long term operations technical advisory committee ... · as of october 2015: 250 npps > 30 years...

© 2016 Electric Power Research Institute, Inc. All rights reserved.

Mike Gallagher

Exelon, VP License Renewal

Sherry Bernhoft

EPRI, Senior Program Manager

Nuclear Power CouncilTuesday, August 30, 2016

Long Term Operations Technical

Advisory Committee

Introduction and Program

Summary

August 25, 2016 R.2

2


Meeting Purpose

EPRI LTO program created in 2010 to accelerate and coordinate

cross-sector research for safe, reliable and economic long-term

operations

Three major roles:

– Technical basis for aging management

– Opportunities for modernization and efficiency enhancements

– Provide technology transfer

US – participation in NEI tasks force and working groups, and

lead plant demonstration

International – participation with the IAEA and workshops at

host sites

LTO Technical Advisory Committee

Provides a review of the technical projects to ensure alignment

with industry needs

3


Long-Term Operations – Global Need

In the U.S.

License renewal – 40 to 60 years

Second license renewal – 60 to 80 years

As of October 2015:

250 NPPs > 30 years of operations

68 NPPs > 40 years of operations

Without SLR the U.S. will lose 30,000 MWs between 2029 and 2035.

Total Number of Reactors: 438Number of Reactors

Num

be

r o

f R

ea

cto

rs

35

30

25

20

15

10

5

0

If all existing nuclear

plants operate for 60

years.

If all existing nuclear

plants operate for 80

years.

Source: Capacity – Energy Information Administration; License Expiration –

Nuclear Regulatory Commission

Projected U.S. Nuclear Power Capacity(Megawatts)

4


Agenda

Welcome & Introductions

Program Highlights and Projects Plans for 2017 – 2019

US DOE –LWRS Program Update

LTO Research at the Materials Ageing Institute (MAI)

License Renewal for Angra-1

Materials Issue Programs Report

Concrete Research Projects for LTO

Cable Research for LTO

Control Upgrades and Modernization Project

Integrated Life Cycle Management Update

5


Member Resources:

LTO Program on EPRI.com

– LTO cockpit page

– Monthly updates

– Project Status Updates (PSUs)

– Project Overview Forms (POFs)

– Publications

Joint DOE-LWRS EPRI-LTO R&D Plan

– Updated annually

– INL LWRS website or LTO cockpit

LTO Program Roadmaps

– Updated every 6 months

– Link to Sector Roadmaps at bottom right of LTO Cockpit Home Page

Opens at LTO Roadmaps but includes all for Nuclear Sector

LTO Contacts:

– [email protected]

– [email protected]

mailto:[email protected]

mailto:[email protected]

6


Topics

Strategic Research Focus Areas (RFAs)

– Results of members feedback

Key accomplishments for 2016

Project plans for 2017 and 2018

– Two year project look ahead

Member Satisfaction Survey

High Priority:

1. Reactor pressure vessel

2. Primary system metals, welds and piping

3. Electrical cables

4. Concrete and containment structures

Aging Impacts:

– Increased thermal exposure

– Increased radiation exposure

– Stress corrosion cracking

– Fatigue usage

– Wear

– Etc…..

7


Research Focus Areas (RFAs)

8


Prioritization Process

EPRI:

– Provided a written description of strategic focus areas sent out in May 2016

– Included a description of the types (examples) of projects

– Ranking sheet for completion by IC and TAC advisors

– Additional details provided in the LTO Program Plan (on the LTO Cockpit)

Advisors:

– Had fours weeks to review and provide comments

– Feedback was in the form of 1,2, or 3 ranking (1-highest) and any written

comments

Goal - Have the portfolio for 2 years out finalized in September

2017 – 2018 portfolio finalized in August 2016

Reviewed by TAC & IC at the August NPC

9


Strategic Focus Areas (1 – High, 3 – Low)

Strategic Focus

Area

Ranking 2015 Ranking 2016 Comments - Summary

Aging management

for RCS metals,

RPV

1 1.22 Critical area for interface with MRP, BWRVIP and

reactor pressure vessel integrated surveillance

programs

Aging management

for concrete and

structures

1 1.22 Support for concrete aging management

programs, ASR and irradiation impacts

Aging management

for electrical cables

1 1.67 Need to understand synergistic effects testing and

impacts on cable qualifications (EQ)

Opportunities for

modernization and

efficiency

improvements

2.75 2.78 Needed to ensure cost effective LTO

Support for

industry and lead

plant activities

1.5 2 EPRI needs to stay engaged in industry activities

and provide support on technical issues

10


EPRI LTO R&D Projects - 2009 through 2014

Aging Management Research

– RCS primary system metals

Advanced welding for highly irradiated materials - repair strategy

Advanced radiation resistant materials - future replacement strategy

– Reactor pressure vessel embrittlement

– Concrete and concrete structures

– Electrical cable systems

Opportunity for Modernization

– Centralized on-line monitoring

– Advanced I&C

– Enhanced safety and risk analysis

Enabling Technologies

– Integrated Life Cycle Management

– Plant Demonstration Projects

11


EPRI LTO R&D Projects – 2015 through 2019

Aging Management Research

– RCS primary system metals

Advanced welding for highly irradiated materials - repair strategy

Advanced radiation resistant materials - future replacement

strategy

– Reactor pressure vessel embrittlement

– Concrete and concrete structures

– Electrical cable systems

Opportunity for Modernization

– Centralized on-line monitoring – Transitioned to Fleet-Wide Health Monitoring

– Advanced I&C

– Enhanced safety and risk analysis – Advanced PRA (Phoenix) Risks & Safety Management

Enabling Technologies

– Integrated Life Cycle Management – Transitioned to Plant Engineering

– Plant Demonstration Projects

12


Key Accomplishments for 2016

13


Industry Support

Technical reviews, comments and public meetings on NRC draft subsequent license renewal (SLR) GALL

