Managing I&C Obsolescence for Plant Life Extension IAEA-CN-155/075 Larry Chi Consulting Engineer Bin Zhang Senior Engineer GE-Hitachi Nuclear Energy October 2007 1
Managing I&C Obsolescence for Plant Life Extension Background I&C Obsolescence Issues Challenges GEH Approach Six Sigma Potential Upgrades Long Term Strategy Summary 2
Background 49 GE Designed BWRs in operation worldwide I&C systems ranging from 1960/1970 s style of analog equipment to modern digital controls U.S. current practice is to upgrade when needed Regulatory driven Cost benefit analysis I&C Upgrade will be a major task to support Plant Life Extension Significant potential benefits from Plant Life Extension Increased total revenue from $178~356 billion Significantly higher with program such as Performance 20 TM Plant Life Extension changes the landscape for I&C upgrade 3
Instrumentation & Controls Products & Services GEH Scope of Supply: Over 40 years of design, manufacturing and service of I&C for GE BWR 4
Power Plants Commercial Operation Date License Expiration Date Nine Mile Point 1 (213) - I 26-Dec-76 22-Aug-09 Oyster Creek (213) - I 1-Dec-69 4-Apr-09 Tsuruga (171) - I Mar-70 14-Mar-10 Dresden 2 (251) - I 20-Feb-91 22-Dec-09 Dresden 3 (251) - I 12-Jan-71 12-Jan-11 Fukushima 1 (188) - I Mar-71 26-Mar-11 Monticello (205) - I 9-Jan-81 8-Sep-10 Santa Maria De Garona (Nuclenor) (188) - I 2-Mar-71 11-May-11 Pilgrim (224) - I 9-Dec-72 8-Jun-12 Quad Cities 2 (251) - I 10-Mar-73 13-Dec-12 Browns Ferry 1 (251) - I 20-Dec-73 20-Dec-13 Browns Ferry 2 (251) - I 2-Aug-74 28-Jun-14 Browns Ferry 3 (251) - I 18-Aug-76 2-Jul-16 Brunswick 1 (218) - I 12-Nov-76 8-Sep-16 Brunswick 2 (218) - I 27-Dec-74 27-Dec-14 Chinshan 1 (201) - I 15-Dec-78 14-Dec-18 Chinshan 2 (201) - I 15-Jul-79 14-Jul-19 Cooper (218) - I 18-Jan-74 18-Jan-14 Duane Arnold (183) - I 20-Feb-75 21-Feb-14 Fermi 2 (251) - I 15-Jul-85 20-Mar-25 FitzPatrick (218) - I 10-Oct-74 17-Oct-14 Fukushima 2 (218) - I Jul-74 18-Jul-14 Hatch 1 (218) - I 13-Oct-74 6-Aug-34 Hatch 2 (218) - I 13-Jun-78 13-Jun-18 Hope Creek 1 (251) - I 25-Jul-86 11-Apr-26 Muehleberg (KKM) (158) - I 15-Nov-72 14-Nov-12 Limerick 1 (251) - II 8-Aug-85 26-Oct-24 Limerick 2 (251) - II 25-Aug-89 22-Jun-29 Peach Bottom 2 (251) - I 25-Oct-73 8-Aug-13 Peach Bottom 3 (251) - I 2-Jul-74 2-Jul-14 Susquehanna 1 (251) - II 12-Nov-82 17-Jul-22 Susquehanna 2 (251) - II 27-Jun-84 23-Mar-24 Vermont Yankee (205) - I 28-Feb-73 21-Mar-12 Columbia (251) - II 13-Apr-84 20-Dec-23 Fukushima 6 (251) - II Oct-79 24-Oct-19 Laguna Verde 1 (201) - II 29-Jul-90 14-Jul-30 Laguna Verde 2 (201) - II 10-Apr-95 14-Apr-35 LaSalle 1 (251) - II 17-Apr-82 17-Apr-22 LaSalle 2 (251) - II 16-Dec-83 16-Dec-23 Nine Mile Point 2 (251) - II 2-Jul-87 31-Oct-26 Tokai 2 (251) - II Nov-78 27-Nov-18 Clinton 1 (218) - III 24-Nov-87 29-Sep-26 Cofrentes (218) - III 11-Mar-85 10-Mar-25 Grand Gulf 1 (251) - III 1-Oct-84 16-Jun-22 Leibstadt (KKL) (238) - III 15-Dec-84 15-Dec-24 Kuosheng 1 (218) - III 15-Dec-81 14-Dec-18 Kuosheng 2 (218) - III 15-Mar-83 15-Mar-23 Perry 1 (238) - III 13-Nov-86 18-Mar-26 River Bend 1 (218) - III 20-Nov-85 29-Aug-25 Life Chart 1960 1970 1980 1990 2000 2010 2020 2030 2040 2050 FIG. 1. Current operating GE BWR NPPs and life status 5
Histogram of Years of Operation Histogram of Years of Licensed life left 7 7 6 6 5 5 4 4 3 3 2 2 1 1 0 0 1 0 2 0 3 0 4 0 Years 0 1 0 Years 2 0 3 0 26.5 year 11.8 year FIG. 2. Comparison of operated life vs.initial licensed life left 6
I&C Obsolescence Issues Technology Obsolescence Major design architectures System communication bus standards Related assembly and manufacturing processes Requires major redesign Parts Obsolescence Parts no longer manufactured Requires redesign if alternative parts cannot be found Diminishing Skill Sets Knowledgeable plant and supplier staff are lost by attrition or retirement Young engineers do not have training on older equipment Regulatory Hurdles Costly and complicated review process for safety related systems Discourages both I&C upgrades by plant owners and Introduction of new products by vendors 7
I&C Upgrade Challenges Ability to predict when parts become obsolete Market driven Small volume for nuclear application Effective Maintenance Program Responds to pressure to bring plant on line New Generation of I&C Development New products to meet market needs Regulatory and Industrial Requirements Evolving changes Requires systematic approach to to identify and prioritize I&C upgrade for Plant Life Extension 8
