% 20% 30% 40% 50% 60% 70% 80% 90%
100%
Initiateworkrequ
est
Screen
ingworkrequ
ests
Planne
rcreatesworkpackage
Planand
con
ductpre-im
plem
entatio
n…
Supe
rviso
rselectio
nandassig
nmen
tof…
ValidationofCraft'sq
ualifications
Cond
uctp
re-jo
bbrief
Verifythecurren
trevision
ofall…
Walkdow
nclearancetoverifyprope
rly…
Sign-onclearanceandup
dateth
e…
ReceiveOpe
ratio
n'sp
ermissiontostart…
Signontoapprop
riateRadiatio
nWork…
Performworkactiv
ity
Sign-offclearance
Supe
rviso
rreview
Workpackagedisassem
bly
FilingofQArecords
Archiving
WhatandHowtoChangetheProcess
Automate Remove Change(butnotautomate) Keepasis
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Abilitytochangelevelofdetailintheworkinstruction…
Augmentedreality(e.g.,technologysimilartoGoogle…
Automatictoolrecallforcalibrationordisqualification
Locationtrackingoftoolsandspareparts
Automaticreassignmentoftoolswhennotneeded
AutomaticevaluationofCraft's performance
AutomaticnotificationtoresourcesforQAandother…
Remotevideomonitoringof taskexecution
Remoteaccessoftaskprogresstoallinvolvedentities
Voiceassistedinstructions(e.g.,talk-to-text)
AutomaticnotificationstoSupervisors,Operations,…
AutomatictrackingofCraft’slocation
Automaticplacementand/orremovalofholdpoints
Automaticschedulingandguidanceofwalk-downs…
Pre-recordedpre-jobbriefvideosforfrequently…
Automaticallocationandreleaseoftoolsand…
Automatictrackingoftaskprogress
Automaticintegrationofplantriskinformationduring…
Automaticschedulingoftasksaccordingtothe…
Automaticacquisitionofplantinformation
Automaticpopulationofworkpackageinformation…
Historicaldatacollectionofequipmentfailures
Integrationofenterpriseassetmanagementsystem…
Whichof thelistedcapabilitieswouldhelpincreasetheefficiencyoftheworkpackageprocess?
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Infrastructure Development of Work Packages
eWPPWP AWPText Data
Perform….onequipment…usingtool…;refertodocument…forinformation;….
Thefullmigrationofoneworkpackagefrompapertodataresultedinthefollowingexampledataarchitecturefindings:1. Topology:hierarchicalmeshofdata2. Functionality:liveandconfigurationversionsof
thesamedata.3. Properties:aggregatedupwardsanddownwards
thehierarchy.
Work Package
Worker Order
Documents References
…
Group of Steps/ Task
Material list, equipment
list, ...
StepGroup of
Steps/ Task
Step StepTool
Equipment
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Materials, Tools, and EquipmentThenuclearpowerindustryisinneedformeanstoautomatematerials,tools,andequipment's(MTE)trackingfor:1. VerificationofproperMTEuseby
thecraft.2. Accountabilityinforeignmaterials
exclusionszones(FMEZ)thatimpactstheplantcriticalpath.
3. Enforcingcalibrationschedulesfortoolsandequipmentinthefield.
4. PreventingremovalofcontaminatedMTE.
5. PreventinglossofexpensiveMTE.6. Inventoryofoutagecontainers.
Step
Materials
Documents
HazardsDiscipline
Cautions
Trainings
Tools
Notes
Qualifications
Review
Risks
Tags
Tests
Equipment
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Ultra High Frequency Radio Frequency Identification ( UHF RFID)
• Passivelypoweredtags.• Variousformsandsizesoftags.• Varioustypesofreaderspower
methodandantennasconnection.• Low-costtechnology.
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UHF RFID Prototype and User Study
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Example of study findings• TagSize:
– Largetagscausespuriousdetection;smalltagsarehardtodetect.Optimaltagsizewasidentified.
• SetupLayout:– Portablereaderwithanintegratedantenna forFMEZ.– PortablereaderwithexternalantennaforsearchingofMTE.– FixedsetupwithantennasgateforpreventingremovalofcontaminatedMTEand
lossofexpensiveMTE.• TagMountingandStructure:
– Tagsarealmostalwaysbiasedtowardscertainorientation,andneedtobeinstalledinamannerthatfavorsexposureofthatorientation
– Tagsaresensitivetointerference(includinghumanbody),andneedtobeinstalledinlocationsthatminimizesinterference.
– Sometagsaremoresuitableforcertaintypeofsurfaces.Forexample,notalltagsaremountableonmetals.
– Tagsthathavesoftorrubbersurfacescanbehardtodecontaminate.– Radiationtoleranceoftagsremainsunknown.
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Cautions and Hazards: Asthenuclearpowerindustrymovestowardsmobiledevices,theindustryisinneedtodetectthecraftlocationfor:• Complementingtheconventionalwarnings
withelectronicwarnings.• Automaticallyenforcingsafetymeasuresin
criticalsituations.
Step
Materials
Documents
HazardsDiscipline
Cautions
Trainings
Tools
Notes
Qualifications
Review
Risks
Tags
Tests
Equipment
BluetoothLowEnergyBeacons:• CanbedetectedbyanyBluetooth
enableddevice.• Verycompact,light,andeasilyattachable
towallsandsurfaces.• Verylowenergyconsumption.• Inexpensive(tensofUnitedStates
Dollars).• Thresholdtriggeringofradiosignal
strengthwasused.• Thresholdassignedtoactionsthrougha
textfile.
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Example of study findings
– BroadcastsofthebeaconIDandbatterylevelaremoresuitablethanpeertopeercommunicationfromacommunicationandpowerperspectives.
– Broadcastsfrequencyshouldberelativelylowtopreservepower,butnottoolowtoresultinmisdetection.Multiplebeaconstoinitiatethesameactioncanbeusedtocompensateforthelowbroadcastsfrequency.
– Increasingtherangeincreasestheprobabilityofdetectionbutincreasesthepowerconsumptionandfalsepositives.Thesignalstrengthneedstobeoptimizedaccordingtothenatureofthelocationandtheapplication.
– Radiationtoleranceofthebeaconsarenotexpectedtopresentasignificantlimitation.Modulescanbereplacedannuallyifneeded,duetotheirlowcost.
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Video Recording and Remote Monitoring Thenuclearpowerindustryisinneedformeanstoimprovetheprocessof:• Peerreview• Remotesupervisionandapprovals.• Trainingincludingjust-in-time
training.• Pre-jobbriefings.• Qualityassurance.
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Conclusions
• Identified50functionsthatcanbeaddressedbyautomatingtheworkpackagesprocess.
• Verifiedthealignmentoftheproposedfunctionswiththeindustrythroughasurvey.
• Developedthedataarchitectureprinciplesoffullydigitizedworkpackage.
• Prototypedandstudiedthefeasibilityandimpactofmultipleworkpackageautomationtechnologiesinnuclearpowerplants.
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?