on-line monitoring and calibration techniques in … i&c on-line monitoring and calibration...
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Advanced I&C
On-line Monitoring and Calibration Techniques in Nuclear Power Plants
Prepared by:H.M. Hashemian, President
Analysis and Measurement Services CorporationAMS Technology Center
9119 Cross Park DriveKnoxville, Tennessee 37923
USA
Presented at:International Conference on
Opportunities and Challenges for Water Cooled Reactors in 21st Century
Vienna International CentreInternational Atomic Energy Agency
Vienna, Austria
27-30 October 2009
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Do Not Forget Sensors and Cables
2H.M. Hashemian
Process
Temperature Sensor
PressureTransmitter
Cables
Cables
Penetration
I&C Cabinets(Analog or Digital)
Control Room Area(Mild Environment)
Containment(Harsh Environment)
~150 meters
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Proper Installation is Critical to Temperature Sensor Performance
3H.M. Hashemian
0
4
8
12
Res
pons
e Tim
e (s
ec)
Thermocouple Tag Number
DWM139B-01A
0
1
0 10 20 30 40 50 60
Time (Sec)
Step
Res
pons
e
Fast - GoodSlow - Bad
RTD
Thermocouple
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Nuclear Power Plant Pressure Transmitter Failure Mode Detected by Pure Luck
4H.M. Hashemian
80
90
100
110
120
9:30 AM 10:00 AM 10:30 AM 11:00 AM 11:30 AM 12:00 PM 12:30 PM
RC
S Fl
ow (%
)
Time
JPF025B-04
FT-445
FT-444
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Sensing Lines are Critical to the Performance of Pressure Transmitters
5H.M. Hashemian
Process Pipe or Vessel
Condensate Pot
Vent
ThermalInsulation
Rootvalve
Shield Wall
Penetration
Accessible Isolation Valve
Transmitter
PrimaryContainment
Wall
Restriction Device
Check Valve
~ 50 meters
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Cable Diagnostics
1 2 3 4
RTD
-0.5
0
0.5
-200 0 200 400 600 800 1000
1,22,3
3,4
Distance (Feet)
6H.M. Hashemian
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Signal Problems are Not Always in Cables
Current MeterN
eutr
ons
Current Voltage Source
+
NeutronDetector
7H.M. Hashemian
-
I – V Test
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10H.M. Hashemian
MaintenanceClasses
Predictive Maintenance
Methods that use Data from Test
Sensors
Predictive Maintenance
Methods that use Data from Existing Process Sensors
Predictive Maintenance
Methods Based on Active Measurement
Signals
Detection of Fouling of
Venturi Flow Elements
Detection of Sensing Line
Blockages
Instrument Calibration Verification
Loose Parts Monitoring
Leakage Monitoring
Vibration Measurement
Sensor Installation Verification
Sensor Response Time
Testing
Cable Condition Monitoring
Conventional and Advanced Predictive Maintenance Technologies
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Plant Implementation of On-Line Calibration Monitoring
H.M. Hashemian 9
PlantComputer
Data
Status of Plant Instrumentation
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Plant Startup and Shutdown Data
10H.M. Hashemian
0
10
20
30
40
50
60
70
80
90
0 500 1000 1500 2000 2500
Pres
sure
Time (Minutes)
Startup Data KDL204A-01
0
10
20
30
40
50
60
70
80
90
0 300 600 900
Pres
sure
Time (Minutes)
Shutdown Data KDL204A-02
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On-Line Calibration Monitoring Results Covering the Full Operating Range of a Transmitter
11H.M. Hashemian
-1.0
-0.5
0.0
0.5
1.0
7.5 20 30 40 50 60 70Operating Point (%)
+ (ALLOWABLE CALIBRATION LIMIT)
- (ALLOWABLE CALIBRATION LIMIT)
CRS038B-01D
evia
tion
(%)
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Conclusions and Recommendations
• Do not forget the sensors, process-to-sensors interfaces, cables, connectors, and penetration
• The validity, accuracy, and fidelity of process signals depends on proper installation of sensors and flawless cables and connectors
• On-line monitoring techniques and in-situ test methods are now mature enough for ready use in nuclear power plants
• Regulators have approved the OLM concept to verify the calibration of nuclear plant pressure, level, and flow transmitters
• U.S. plants are applying for generic NRC licensing to implement OLM for online calibration monitoring of pressure, level, and for transmitters
• Research is needed to establish the uncertainty of modeling techniques for on-line calibration monitoring applications
H.M. Hashemian 12
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Thank You
13H.M. Hashemian