Research ‘deep dive’ meetings with NRC and DOE-LWRS

Update the Advisory Committee on Reactor Safeguards (ACRS) on research status for SLR

NEI Task Force and Working Group meetings

IAEA IGALL, revision 3 – technical experts are participating on the steering committee, mechanical, electrical and structural working groups

IAEA SALTO lessons learned workshop

International member workshops on LTO

COG R&D Strategic workshop

Will be updating the IGALL EPRI product mapping

Research

Operating Experience

Inspection Results

Living research programs –

14


Cable Aging Management

Updated joint EPRI-DOE-NRC cable aging research roadmap

IAEA IGALL working group on cable aging management

Workshops with UNESA (Spain) and CEZ on cable inspection and condition monitoring programs

Harvested cables from Crystal River for testing by NRC Research, DOE at PNNL, and EPRI

Submerged cable condition monitoring (EPRI technical report under review by NRC)

Temperature and radiation data capture (data loggers) continuing at Palo Verde

Starting update of License Renewal Tools Report for Electrical Equipment

15


Concrete Aging Management

Updated joint EPRI-DOE-NRC concrete aging research roadmap

IAEA IGALL working group on containment structures

Alkali Silica Reactions (ASR)

– Developed roadmap with technical report milestones

– First report on structural implications in draft

– Will be supporting lead plant structural monitoring program walk downs

Irradiation and gamma heating degradation of concrete support structures

– Published report on structural implications on BWR cavity and support structures

– Completed modeling and will be publishing a report on the impacts on the PWR biological shield wall

– Completing assessment on the impacts of gamma heating

Spent fuel pool leakage and boric acid corrosion

– Report with results from a three year study on the impacts of boric acid on SFP concrete

Working with Spain on harvesting irradiated concrete cores from Zorita

Progress is being made on NDE techniques for concrete

16


RCS Metals and Reactor Pressure Vessel

Completed the roadmap to update technical reports for SLR

– Approval from the Materials program executives and funding to perform the work

– Presented to the NRC

Working closely with two lead US plants (PWR & BWR) to develop programs that will be the template for future SLRAs

– Includes approach for BWR integrated surveillance monitoring program for 60 to 80 years

– PWR supplemental surveillance program

Working with ORNL (DOE-LWRS) completed installation of welding cubicle in the hot cell and irradiating additional specimens for welding demonstrations

IAEA Working Group on materials aging management

International workshops on use of EPRI reports to support technical basis for LR

Starting work on updating the LR Mechanical Tools Report

17


Opportunities for Modernization

Completed feasibility study and literature

survey with INL (LWRS-DOE) for

development of a Structural Heath

Monitoring program

Supporting INL (DOE-LWRS) on control

room modernization project at APS

Collaboration with INL (DOE- LWRS) on

advanced risks informed safety margins

analysis

Application of risk informed safety margins to

evaluate life cycle management (Xcel pilot)

Integrated Life Cycle Management (ILCM)

completed turnover to Plant Engineering

– Pilot plant studies underway

– Interest group being formed

ISSUE DEFINITION

MANAGEMENT

ANALYSIS

STEP

S O

F TH

E R

ISM

C M

ETH

OD

Decision maker characterizes the issue(s) and analysis

scope

Determine risk-based scenarios

Safety case used to support decisions and Risk-Informed

Margins ManagementManage uncharacterized risks

Safety margin and uncertainty

quantification

Represent plant operation

probabilistically

Augment the plant model with issue specific knowledge

1 2

3 4

Represent plant physics

mechanistically

5 6

87

Coupling and Interactions

18


LTO Project Plans for 2017 & 2018

19


LTO Funded Projects for 2017 & 2018

Metals Materials Aging Management

– Advanced welding project for repair and replacements

– BWR Integrated Surveillance Program development

Concrete Aging Management

– ASR Aging Management studies

– Structural assessment of irradiated concrete

– Harvesting and testing irradiated concrete cores from Zorita

Cable Aging Management

– Cable vulnerability studies based on temperature and radiation data collection

– Cable harvesting and testing

– Advances in condition monitoring technology

Modernization and Efficiently Improvements

– Structural monitoring program

– Interface with INL on control room upgrades

– Risk Informed Safety Margin Characterization

Industry Support

– Subject matter experts

– Lead plant support

– Joint roadmaps and coordination with research partners

– IAEA IGALL participation

– International workshops

20


Aging Management Roadmap

21


Enhancement and Modernization Technology Roadmap

22


Member Satisfaction Survey

23


Member Satisfaction - Background

EPRI has captured member satisfaction

feedback in various forms for many years

Current member satisfaction survey

adopted by Board in 2006

Results reviewed regularly with Board

– one of Corporate Performance Indices (CPIs)

Member feedback used to drive

continuous improvement across EPRI

Helps prioritize efforts

– focus on areas with greatest impact on

satisfaction

24


Nuclear Member Satisfaction Survey Results

Overall Performance

Ease of Doing Business

Technical Program Value

Overall Satisfaction

2015 Results

2010-2015 Trend

92.3%

Overall

PerformanceEase of Doing

BusinessTechnical

Program Value

86.1%

93.2%

92.4%

75%

80%

85%

90%

95%

100%

2010 2011 2012 2013 2014 2015

• Impact of research on improving my business

• The program's strategic priorities and directions

• Quality of research results

• Relevance of research carried out by the program

• Technical staff expertise

Top ranked aspects of EPRI Experience

Who completed the Survey

25


Category Initiative Timeframe

Research and

Development

• Research Focus Areas

• Project Overview Forms

• Quality Management ProgramImplemented 2016

Tech Transfer

• Executive Summary

• Onsite EPRI updates/regional meetings

• International workshops

• International NPC

• Digital Strategy (ongoing)

Implemented 2016

Simplification

• On-line Pricing

• Invoice Review

• New Pricing Model

Implemented 2016

Website• New Search Engine

• Member Center ImprovementsImplemented 2016

Improvement Initiatives

Listening and Responding to the Feedback of our Members

26


Digital Delivery Enhancements

Becomes

27


Becomes

Digital Delivery Enhancements

28


New Search Engine

The search engine gets smarter over

time based on use.