GEH Approach Customer Satisfaction and Benefits Minimal outage Life extension Power output uprate Safer, more secured and reliable operation Part Obsolescence Analysis and Predication Major parts (component life and reliability, new product availability) Major architecture and structure (buses, interconnections, and networking) Sourcing and supplier (multiple long term supply chains) Effective Maintenance Service personal training Computerized and database managed documentation and tracking system Procedure based maintenance GENE Solutions Modular Design Six Sigma and Lean methodology Design Basis Advanced simulation and analysis Hardware and software V&V Inspection, test, standard and compliance compatibility New Generation I&C Development Design upgrade toward fully digital system Modernized human machine interface Simplified system design More secured and optical network monitoring and control Improved reliability design with longer system life Industrial and Regulatory Requirements Licensing process for safety related controls Update of industrial standards Plant process for implementing upgrades FIG. 3 Overview of GENE Approach in Dealing with I&C Obsolescence 9
GEH Approach Overview Feature Modular Design Maintain Design Basis of System Advance simulation Execute rigorous design process Maintain System Design Requirements for replacement parts (e.g., EMI, environmental) Apply Six Sigma and Lean Methodology Benefit Limited impact from parts obsolescence Allows redesign without impact system design basis Facilitate design process Maintain integrity of redesigned parts or system Meets regulatory requirements Systematic approach 10
GEH Approach Example Function Design Logic Architecture Code Design Resources IP cores Code libraries Logic functional cells Design Results Result Verification Net list file Pin configuration Layout and routing Define constraints Programmin g FPGA Simulations Debugging Testing Final prototyping FIG. 4 Overview of design flow of FPGA devices 11
GEH Approach Example FIG. 5 A programable device used to simplify and upgrade a design of BWR reactor rod control board 12
Six Sigma Methodology Apply Six Sigma to define and prioritize plant needs Data-based design Systematic approach with entire plant perspective Many tools available Quality Functional Deployment (QFD) Translate customer requirements into design requirements Customer Requirements - Critical To Quality (CTQ) Quality System Thinking 13
QFD Application to Plant Life Extension Select Team Diversity involves all stakeholders or process owners Example: Engineering, Maintenance, Operation, QA, Licensing Define CTQ that is applicable to the plant Reliability Ease of Maintenance Ease of Operation Outage Impact Long Term Viability ALARA Ability to Support Plant Operation (e.g., EPU) 14
FIG. 6 Application of QFD tool for I&C upgrade 15
Examples of Potential Upgrades (1) Wide Range Neutron Monitor (WRNM) Replaces Source Range Monitor and Intermediate Range Monitor Reactor Pressure Vessel Retractable Sensor Flexible Shaft Core Dry Tube Position Switches Mot or Flexible Cable Drive Control IRM SRM Electronics Penetration Reactor Pressure Vessel Fixed Incore Regenerative Sensor Core Dry Tube Connector Cable Drywell Preamplifier Penetration Reactor Building Control Room Monitor Control Room Existing System Advanced System (WRNM) 16
Examples of Potential Upgrades (2) Power Range Neutron Monitor (PRNM) Replaces Average Power Range Monitor 17
Examples of Potential Upgrades (3) Rod Control and Management System (RCMS) Replaces Rod Position and Information System and Reactor Manual Control System 18
Examples of Potential Upgrades See IAEA-CN-155-048P 19
Long Term Strategy Recommended Approach is only the first step in managing obsolescence Everything will become obsolete Cost of eventual upgrade increases with time Need Continuous Pro-active Practice Continuous evaluation of plant health Take pro-active actions to stay ahead of obsolescence Take the view of long term plant operation instead of from outages to outages 20
Summary Plant Life Extension has huge economic benefits I&C upgrade is need to meet Plant Life Extension goals Systematic Approach to I&C Upgrade Six Sigma Methodology to define and prioritize plant needs Involves diverse plant staff Define, implement and maintain long term strategy Plan I&C upgrade to Improved Plant Reliability, Operation and Supports Plant Life Extension 21
GE s Advanced BWR Control Room 22