Nuclear Engineering Panel Technical Presentation

The OPAL Reactor – Successes and ChallengesDate: Wednesday, 28th May 2014Time: 5.30 pm for 6.00 pmVenue: Engineers Australia Harricks Auditorium,

Ground Floor, 8 Thomas St, ChatswoodSpeaker: David Vittorio, BSc, MBA

ANSTO

ABSTRACT:

OPAL commissioning commenced in 2006. Since that time, aspects related to theengineering design and operational practices of the facility have evolved to better align withimprovements in international practices in safety, operation and utilisation. In its first fullyear, OPAL operated for some 94 days. Today, OPAL is respected as one of the mostmultifunctional and highest availability research reactors in the world. To achieve this, anumber of technical challenges have been faced and engineering modifications have beenundertaken. As a research reactor with high availability, OPAL has provided benefits to thelocal and international research communities, nuclear medicine communities and variousindustries.

PERSONAL DETAILS:

David Vittorio has been working at ANSTO for over 14 years, specialising in fuelmanagement and operations management. David holds a Bachelor of Applied Science(physics), post graduate qualifications in Energy Studies and a Masters in BusinessAdministration. He has led key ANSTO projects, including the management of two spentfuel shipments and conversion of HIFAR from HEU to LEU fuel. He has also coordinatedthe planning for the commissioning of OPAL as part of the Commissioning OperationsGroup. His interests in business management coupled with his experience in reactoroperations led to his appointment as the OPAL Reactor Manager in 2010.

OPAL Reactor

“Successes and Challenges”

28 May 2014 – Engineers Australia

David Vittorio

OPAL Reactor Manager

Overview

• OPAL – Description

• Technical Challenges and

Improvements

• Practices and Processes

• Utilisation and Operating

Performance

OPAL – Multipurpose

Pneumatic

Transfer

Irradiation

Facilities

Primary

Coolant

Large Volume

Irradiation

Facilities

Cold Neutron

Source

Core

Bulk Irradiation

Facilities

Neutrons – For Health

10,000 hospitals in the

world use radioisotopes

40 million patients per year

Diagnostics (cardiology,

oncology, neurology)

Therapy / palliative care

10%

90%

Neutrons – for Science

Small Angle

Neutron Scattering

High Intensity –

Powder Diffractometer

Reflectometer

High Resolution –

Powder Diffractometer

Laue

Diffractometer

Strain

Scanner

Time Of Flight

Inelastic Scattering

Ultra Small Angle Neutron

Scattering

Back-

Scattering

Crystal

Alignment

Small Angle Neutron

Scattering

Operating instruments

Construction/commissioning

Neutrons – For Industry

Source: Topsil and Yole Development

• High and very high voltage markets• Low volume specialty products

• High and medium voltage markets• Medium volume specialty products

NTD - Silicon

Technical Challenges and Improvements

Cold Neutron Source

• Cryogenic Refrigeration System

• Cold Neutron Source Helium Compressors

• Multiple component failures

– Compressor Bearing Instability

– Compressor Air End Screw Failures

• Consequence

– Failures resulted in unreliable operation of reactor and

CNS supply

– Major maintenance intervention to rectify

– Suspension of CNS science based program

Helium Compressor – Component Failures

2 x 250kW Helium compressors supply high pressure/high flow helium to the Cold Neutron Source cryogenic system

Compressor Screw Air Ends

Root Cause Analysis

• Root Cause Analysis Outcome– Compressor oil degradation resulting in bearing instability

– Compressor oil degradation resulting in air end screw failures

High Oil

Temp.

Low

Viscosity

Screw

Contact

Debris

Filter

Blockage

Reduced

Oil Flow

FAILURE

CNS Compressor Rectification

• Compressor Screw oil

injection temperature

reduced 45oC

11

• Installation of high capacity

plate-and-frame Heat

Exchangers

Performance Indicator Actual Target

CNS Cold Source operations since

18/07/13 to 26 May 2014

- Days at full power in NO mode

- CNS Operational Availability

Reactor days at power

315.0

99.8%

315.0

95.0%

OPAL Full Power Days –

Calendar 2014 to 26 May

122 122

CNS Operational Availability in 2014

(to 26 May)

100% 95.0%

CNS Performance

• Benefits

– Cost effective approach

– Local suppliers

– Lead times reduced from 19

weeks to 4 weeks

– Superior corrosion protection

than original

Cooling Tower Fan Refurbishments

• Aim

– Refurbish fans to extend life and improve

reliability

– Cost effective approach

– Keep installed spare fan operational

– Utilise standard shutdown periods

7 x Al Blades (re-use)

Motor 45 kW (replace)

Gearbox (refurbish), specialist

Support Frame (refurbish), new HDG

Removable Walkway (refurbish), new HDG

All fasteners, (replace), use HDG

14 x hub blocks (refurbish), zinc electroplate

1 Hub (refurbish):

ENECON CeramAlloy CP & ChemClad SC

7 x blade shafts (replace), Bisplate 80 + HDG

Original Fan Assembly New Fan Assembly

• Challenges

– Source local suppliers

– Identify suitable equivalent material for fan blade shaft

replacement

� Chemical analysis

� Physical properties analysis

� Metallographic examination

� Suitability for HDG

Practices and Processes

How do we decide and define an optimum mix of

maintenance tasks ?