It tracks what people search and where

they go with the results.

The more the search engine is used, the

faster it learns.

As it learns, features such as relevance

and search term recognition will

dramatically improve, and as a result

improve your search experience.

You make the search engine better by

using it!

29


LTO Program Improvement Initiatives

Based on survey feedback:

Complete the process to identify and

scheduled the updates to the technical

reports for M-AMPs out to 80 years

Clear timeline for concrete and cable aging

management work

Ensure relevance and support for the

international members

Actions:

Review completed, resources allocated and

plan endorsed by Materials Executives

advisors – focus is support for lead plants

Developed – joint EPRI-DOE LWRS- NRC

Research roadmaps have been developed

for:

– Cable aging management

– Irradiated concrete aging management

– ASR aging management

IGALL support and international workshop

– IGALL working groups

– Workshops on LTO, cables and materials

– Looking to support ETN

30


Survey instrument

Key components …

1. Who you arewithout a name and organization, we can’t

count your input!

2. Number of years you have been an Advisor

3. How we’re doing

4. How you assess EPRI value

5. Key improvement in ease of doing business

6. Value you have received from this Program

31


Survey instrument

Key components

7. Rate each statement based on how

satisfied you are

8. Rank the top 5 statements as

indicated in the instructions

9. Would you recommend EPRI

10.If you are not satisfied with us in any

area, please tell us why

9

10

7

8


Backup Slide on 2015 Results

33


2015 Nuclear Member Satisfaction Scores, By Area≤86% 87%-90% ≥91%

Program AreaSurveyed

Co's% Response

Overall

Performance

Technical

Program Value

Ease of Doing

Business

Overall

SatisfactionTotal

Nuclear Sector Council 19/39 48.7% 94.4% 96.6% 81.1% 93.3% 91.3%

Materials Degradation / Aging 18/40 45.0% 91.5% 92.1% 84.2% 92.1% 90.0%

Fuel Reliability 15/40 37.5% 89.5% 91.4% 89.5% 89.5% 90.0%

Used Fuel and High-Level Waste Management 16/40 40.0% 96.8% 96.0% 90.5% 97.8% 95.3%

Nondestructive Evaluation 13/40 32.5% 90.0% 92.7% 81.8% 90.0% 88.6%

Equipment Reliability 30/40 75.0% 91.0% 91.2% 83.8% 90.7% 89.2%

Risk and Safety Management 16/40 40.0% 92.2% 94.4% 91.1% 91.1% 92.2%

Strategic Initiatives (ANT and LTO) 20/40 50.0% 95.0% 95.7% 90.7% 95.7% 94.2%

Chemistry, Low-Level Waste and Radiation

Management15/40 37.5% 94.4% 94.4% 88.8% 95.8% 93.3%

Total 92.3% 93.2% 86.1% 92.4% 91.0%

34


Together…Shaping the Future of Electricity

US Department of Energy Light Water Reactor

Sustainability Program Update

EPRI LTO TAC Meeting

New Orleans, Louisiana

August 30, 2016

Kathryn A. McCarthy

Director, LWRS Technical Integration Office

Idaho National Laboratory

Presentation Outline

Program Highlights

– Materials Aging and Degradation

• Reactor Pressure Vessel

• Cables

• Advanced Weld Repair

• Concrete NDE

• Service-aged materials from Zion

– Risk Informed Safety Margin Characterization

• Industry Application #2: External Events

– Advanced Instrumentation, Information, and Control Systems Technologies

• Control Room Modernization

• Computer-Based Procedures

• Business Case Example: Advanced Outage Management

– Reactor Safety Technologies

• Fukushima Daiichi Forensics Planning

FY-17 Look-Ahead

2

US Department of Energy Light Water

Sustainability Program Goals and

Scope

Goals– Develop the fundamental scientific basis to

understand, predict, and measure changes in materials and systems, structures and components (SSCs) as they age in environments

– Apply this knowledge to develop and demonstrate methods and technologies that support safe and economical long-term operation of existing reactors

– Research new technologies that enhance plant performance, economics, and safety

Scope– Materials Aging and Degradation

– Risk-Informed Safety Margin Characterization

– Advanced Instrumentation, Information, and Control Systems Technologies

– Reactor Safety Technologies

3

Materials Aging and

Degradation Pathway

Develop the scientific basis for

understanding and predicting long-term

environmental degradation behavior of

materials in nuclear power plants

Provide data and methods to assess the

performance of systems, structures, and

components essential to safe and

sustained nuclear plant operations

Develop means to detect and characterize

aging degradation processes

4

Pathway Lead: Keith Leonard,

ORNL

Areas of materials R&D

– Metals

– Concrete

– Cables

– Mitigation Technologies

Data from RPV Materials Irradiated in the INL

Advanced Test Reactor Provide Important

Information on RPV Aging

Significant progress in FY16 evaluating

mechanical properties (tensile, shear

punch, microhardness) and

microstructure (TEM, APT, SANS, SAXS)

