OPERATION AND MAINTENANCE

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1 OPERATION AND MAINTENANCE PRODUCTION POLICY AND OPERATION HISTORY Harri Varjonen

2 OLKILUOTO NPP PRODUCTION POLICY Disturbance free Operation High safety culture Predictive, efficient and advanced maintenance Competitive production costs To maintain the plant units in modern condition Always 40 years lifetime To maintain high environment, personnel and plant safety level and open public relations 2

3 OLKILUOTO 1 OPERATING DIAGRAM 2013 Production Load factor ,2 97,1 MWh % January February March April May June July August September October November December 3

4 OLKILUOTO 2 OPERATING DIAGRAM 2013 Production Load factor ,6 93,1 MWh % January February March April May June July August September October November December 4

5 OL1 + OL2 KESKIMÄÄRÄISET KÄYTTÖKERTOIMET JA TUOTANTO AVERAGE LOAD FACTORS AND PRODUCTION 5

6 KESKIMÄÄRÄISET 12 KK LIUKUVAT KÄYTTÖKERTOIMET AVERAGE 12-MONTH LOAD FACTORS OF DIFFERENT COUNTRIES Tilanne/Situation 03_2013 6

7 OPERATION AND MAINTENANCE OUTAGE PRACTICES

8 OLKILUOTO NPP - OUTAGE POLICY Working period for OL1 and OL2 is 12 months. (Fuel cycle is approximately 12 months.) Annual outages are agreed to be carried out between May and June. - availability of substitutive energy (Hydro power) - power market situation - availability of human resources There are two kind of annual outages: - Refueling outage (7 days) - Service outage (2-3 weeks) Every year one unit has refueling outage and the other unit has service outage. TVO has decided that shorter, refueling outages comes first (since 2007). It s important to keep the time between these two outage as short as possible to ensure the best possible production. 8

9 OLKILUOTO NPP REFUELING OUTAGE Refueling Repairs Annual test and inspections according to the technical specifications Annual service and inspection works (one year period) Minimizing refueling only outage scope 9

10 OLKILUOTO NPP SERVICE OUTAGE Refueling Repairs Annual test and inspections according to the technical specifications Annual service and inspection works (one year period) Major Overhauls Service and Inspection works Modifications and Improvements 10

11 BIG COMPONENTS WHICH HAVE BEEN REPLACED IN NORMAL OUTAGES DURING 30 YEARS OPERATION In Reactor: Upper fuel support moderator tank cap water separators Steam dryers RIP impellers In NI: Pressure Relief Valves Isolation valves Insulations In TI: Generator (twice) HP turbine LP turbines Reheaters Condensers Seawater pumps Electric systems: Generator Circuit Breaker Unit Transformers Plant Transformers Start-up Transformers 6,6 kv switchyard 660 V switchyard RIP frequency converters UPS, AC/DC converters HV cabling I&C: Turbine automation MCR MMI Vibration monitoring system Neutron Flux Measurements 11

12 OL1 OL2 REALIZED LENGHT OF ANNUAL OUTAGES AND ESTIMATION FOR YEARS

13 OPERATION AND MAINTENANCE MAINTENANCE CLASSIFICATION

14 OPERATION & MAINTENANCE PHILOSOPHY Keeping the load factor over 90 % and avoiding operational disturbances. Keeping the technical condition of the plant units as new (40 years ahead). Continuous learning and development of operation and maintenance functions. Decreasing the production costs by optimizing the activities. Outages have the biggest influence to load factor (3-5%) 50 % of maintenance manhours during annual outages 14

15 SOME CRITERIA FOR CLASSIFICATION AND O&M Priority 1, Always in working order Failure causes directly TechSpec limitations, repair not possible during operation Failure (no other failures at the same time) causes directly reactor scram, turbine trip or power reduction Failure (for example measurement) causes directly a functional failure on other equipment unit (for example pump) classified to priority 1 O&M: Good condition supervision combined with time based PM Priority 2, Limited unavailability allowed Safety related equipment units which have periodic tests/tasks acc. to TechSpech Failure causes TechSpec limitations, but repair is possible during operation Failure causes reactor scram, turbine trip or power reduction if parallel equipment unit has been failed at the same time O&M: Good condition supervision and mainly condition based PM or actions preventing failures (lubrication etc). 15

16 SOME CRITERIA FOR CLASSIFICATION AND O&M Priority 3, Economically reasonable maintenance allowed Economically reasonable maintenance allowed (otherwise it can be run to failure = priority 4) O&M: PM based mainly on operation/condition monitoring or actions preventing failures (lubrication etc). Priority 4, No planned maintenance Failures has no affect to safety/availability: can be run to failure Repair (for example filter exchanges) can be done according to normal operation monitoring during operation No reasonable maintenance can be done (for example small valves) (Spare parts, preparedness to repairs must be evaluated) O&M: CM based on operation monitoring 16

17 OLKILUOTO NPP - MAINTENANCE ANALYSIS MAINTENANCE (PLANNING) PRIORITY OF EQUIPMENT UNITS Yes Does the failure affect plant safety and/or operational availability? No Does the failure affect immediately? Yes No Maintenance Priority 2 Limited unavailability allowed Yes Maintenance Priority 3 Economically reasonable maintenance allowed Is maintenance economically reasonable? No Maintenance Priority 1 Always in working order Expensive Repair Costs Operation and Maintenance Experience Maintenance Priority 4 No planned preventive maintenance Normal Operation Supervision is enough 17

18 OLKILUOTO 1 AND 2 - MAINTENANCE PLANNING PRIORITY OF EQUIPMENT UNITS More attention on priority 1 and 2 components! Maintenance Planning Priority 1 Maintenance Planning Priority2 Maintenance Planning Priority3 Maintenance Planning Priority4 Less unnecessary maintenance! Puisto Timo 18

19 Reporting PLANNING OF PREVENTIVE MAINTENANCE Operation and Maintenance Experience Safety Demands Availability Demands Maintenance Planning Priority of Equipment units Analyses of Failures 4 Operation and maintenance history, experience, FMEA : Functional Failures/Failure Mechanisms Controls Maintenance Planning for component process places 4 Normal Operation Supervision -> repair/overhaul at need Selection of measures Preparing Execution Process Measurements and Condition Supervision, Periodical Testing, Inspections and Overhauls Failure Detection / Prevention in time Preparedness to repair,spare parts, resources, instructions, training, tooling, data systems Changing of Maintenance Planning Priority if needed Maintenance Planning Priority: 1 Always in working order 2 Limited unavailability allowed 3 Economically reasonable maintenance allowed 4 No planned maintenance 19

20 RESPONSIBILITIES OF MAINTENANCE PLANNING On Line Maintenance Production Maintenance Areas Technical Responsibilities (Eng. dpt) Next Outage Focus of Maintenance Planning Medium Range Planning Maintenance Activities Long Term Planning Plant Life Time Management Time Focus of Plant Life Time Management Engineering Working Groups (Prod./Eng.) 20

21 OLKILUOTO NPP - SPARE PARTS POLICY Complete Component Replacement Units Generator Rotor Generator Stator One turbine train Control Rod Drives Servomotors Valve Internals - Total Valves Pump Internals - Total Pumps Pump Motors Transformers Diesel Engine Etc. Replacement During Outage Service before Outage in Workshop Condition Value of Spare Part Stock: ca 50 M 21

22 Thank you