Maintenance Strategy Optimisation

• Condition Monitoring Tasks - Surveillances, inspections,

testing, monitoring, trending or analysis tasks

addressing failure modes with a defined P-F interval.

• Fixed Time Tasks - Fixed time overhaul, restoration or

replacement tasks addressing failure modes that exhibit

a wear-out failure pattern.

• Corrective Maintenance Tasks – Correct expected or

unexpected failures.

Condition

Based Task

3

Failure will

always be a

breakdown

(Expected

failure)4

Fixed Time Task

1 Fixed Time Task

Condition Based Task

OR

2

Pa

tte

rn o

f F

ail

ure

Rate of Deterioration

Age-Related (Wear-Out)

Random

Sudden

Gra

dualP

F

P-F interval(Potential to Functional failure)

P

F

P-F interval(Potential to Functional failure)

Safe or Economic Life

4%

2%

5%

7%

14%

68%

Quadrant 1

Fixed Time Strategy is the only option

Task interval is set by the safe or economic life (or

MTBF)

(Eg – Limit switches in a hot cell)

Quadrant 3

Condition Based Strategy is the only option

Task interval is set by the P-F interval

For the task to be feasible there must be:�A clearly defined P condition that the task is able to reliably detect

�A fairly consistent P-F interval

�A P-F interval that is long enough to be of practical use

Quadrant 4

Run to Fail strategy is the only option

(Eg Lighting)

Quadrant 2

Either Fixed Time or Condition Based

Strategy is an option

First look for a Condition Based Task (Quadrant 3)

Then look for a Fixed Time Task (Quadrant 1)

Maintenance Strategy Optimisation

Condition Monitoring

• Condition Monitoring fits into quadrant 2 & 3 of

the Maintenance Feasibility & Effective Analysis

Random

Condition

Based Task

3

Failure will

always be a

breakdown

(Expected

failure)4

Fixed Time

Task

1 Fixed Time

Task

Condition

Based Task

OR

2

Pa

tte

rn o

f F

ail

ure

Rate of Deterioration

Age-Related

Sudden

Gra

dual

Quadrant 3 & 2

Condition Based Task is the only option

Task interval is set by the P-F interval

For the task to be effective there must be:

�A clearly defined P condition that the task is able to

reliably detect

�A fairly consistent P-F interval

�A P-F interval that is long enough to be of some use,

i.e. it is practical to monitor within the P-F interval

and there is sufficient time to plan and take action

before reaching the F condition

Condition Monitoring for Safety and Reliability

• Vibration Monitoring (VA)

• Thermography

• Oil Analysis & Lubrication Management

• Chemistry Control

• Process Data review and trending

CM Techniques

Bearings & Couplings (pump and fly- wheel):• Temperature• On-line VA• Handheld VA

Process:• Measurement of

inlet & outlet pressures (efficiency)

• Flow trending

Mechanical Seals:• Trending of

leakage rates

Oil Analysis of bearings

Thickness testing of pipes

Motor:• Bearings (VA)• Thermography• Insulation/winding

resistanceProcess:• Chemistry control

and monitoring

Condition Monitoring - Example

• 129 Hz fault plus harmonics and the trend of worsening

condition.

Condition Monitoring - Example

CM -Thermography

• Switchboards

• MotorsOVERLOADS

Utilisation and Operating Performance

Status of Mo99 Supply

Australia

< 5%

ANSTO

Canada

40%

Netherlands

30%

Belgium

10-15%

South Africa

10-15%

SAFARI

HFR

NRU

Poland

5%

Maria

BR-2

France

10-15%

OSIRIS

Performance – Operating days

0

50

100

150

200

250

300

2006 2007 2008 2009 2010 2011 2012 2013 2014

39

94

128

248

286282

270

296

108 108

294

Total Power

Days (Calendar Years)

Ta

rge

t D

ay

s

Target - 300

Safe Days

OPAL critial

on 12 August 2006

2014 Status at:

Tuesday 28/4/14

Fo

reca

stP

ow

er

Da

ys

Act

ua

l P

ow

er

Da

ys

2012 – Planned

Long Shutdown (42 days)

Performance – Availability to Plan

60

65

70

75

80

85

90

95

100

2008 2009 2010 2011 2012 2013 2014

72

91

9392

97

94

98

Availability to

Planned Schedule (%)

OPAL critial

on 12 August

2006

2014 Status (current): From 1/1/14 to 28/4/14

98% - Target Availability to Plan