at University of California Santa Barbara,

ONRL and INL

Work continues in FY17 collecting further

experimental data to formulate the

transition temperature model for RPV

steels over varying compositions and

fluences

5

Model for Transition Temperature Shift in RPV Steels in 2018

Progress in Cable Aging

Activities

BIW Control Rod Cable– Harvested from Callaway plant after in vessel

service for 30 years

– Hypalon (CSPE) jacket & EPR insulation

– Remaining Useful LIfe estimated compatible with SLR

Rockbestos Firewall III (RB FIII) power cable

– Harvested from San Onofre storage facility in 2014

– CSPE jacket & XLPE insulation

Radiation aging in Co-60 source at 25°C Rockbestos Firewall III & BIW cable

compared to multiple SCRAPS data– Hyp-04: Anaconda Flameguard

– Hyp-05: RB FIII

– Hyp-06: Eaton Dekoron

6

EAB for BIW Hypalon & Rockbestos CSPE

compared to multiple Hypalon conductors

from EPRI / SCRAPS data base

EAB for BIW Hypalon/EPR at

120°C compared to Hyp-08

Model for Cable

Degradation in

2019

FY-17 Plans for Developing Cable

Aging Model

Additional testing of service-aged and laboratory-aged material

Characterize material changes with aging and compare behavior with existing

data with regards to current aging models; will include comparative analysis of

harvested materials with predictions based on Arrhenius model

Continue investigation of microstructural changes in materials with aging to

further understand fundamental aging mechanisms

Investigation of dose rate and inverse temperature effects in simultaneously

aged XLPE to ascertain the relative dominance of thermal versus radiation

aging

7

Discussions with EPRI are underway regarding potential modeling activity

to support dose estimate of cable underway with Palo Verde

Advanced Welding R&D: Providing

Options for Welding Irradiated Material

Jointly funded by DOE and EPRI

Repair highly irradiated reactor internals without helium-induced cracking

Modeling and experiments to investigate long-term performance and cracking resistance

Installed the integrated welding hot cell

– State-of-the-art facility at ORNL for welding R&D to repair irradiated

– Demonstrated the baseline performance of friction stir weld subsystem

– Laser subsystem installation mid-August

8

Technology will be transferred to industry in 2018

Welding Task: Plans for FY17

Test laser welding subsystem

Demonstrate friction stir weld on irradiated samples

Examine irradiated friction stir weld material via optical,

microhardness and electron microscopyperform analysis on weld

cross-sections

Two rounds of irradiations in the High Flux Isotope Reactor (HFIR) to

prepare irradiated material for subsequent welding in the cubicle

– Material is pre-fabricated B-doped material supplied by EPRI

Access to Service-Aged Materials

Such as the Zion RPV are Essential

to Understanding Aging Behavior

RPV panels removed in 2015, test specimens

fabrication through 2017.

Sections contain belt-line weld (Linde 80, WF-

70 weld)

Peak fluence = 0.75x1019 n/cm2 (>1MeV),

anticipated temperature transition shift is

145°F.

High interest in:

– Evaluation of radiation damage models

– Attenuation studies, through wall variation in base

and weld metal.

– Mitigation techniques - annealing / re-irradiation

studies.

Axial Weld

WF-70, Belt-line

Weld

Risk Informed Safety Margin

Characterization Pathway

Develop and demonstrate a risk-assessment method coupled to safety margin

quantification that can be used by nuclear plant decision makers as part of their

margin management strategies

Create advanced “RISMC toolkit” that enables more accurate representation of

nuclear plant safety margin

11

RISMC methods understood

Now applying RISMC methods to make it useful

for decision makers

Currently refining some of the technical aspects of

the methods

RISMC Toolkit

Domain Knowledge (failure models,

operational data, etc.)

RAVEN

(Controller and Scenarios)

RELAP-7

(T-H)

Grizzly

(Aging Effects)

Peacock(Graphical Interface)

Moose

(Solver Framework)

. . .

MOOSE (Solver Framework)

Pathway Lead:

Curtis Smith, INL

RISMC Activities: Balanced Focus

On Methods / Tools / Data

12

Verification,

Validation, &

Uncertainty

MAaD R&D Pathway

Adv. IIC Sys. Technology R&D Pathway

RST R&D Pathway

Plant

Owners/

Operators/

Vendors

Integrated Tools

Modern Framework

TOOLSDATA

METHODS

DOE LWRS

Program

Industry

Stakeholders

RISMC Activities

RISMC

Pathway

RISMC Industry

Applications (IA)

IA 3

Reactor

Containment

Analysis

EPRI

LTOIA 2

Enhanced

Seismic/

External Hazard

Analysis

IA 1

Integrated

Cladding / ECCS

Performance

Analysis

RISMC R&D Pathway

RISMC Toolkit Development Risk-Informed Margin Management (RIMM) Applications

Componen

t

Subsyste

m

Syste

m

Facilit

y

Region

al

Type of information and

data

IA 4

Long Term

Coping

Studies -

FLEX

Risk-Informed Safety

Analysis Methods

Development

IA Safety Analysis Guidelines

FY15 start

Modeling of external events

13

Seismic

Flood

Winds

…

Recent accomplishments in

Seismic Modeling

MASTODON code development (MOOSE based

seismic soil-structure analysis and structural

dynamics)

– Implemented nonlinear soil constitutive model

Performing a rigorous verification effort for

structural dynamic calculation capabilities including

– Linear and nonlinear seismic wave propagation

– Gapping and sliding activities

– Size of nonlinear seismic analysis finite element domain

Planning for large scale geotechnical laminar box

test (September 2016)

– Used for benchmarking and validation of 1D site response

14

INL

Beta Version of Seismic PRA Model Will be Released in 2017

Advanced SPRA Results: Conditional probabilities

of failure – nonlinear soil structure interaction can

result in significant reductions in system risk

15

Pump Battery

Switch

gearDistribution

panel

Block

wall

Advanced Instrumentation, Information, and Control Systems Technologies Pathway

Address long-term aging and reliability

concerns of existing II&C technologies:

– Establish a strategy to implement long-term

modernization of II&C systems.

– Develop, test, and deploy advanced technologies.

– Promulgate technologies, lessons learned, and foster

industry standardization.

– Develop advanced condition monitoring technologies

to monitor, detect, and characterize aging and

degradation processes.

