The Successful use of HDS for Nuclear Power Generating Plant Applications

Transcription

1 AREVA NP Inc. Metrology Services The Successful use of HDS for Nuclear Power Generating Plant Applications SPAR 2006 Lona Shaw Supervisor, CAD Unit

2 Who is AREVA? > AREVA group has 70,000 + employees world wide Provides nuclear engineering, products, and services including: Uranium Mining Uranium Enrichment & Nuclear Fuel Fabrication Engineering Services Heavy Component Design & Fabrication (New Reactors) Power Distribution & Transmission Nuclear Waste Reprocessing & Recycling > AREVA NP An AREVA and Siemens company More than 3000 employees in the United States Nuclear Engineering and Plant Modifications Nuclear Fuel and Related Components Nuclear Components, Inspections, Repairs, and Replacements Metrology 2

3 AREVA NP Metrology Services - Background Nuclear Industry Resurgence Plant Life Extension New Construction Completely Contained Within AREVA NP Initially an In-House Resource to Support Steam Generator Replacement Projects Nuclear Industry Leader in Diverse Metrology Applications; Performed dimensional control surveys, including more than 310 laser scanning applications Since Jan 2005, AREVA NP has completed 38 large-scale laser scanning projects Recently completed some of our most challenging laser scanning projects to date 3 projects of 100+ HDS laser scans each Complete Internal Collection of Metrology Technologies Industrial Photogrammetry Laser Tracking Laser Scanning Industrial Total Stations Proprietary Component Fit-up Optimization Software 3

4 Nuclear Industry Challenges > Limited Access Power Plants refuel every months Standard refuel outage durations average 3 weeks Personnel access is typically only allowed during scheduled refueling outages Must wait until next refuel outage to collect additional data one-time shot > Environment Radiation Exposure Anti-contamination Clothing Heat Stress Real Estate > Equipment & Personnel Contamination > Temporary Structures Scaffolding Radiation Shielding > Customer Acceptance 4

5 Project Applications > Reverse Engineering & System Modification Assist with design engineering Independent review of system modification designs > Interference Detection Simulate component load-path movement sequences Identify interferences > Mock-up Training Create welding & machining mockups to train craft on actual weld geometry Reactor Vessel Head Installation Pressurizer Replacement > Tool Clearance Evaluation Ensure sufficient clearance for safe operation of automated welding and machining tooling Steam Generator Replacement 5

6 Pre-Deployment Planning > Review Survey Requirements General survey requirement review with requesting department Detailed description of critical areas Accuracy requirements Incorporate photogrammetry and laser trackers as required Desired output > Survey Plan Raw point clouds Applicable CAD format Review general arrangement drawings Estimate required number of station setups and their approximate locations Determine actual on-station time for radiation exposure estimates > Submit Survey Plan to Customer Exposure estimates are evaluated On-station requirements incorporated into outage schedule 6

7 Field Data Collection > Field Crew Training General understanding of nuclear power Risks of radiation exposure How to properly work in a radiologically controlled environment Security clearance > Job Site Preparation Personnel and equipment must go thru several Plant security access points to access survey areas Personnel and equipment must be checked over by the site Radiation Protection prior to and after survey activities. Survey equipment is assigned a specific area to be stored while not in use in the Reactor Building > Job Execution Establish control network Collect documentation images Perform total station and scanning activities in parallel to maximize schedule availability Implement photogrammetry & laser tracker as required > Site Demobilization Ensure equipment and personnel are not contaminated If contaminated, non-destructive decontamination activities are initiated 7

8 Data Processing > Project Handoff Between Survey Lead and Registration / Modeling Application Engineer Submit survey plan documenting actual station locations Review documentation images Review control network Identify trouble areas > Point Cloud Registration Relativity Control and /or Geometric Gravity > Modeling (if required) Cyclone modeler Incorporate company standards Orientation relative to site-supplied general arrangement drawings Use of Cloudworx where appropriate > Export to Applicable CAD Format > Animation Creation 8

9 > Required to Support Detailed Surface Modeling of Approximately 75% of the Entire Reactor Building 100 Tall X 130 Diameter Compartmentalized Containment Extensive Temporary Structures to Support Outage Maintenance Activities Obstructed Access Operating Equipment Vibration, Outage Maintenance Personnel Foot Traffic (2500 workers) and Radiological Isolation Zones Limited Suitable Station Setup Locations > Data Collection and Post Processing Both a Leica HDS 3000 and 4500 Were Used More Than 100 Scans Collected Field Data Collection Required 500+ Man-Hrs Project Registration and Modeling Required 650+ Man-Hrs > Model Usage Included: Large Component Replacement Interference Analysis Machining and Welding Tooling Clearance Evaluation System Upgrade and Modification Design Engineering Craft Pre-job Planning Project A 9

10 Project A Continued > Registration Challenges Entire Survey Volume Required Accurate Relative Registrations Congestion and Compartmentalization Limited Point Cloud Registration More than 125 Targets Were Acquired for the Control Network Several Different Elevations with No Direct Line-of-Sight Separated by 1 2 feet of Concrete Flooring Several Compartments with a Single Entrance / Exit 10

11 Project B > Expanded Coverage of Previously Supplied Model to Support Emergent Work > Areas Originally Collected in 2003 Operating Elevation of The Reactor and Auxiliary buildings 170 Scans Collected Using a CYRAX 2500 Scanner > Supplemental Data Collected in 2005 Collected Using a Leica HDS Additional Scans Concentrating on Additional Areas of Interest > Data Merge Cloud-to-Cloud Registration Special Consideration to Changed Conditions (Plant Modifications and Temporary Structures) 11

12 Project B continued > Model Usage Component Replacement Interference Analysis Replacement Component Design Engineering > Animation Creation Created to Illustrate Reactor Vessel Head Replacement Process Target Audiences Included; Public Hearings Board of Directors Outage Management Craft Professionally Narrated Voiceover 14 minutes long 12

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