best practices to design, develop and integrate new ... · pdf filebest practices to design,...

David and Rosemary GreeneGreene R&D International Inc. USA [GRDI]

PLiM Symposium Paper # IAEA-CN-155/076Shanghai, CN, October 2007

Best Practices toDesign, Develop and Integrate

New Instrumentation withExisting Systems and Processes

BatScan System for Nuclear PowerBatScan System for Nuclear Power

Part 1: General Best PracticesPart 2: Case History - BatScan system


Best Practice #1: Always state the obvious. PLiM is essential for safety & economy• Document performance that reflects reality• Capture experienced personnel knowledge • Develop training programs to transfer skills•….. and so on …..Conclusion: Any new system or change is never simple and takes time, money and dedication. There are no shortcuts.

BatScan System for Nuclear PowerBatScan System for Nuclear PowerBest Practice #2: Get feedback and buy-in from all stakeholdersPerfect Technology is not enough to solve problems; solution must integrate requirements/expectationsfrom all stakeholdersConclusion: All successful systems must include the right people from project inception to plant operation.

Best Practice #3: Always address the real issue or problem


Solutions must not be skewed to satisfy a powerful stakeholderProblems must not be redefined to match capabilities Conclusion: Do what is required, not what can be done. Anything else leads to failure.


• Concept verification took ~3 months• Full problem definition took ~3 years•Main and complementary R&D took ~ 5 years• Engineered system and V&V took ~ 2yrs• Enhancements and updating – ongoing ~10 yrs

Problem solution was essential. If not solved, economic viability of NPP design was questionable.

Best Practice #4: Use a fully validated system model (such as BatScan) to reach an engineered solution for a NPP

Step 1: Define the ProblemEvent: Steam generator severely damaged by

sodium water reaction, (FERMI, PFR, BN-350)

Unexpected: It happened fast, initiated by small fault

Outcome: Changes to component design, materials, operations, economics, R&D programs

Mitigation: Required enabling technology

Steam Generator Leak Detection System

How fast is damage propagation What can be monitoredHow big is fault, what is dangerous

Regulatory bodies, V&V?What is maximum damage How does it propagateCan damage be mitigated What do plant operators needWhat does it cost, is it affordable Etc etc etc etc ……………..

Questions

AcousticDetector

Chemical Detector

Analytical/Computer Simulations

NPP Secondary System Design/Material ChangesExotic Approaches

BatScanBatScan System for Nuclear PowerSystem for Nuclear Power

What BatScan is:Nuclear Power Plant (NPP) Nuclear Power Plant (NPP) Component Fault Detection Component Fault Detection

System. System. Industrial strength, Industrial strength, validated system for NPP validated system for NPP environments.environments.Sensor array mounted Sensor array mounted externally, no penetration of externally, no penetration of component shell. component shell.

BatScan system simulates• Thousands of virtual microphones within a defined volume.•Measures the absolute levels of sounds generated at each virtual microphone.

ConceptBatScanBatScan System for Nuclear PowerSystem for Nuclear Power

An Engineered System �Relationships between parameters known�Set any 4 of these 5 parameters, the other

parameter will change/adjust to match� System sensitivity (S/N ratio) � False alarm rate� Detection time (fault growth)� Space (volume monitored)� Cost


NPP Regulatory Bodies�Verification and Validation needs � V&V requirements document� Key feature tests � Demonstration test(s)� Operator interface/alarm test � Data archiving, operator’s charts


Owner/Operator needs�Industrial quality I&C systems� Sensors, electronics, computers� Reliable supplier with timely support and replacement parts. e.g. GE-FANUC

�Integral simulation of system � allows for demonstrating ‘what if’ design/operating scenarios � operator training�“Invisible system”� Designed to avoid obsolescence� No operator distractions� No special maintenance requirements


What BatScan is - OverviewBatScan System for Nuclear PowerBatScan System for Nuclear Power