16

Pathway Lead:

Bruce Hallbert, INL

Control Room Modernization

Project begun with Arizona Public Services’ Palo Verde Nuclear Generating Station to

develop an end state for long term control room modernization informed by the plant’s

strategic modernization plan

Addresses feasibility and benefits of adopting a longer term outcome as a part of strategic

modernization

Employing best available technology optimized for safe and efficient operator use through

widespread inclusion of human factors principles

Design options are tested with Palo Verde staff in the INL’s Human System Simulation

Laboratory

17

Transformed Control Room (conceptual)Graphic of Current Control Room

Integral Human Factors Engineering

18

3-D Model of the Palo Verde conceptual design control room – 95th percentile male and 5th percentile female figures are used to check ergonomic aspects for anthropometric aspects of conceptual design using automated software tool

Control Room Modernization FY-

17 Plans

Develop an end-state design concept for the panels and systems involved in

the second phase

Develop a human factors engineering (HFE) plan to support the main control

room modernization effort at Palo Verde

Palo Verde phase 2 modernization and operator study report

Methodology and results of the Control Room Benefits experimental study

conducted with Palo Verde

Define performance measures for use in nuclear power plant simulator studies

based on Control Room Benefits studies conducted in FY 17

Develop an industry business case framework for control room modernization

Conduct Operator study to evaluate the design concept

Develop the Computerized Operator Support System to support Phase 2 of the

control room modernization

Conduct an industry peer review of the business case framework

19

Computer-Based Procedures

20

Field-based CBPs are one of the top enablers of improved efficiency and

human performance for NPPs, as well as a key foundation for future

technologiesError-Prone Situations Solutions

Omitting steps

Doing steps out-of-sequence

Making poor field decisions (failure to

adhere to procedure)

Manipulating wrong equipment

Relying on operator memory and experience

Automated Place-Keeping

Dynamic Context Sensitivity

Simplified Step Logic

Automatic Verifications

Dynamic cues to highlight important information

Access to supplemental materials

Automated aids Four Field Tests

– Catawba

– Palo Verde

– Diablo Canyon

– Vogtle 1 & 2

The CBP design requirements have been evaluated and validated

and will be published through NITSL and NEWPER in a Procedure

Professionals Association standard for dynamic smart documents

(CBPs), and a Design Guide for CBPs will be published

Business Case Example – Advanced

Outage Management

Completed the Advanced Outage Management Business

Case in March, working with ScottMadden and Duke

Energy

This business case was built on top of the Mobile Work

Packages business case to leverage mobile technology.

The result is an annual savings of >$7.7M, with a present

value >$48M over 15 years

Improvements are in better work

coordination, schedule analytics

remote job oversight, networked

meetings, and avoided errors

21

Operations$798

Maintenance$3,390

Work Management

$244

Radiation Protection

$289

Chemistry & Environmental

$185

Engineering$584

Training$3

CAP$390

Security$23

MWP and AOM Combined Harvestable Annual Labor Savings ($000s)

$3,277

$2,629

$179

$1,703

$0

$2,000

$4,000

$6,000

$8,000

MWP Benefits Incremental AOMBenefits

Business Case Annual O&M Benefits ($000s)

Labor Savings Non-Labor Savings

Total CombinedBenefit for MWP and

AOM

$ 7,788

Reactor Safety Technologies

Pathway

Evolved from coordinated global effort to

assist in analysis of the Fukushima accident

progression and accident response

Focus: Scientific/technical insights, data,

analyses and methods that can support

industry efforts to enhance nuclear reactor

safety during beyond design basis events

– Accident Tolerant Components

– Severe Accident Analyses

– Fukushima Forensics and Examination Plans

22

Pathway Lead: Mike

Corradini, University of

Wisconsin

Graphics Courtesy of TEPCO

RST Support to Forensics Planning

Forensics effort provides US access to

unique full-scale, prototypic, information for:

– Improved understanding of events that occurred in

each unit at Daiichi

– Reduced uncertainties in predicting severe accident

progression phenomena and equipment

performance

– Confirming/improving guidance for severe accident

prevention, mitigation, and emergency planning

– International effort under NEA appropriate means

for longer-term cooperation

Forensics Effort provides Japan:

– Consensus US input related to high priority

examination information needs

– Access to US expertise in severe accident

modeling, testing, and defueling & cleanup

Look-Ahead: FY-17 LWRS

Program Budget

Congress isn’t likely to pass a budget before October 1, 2016;

Continuing Resolution is likely

Three budgets

– President’s Request: $35.26M

– Senate: $35.26M

– House: $40M

Our budget has been steadily increasing ($25M in FY-12, $40M in FY-

16)

24

The LWRS Program Website Provides a

Range of Program Information

(www.inl.gov/lwrs)

25

Helping to Sustain National Assets

26

© 2016 – Materials Ageing Institute 1

LTO RESEARCH AT THE

MATERIALS AGEING

INSTITUTE

Regis Nhili

EDF R&D, MAI

August 2016


LONG TERM OPERATION

CONTEXT


EDF NUCLEAR GENERATION CAPACITY

IN FRANCEKey figures in FRANCE

58 reactors in operation on 19 sites

63 GWe installed nuclear capacity

1 reactor under construction

PWR technology only

Target : 50 to 60 years


OPERATING LIFETIME CHALLENGES

Large-scale construction in the 1980s and

90s:

Phase the renewal of the generating capacity

operate power plants beyond 40 years

Halt at 40

years:

a major

investment in

new nuclear

power plants


OBJECTIVES FOR THE PLANT OPERATING TIME

Safety improvements

•Ten-year inspection

revaluationSafety inspection every ten years

One file per reactor submitted by EDF

• 40-year key stage:

enhance the safety with

the objectives of new

reactorsREDUCE the consequences of a core

meltdown

REDUCE the probability of a core

meltdown occurring

Meet WENRA* requirements as closely as

possible

•Coexistence of GEN 2 and GEN 3(EPR)

Ageing management

• Replaceable components:

Define the best compromise

between routine

maintenance/preventive

replacement

• Non-replaceable components

Vessel: Demonstration of

endurance until 60 years

Containment: Repairs

*Western European Nuclear Regulators Association


Mechanistic understanding of ageingprocesses and NDT assessment

• Operation feedback• Experiments• Modelling

R&D MISSION FOR UTILITIES

Predictive capability for

• Operation and Maintenance Optimisation• Inspection and Monitoring• Component Replacement

Plant Operators

R&D« Understand »

« Reproduce »

« Anticipate »

« Assess »

LTO objective

Availability

Radioprotection

Environment

°CGy.h-

1


MAI OBJECTIVES AND

STRUCTURES


MAI OBJECTIVES

1. Safe operation of NPPsknowledge-based management of materials

and components

2. Centralize and coordinate R&Dfeedback from NPPs, data, methods and models

3. Training & EducationTrain our next generation: courses, workshops

and seminars in the field of material ageing

4. Improve fundamental knowledgestudy ageing mechanisms with the help of state-

of-the art experimental tools and capabilities


EXPERIMENTAL CAPABILITIES

Access to many experimental facilities


MAI MEMBERSHIP


MAI MEMBERS AND PARTNERS

Universities (Michigan, MIT, Tohoku, Manchester, Imperial, Oxford, Bristol, Rouen, Lille, Paris…), ParisTech (Mines, Ponts, Chimie,

Arts & Métiers), INP-Grenoble, INSA Lyon…

Founding Members

REA


EDUCATION, TRAINING &

WORKSHOPS


1st Benchmark Vercors mock-up (EDF Engineering div.)

MAI (Moret-sur-Loing): 7-9 March 2016 unrestricted

International ChemWorks Workshop (EPRI)

MAI (Moret-sur-Loing): 29-31 March 2016, open to MAI

members

Uncertainty Management in Computational Materials

Science

MAI (Moret-sur-Loing): 5-7 April 2016, unrestricted

Conference on Flow Accelerated Corrosion (EDF

Engineering div.)

Lille (France) : 24-27 May 2016, unrestricted

Master Materials for Nuclear Energy

INP-Grenoble/MAI, September 2016-January 2017

Materials Degradation Course for Engineers in the Nuclear

Industry in the US

EPRI-Charlotte Conference Center, 26-30 June 2017

2016 Programme

EDUCATION AND TRAINING


Maintenance activities and

strategies, human factors,

organisation, operations

preparation and sequences,

industrial strategy,

components, maintenance

feedback, …

CAPITALIZING & SHARING KNOWLEDGE

Degradation observed in

LWRs Photographs, detailed

schematics, concise

analyses, precise

measurements and

recommendations


MAI R&D PROGRAMME

Primary water chemistry optimization to

reduce corrosion and circuit contamination

Secondary water chemistry optimization to reduce corrosion

and Steam Generator fouling and clogging

On-site monitoring and lifetime extension of cables

Justification of safe long term operation of Reactor Pressure Vessel

Justification of safe long term operation of reactor Internals

Civil Engineering structures ageing evaluation and prediction

NDE process optimization and performance assessment

Sharing of operating feedback data: materials damaged in operation,

RPV material ageing data, fatigue data …

Knowledge sharing on material ageing mechanisms: thermal & environmental

fatigue, vibrational wear, concrete degradation…

Benchmarks of methods, models and protocols (RPV, Internals, APT …)

Major Industrial Applications


2016 R&D PROGRAMME

Project Name Technical Area 2016 2017 2018 2019 2020

CORIOLIS SCC, Primary side

CAIMAN Cable Ageing

MANDENA NDE Modelling

SG Wear SG Tubes Wear

RPV Integrity RPV Integrity & Lifetime

CHEOPS Primary Water Chemistry

CORDEE 2 Steam Generators

VIP RPV Internals

CISTERN 2 Concrete structures

MODERN Fatigue & Fracture Mechanics

SHERLOCK Two retired SGs• 11M€ annual budget• Contributing members in each project


CHEOPSCHEmistry Of Primary System

Industrial context

Better understanding materials and chemical species behaviors in the primarycircuit is an ongoing challenge for utilities in terms of radioprotection, safety,plant’s availability and plant’s lifetime expectancy.

Key industrial objectives

Optimization of the primary system chemistry

Reduction of the operators exposure to the primary circuitthrough a better control of the contamination for differentoperating conditions (startup, operation, shutdown)


Major R&D achievements

• Development of a numerical model describing the release of corrosionproducts from steam generator (SG) tubes measured in the BOREAL loop

1st step toward the estimation of the source term as a function of thephysico-chemical parameters of the primary circuit

Associated value

lower dose exposures through a better control of SGT release (690)


Temperature Effect


Major R&D results expected

• Impact of surface condition of SGT on release

• Solubility of Ni and other Corrosion Products

Expected value

• Direct economic value/ lower dose exposures :

Better control of corrosion and release of SGT through the identification of surface condition criteria

• Implicit value through scientific credibility :

A better knowledge of Corrosion Products behavior in the primary system

Reliable database inputs



CORDEE 2Chemistry cORrosion and DEposits in the secondary circuit

Approach

• Prediction of fouling and hard sludge formation

• Mechanisms Knowledge• Kinetics versus parameters

• Evaluation of

• Remedies of fouling and blockage• Alternative chemical conditioning

Objective

Context

• Degradation of the secondary circuits

• Optimization of chemical conditioning to reduce

• Source term of fouling and blockage

• Degradation by corrosion

• Optimization of maintenance operations


CORDEE 2Chemistry cORrosion and DEposits in the secondary circuit

R&D impact and valueSG Fouling

Avoid additional Cu-dedicated chemical cleaning

- Chemical cleaning operation cost saved

- Gain on NPP availability

- Environmental benefit (waste reduction)