Real-time fault detection and damage mitigation systemDesigned specifically for integration into plant I&C systemFully characterized, engineered system fully adaptable to change in specified:• detection time, (fraction of a second) • false alarms (less than once in 30 years) • detection sensitivity, (-25 dB S/N ratio)• space monitored

What BatScan does:BatScanBatScan System for Nuclear PowerSystem for Nuclear Power

Maps threeMaps three--dimensional noise field inside dimensional noise field inside the NPP component volume:the NPP component volume:••Digital Signal ProcessingDigital Signal Processing••Array Processing Array Processing ••Passive Acoustic Passive Acoustic TomographyTomography••Statistical Analyses, etc.Statistical Analyses, etc.

Extracts fault sounds from background Extracts fault sounds from background noise, informs operator of conditionnoise, informs operator of condition••Alarm initiated if fault exceeds threshold level Alarm initiated if fault exceeds threshold level ••Protective shutdown of component (if required)Protective shutdown of component (if required)


What BatScan Provides:Identifies faults at full power operationIdentifies faults at full power operation•• definitive alarm within 2 seconds definitive alarm within 2 seconds •• locates fault to within a few centimeterslocates fault to within a few centimetersFalse fault indicationFalse fault indication•• less than once in 30 yearsless than once in 30 years•• extremely low costextremely low cost--toto--risk ratio risk ratio Engineered system design allowsEngineered system design allows•• Engineering studies, integrated plant simulationEngineering studies, integrated plant simulation•• plant operator trainingplant operator training

BatScan at SCTIBatScan at SCTI�Protected (80 MW)

Steam Generator (SCTI) for Two Years�256 channel system�Used to protecttube sheets (2)tube bundle�3 Computers�170 Sensors attached externally to vessel shell

BatScan

Operational Data

Average of 5 values

Average of 25 values

S/N = S/N = --10dB10dB

BatScan Fault Detection

SCTI SCTI 80 Mw 80 Mw Steam GeneratorSteam Generator

BatScan Industrial Equip. & Environment� 200 Channel System�Tested for 2 Years�70 MW Power Plant� System Performance Validated� Detection, Location Demonstrated� No False Alarms�Earthquake�Shuttle engine test burn�Explosions, drilling into bedrock�Power plant controls etc.�Enhanced System design�Neural net detection �Operator support (Fuzzy logic expert system)

V&V TestsTestsTests

• Hengelo• EBR II• Hydraulic model• LLTR

NPP

Validated Hardware and Software

V&V TestsTestsTests

• Hengelo• EBR II• Hydraulic• LLTR

NPP

Validated Hardware and Software

BatScan Design OverviewBatScan Design Overview�Builds on Decades of Experience from Earlier Programs (Liquid Metal NPP)�Acoustic leak detection system�Wastage damage database�Acoustic database�Enhancements�Modern digital signal processing hardware and software �Integrates information from fault monitoring system and

process instruments�Fuzzy Set Logic pre-processor and post-processor� Neural net pre-processor for rapid leak indication

BatScan – Rotating Machinery

25

Test Setup in Anechoic Chamber

Greene R&D International

Noise generated by axi-symmetric jet


27

Noise generated by axisymmetric jet


Steam Generator Simulator

� Interactive (Custom) Simulator�Impact of Steam Generation System Parameters on S/N Ratio�Impact of Leak Detection System Parameters on Detection Capability�Output: Noise Source Characterization

�SG Geometry, SG Operating parameters�Signal from leak, Background noise�Detection algorithms, Leak location�Number of sensors, Sensor density

Fuzzy Logic Pre-Processor(Enhancement)

�Assesses data from Process Instruments�Acoustic System (axial location)�Reliability (2out of 3 logic)�Pressure Gauge�Temperature, flow, etc �Directs Operator or Controller for Optimized Performance

�Assesses potential fault in human like way

BatScanTomorrows Technology

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