- Gain on SG performance

Identify post-chemical cleaning copper depositionmechanisms

Prevent SG tubes plugging

Intensify final rinsing and lancing chemical cleaning

steps to prevent copper redeposition

Decrease H.P lancing applications frequency

- H.P lancing operation cost saved

- Gain on NPP availability

Reduce SG tubes plugging

- Gain on SG performance

Aluminum key role in hard sludge formation Al uses reduction in maintenance materials

Hard Sludge & SCC degradation

FAC degradation

Prevent pipes rupture

- Safety & availability benefit

PAA injection suspended on French Fleet

Prevent fouling source term increase

Highlight PAA injections impact on FAC


CORIOLIS - CSIStress Corrosion Cracking (SCC) of austenitic materials exposed to primary water

Industrial context

• Need to better explain recent in-service degradations

• Bottom mounted instrumentation nozzles of the reactor vessel: nickel alloys

• Bolts of primary pumps: stainless steels

• Need to evaluate mitigation method:

• Changes in water chemistry (dissolved hydrogen content, zinc injection) to reduce SCC kinetics

• Upgrading surface finishes of components (compressive stresses, limited cold work)

Key industrial objective

• To deliver engineering SCC tool predicting the time to reach a critical crack depth



• Improvement of crack growth models

• Explicit dependence to stress intensity factor, cold work (new), temperature and dissolved hydrogen (new)

• Explicit modeling of slow and fast crack growth regimes: MAI innovative approach

• Improvement of existing initiation models

• Explicit dependence to stress, temperature, heat-to-heat variability, dissolved hydrogen (new) and zinc (new) contents

• Development of a physically-based SCC model: innovative approach

• Satisfying a recognized SCC scenario: incubation → initiation → slow crack growth → fast crack growth

• Relying on physical mechanisms: oxidation, stress concentrations, cracking of oxidized material

Associated value

• Best estimate of components lifetime

• Quantitative evaluation of mitigation techniques,material replacement, design changes


SCC depth

Time

Incubation

(IG oxidation

kinetics)

Initiation (failure of oxidized

grain boundaries)

Slow crack

growth Fast crack

growth



• Development of an innovative methodology allowing to apply R&D models to power plant components

Associated value

• Use of robust and advanced SCC tools by operational units

• Support to in-service failure analyses


Modeling of a simplified

BMI nozzle (residual

stresses after welding)

Prediction of

initiation in the BMI

(nickel alloys)

Prediction of crack growth in

a bolt (stainless steel)


Objectives

• Give a scientific support to Industry for a new codification in fatigue for austenitic stainless steels

• Fatigue life curves

• Parameters (Environment) effects on fatigue life

• Improve advanced methods to assess the fatigue damage

Approach

• Fatigue tests in air and in primary water PWR environment

• Parameters effects on fatigue life (Temperature, mean stress, pre hardening, environment…)

• Statistical analyses

COFATTowards a new codification for fatigue


Major achievements

• Proposal to update the design curve for austenitic SS and incorporating the environmental effect

• Robust proposal

• Incorporate the state of the art in fatigue

• Consistent with international (NUREG/CR-6909) approach

Expected value

• Characterisation of the environmental effect on fatigue

• Reasonably conservative and operational approach

• New approach should become an IAEA guideline

COFATAdvanced method for fatigue crack initiation assessment


RPV LIFETIMEProviding tools and data for RPV Long Term Operation demonstration

Industrial context

• The Reactor Pressure Vessel is one of the major components of a Nuclear Power Plant

• Its replacement is not considered up to now as an industrial option (prohibitive cost)

• RPV integrity needs to be assessed for Long Term Operation (LTO)


• Justify safe and long term operation of RPV

• Increase confidence in RPV integrity assessment models

• Identify and develop MAI common strategies

• Improve knowledge on RPV material ageing by developing new experimental campaigns with a high leverage for members


Major R&D achievementsAtom probe analysis procedure benchmark

• Atom probe analysis are used by MAI members to evaluate the irradiation effects on the material micro-structure

• The benchmark allows to compare the atom probe analysis on samples

Associated value

• Strengthening confidence in the atom probe analysis results, and, as a consequence, in the understanding of the irradiation effects

• Identifying best practices in atom probe analysis

• Performing the benchmark campaign within the MAI allows a significant leverage on the associated cost

RPV INTEGRITYProviding tools and data for RPV Long Term Operation demonstration


Context: Can Internal components operate safely in long term operation?

• Internal components are under very high irradiation levels and temperature.

• Long term operation affected by material degradation mechanisms: hardening, swelling, Irradiation Assisted Stress Corrosion Cracking (IASCC).


• Determine conditions for which there is a

risk of component failure due to:

o IASCC

o Void Swelling

• Characterize operating conditions:

Dose, Temperature and Stress assessment

VESSEL INTERNALS PROJECTLong Term Operation of Lower Core Internals


MAI projects (LCI, INTERNALS, VIP) have enabled EDF to share all of the findings of the past and current research programs on irradiated internals.

• Irradiated Austenitic SS evolution (2010)• IASCC initiation sensitivity (2014)

Material assessment of IASCC initiation sensitivity

• French operating experience found cracked bolts due to IASCC in the 1980’s.

• As a consequence, EDF is a historical leader in IASCC investigations.

• Since the 1990’s, EDF led multiple major international programs to collaborate on IASCC investigations (CIR, JoBB, IAC…).

• Irradiations in Bor-60 and SM2 reactors at RIAR.

• Irradiated material investigations (mechanical, microstructure).

• IASCC initiation and propagation testing.

• Operating conditions – dose, T, stress/strain calculations.


316/316LTEM observation of Frank Loops and Cavities


Void swelling of internals in PWR conditions

• Void swelling is a potential issue for western plants.

• Void swelling laws are all currently calibrated on Fast Breeder Reactor (FBR) data often at high temperature. However, research has shown that they are very sensitive to irradiation temperature and neutron energy spectrum.

A more accurate swelling law for PWR conditions is required.

• Current Vessel Internals Project aims to determine risk and kinetics of void swelling in PWR conditions.

• Microstructure and Multi-scale modelling investigations of internal components.

• Dose and Temperature validation through benchmark.

Associated value

• More accurate swelling laws are most probably less penalizing than FBR calibrated laws

• Calculation benchmark: international validation of calculation methods used by the different participants



CAIMANCable AgeIng MANagement

Industrial context

• ~1500 km of cables for one production unit

• Replacement of cables technically difficult and costly because of associated plant shutdown (a partial re wiring in Sweden took 1 year)

• Multiple designs of cables and materials that leads to the inefficiency of strategies based on large databases to cover all situations (in terms of ageing factors)


• Benefit of robust polymer lifetime predictions

• Provide suitable techniques and methodologies for on-site monitoring of cables

• Acquire experimental data coming from cables removed from sites after several years to justify the good conditions of cables and validate their lifetime predictions




• Modelling of polymer ageing with consideration of key chemical ingredients with regard to ageing

• Antioxidants for EPR

• Plasticizers for PVC

• Sensitivity studies of polymer oxidation as a function chemical composition and range of irradiation/temperature couple

Associated value

• Accurate lifetime predictions taking into account the polymer composition

• Lifetime variability of polymers with environment conditions thanks to numerical simulations




• Analysis of aged cables removed from site

• 7 cables analysed after more than 30 years of service

• Characterization: Visual inspection + Physical properties + Mechanical properties

=> Good condition of PVC and EPR insulated cables aged on site (significant margins were found in relation to end-of-life criteria)

Associated value

• Real data on cables aged in service

• Consolidation of cable lifetime numerical simulations

• Identification and quantification of margins


CAIMAN – POLYAGECable AgeIng MANagement – POLymer AGEing


• Identification of cable compositions sensitivity to ageing after 60 years

• Identification of suitable criteria, measurable by NDE techniques or micro sampling techniques, to monitor the polymer ageing

• Comparison of modelling results and experimental analyses of aged cables

• Check, by simulation, the potential existence of a cliff-edge effect for EPR insulations of nuclear cables

Expected value

• Define suitable criteria to anticipate the ageing behaviour of polymers and define acceptance criteria for on-site reception of new cables

• Provide techniques and methodologies for on-site monitoring of PVC and EPR insulated cables

• Benefit of robust R&D numerical tools and studies to predict polymers ageing


MANDENAModelling Approaches for NDE for Nuclear Applications

Industrial context

• Lifetime extension of existing nuclear fleet requires more efficient NDE techniques and more regular inspections of critical ageing components

• EDF develops finite element and Monte Carlo-based models, complementary to commercially available semi analytical models

• Computer modeling of NDE has high potential for method development, performance demonstration and expertise


• To obtain validated, operational tools and methods to justify the performances and limitations of NDE techniques in support of plants needs

• To solve physical problems exhibiting complex requirements (material, geometry, flaw,…).

• Gain the required credibility for performance demonstrations of NDE applications


- Evaluation of the

X-probe

performance as an

alternative to

rotating probes

- Electronic

commutation of

coils replaces

rotating movement

- Shorter inspection

time

- Modeling

accompanied first

performance

evaluation AND

subsequent initial

deployment stage

on site

MANDENAModelling Approaches for NDE for Nuclear Applications

ET modeling use case : X-probe

Plate

Tube

Multi-

coil

probe


CISTERNCivil Structure Engineering Resilience for Nuclear

Industrial context

• Necessity to better plan potentially expensive maintenance policies

• Containment ageing faces several physical phenomena that were not completely anticipated and might cause definitive loss of a complete production unit


• Improve physical modelling of reinforced concrete material and building ageing

• Provide operators with key data to face known civil engineering issues (i.e. pool leakage, liner/rebar corrosion…)

• Provide NDE techniques for civil engineering structures performance evaluation and demonstration in accordance with nuclear industry requirements


CISTERN 2Civil Structure Engineering Resilience for Nuclear


• Diagnosis : Corrosion detection

• Diagnosis : NDT international benchmark evaluation

• Forecasting : Cement addition effect on physical properties and weather condition structural influence

Expected value

• New modeling tools to better anticipate ageing of concrete and buildings

• Evaluation of new concrete (fly ashes, furnace slag…) composition effect on performance

• Improvement of maintenance policy according to NDT evaluation performance with regards to nuclear industry specific needs


ACTIVE CONTRIBUTIONS FROM EPRI

CORDEE: CIRCE Version 3 code development 2013 – 2014. Ongoing up to end of 2016.

MANDENA: Experimental validation of NDE codes. 2013 – 2016.

VIP: Development of a Standardized Procedure for Acquisition and Analysis of APT Data

on Irradiated Stainless Steels. 2015-2017.

CHEOPS: Chemistry strategies for surface passivation of new replaced or

decontaminated primary circuit component. 2015-2018.

CHEOPS: Advanced modeling of nickel-based alloy corrosion and release. 2015-2016.

CISTERN2: Develop capability demonstration program for concrete. 2016-2019.

CORIOLIS: Direct Measurement of Cohesive Strength of Grain Boundaries Exposed to

PWR Environment. 2016-2017.


MAI IN NUMBERS

total investment by EDF (2008 – 2016)35 M€

annual budget in 201611 M€

researchers, technicians involved100

universities/institutes associated25

members, representing 66% NPPs11

participants yearly in the E&T programme250

deliverables since 2008350


MATERIALS AGEING INSTITUTE

An international centre of excellence

Led by key nuclear utilities

A truly collaborative approach

Sharing of methods, facilities, staff

Benchmark & common development

Fundamental knowledge

Promote

technical

consensus

Long-term

strategic

collaboration

Scientific

credibility


Materials Ageing Institute

Getting the best of what materials can give

http://www.themai.org

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long term operations technical advisory committee ... · as of october 2015: 250 npps > 30 years...

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