Foreign Object Experience Update

Transcription

1 Foreign Object Experience Update 35th EPRI Steam Generator Nondestructive Evaluation and Tube Integrity Workshop Presenter: Robert Huddleston, Rolls-Royce Inspection Services Manager 2016 Rolls-Royce The information in this document is the property of Rolls-Royce and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce. This information is given in good faith based upon the latest information available to Rolls-Royce, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce or any of its subsidiary or associated companies. Trusted to deliver excellence

2 Agenda 2 Foreign Object Detection Update Operating Experience Best Practices Summary

3 Foreign Objects Detected Foreign Object Detection Over Five Years Five Year Total , FO s found currently trending down from 2015 to 2016, however 2012, 2013 and 2015 are similar (29 SG) 2013 (33 SG) 2014 (32 SG) 2015 (34 SG) (8 SG) Year

4 Average Number of Foreign Objects Detected per Steam Generator Foreign Object Detection Over Five Years Five Year Total 0 1, FO s detection steady over the five year period (29 SG) 2013 (33 SG) 2014 (32 SG) 2015 (34 SG) 2016 (8 SG) Year

5 Foreign Objects Detected Foreign Object Detection Over Five Years (by Location) 5 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Year In-Bundle Annulus Tubelane

6 Foreign Objects Detected Foreign Object Detection Over Five Years (In-Bundle Only) 6 Five Year Total , FO s detection steady over the five year period (29 SG) (33 SG) 2014 (32 SG) Year (34 SG) (8 SG)

7 Foreign Objects Detected In-bundle columns inspected Foreign Object Detection Over Five Years (29 SG) (33 SG) FO Located (32 SG) 2015 (34 SG) In-B Inspections Year (8 SG)

8 Foreign Objects Detected Foreign Object Detection Over Five Years (by Tube Bundle) Inlet Outlet Year

9 Foreign Objects Detected Foreign Object Detection Over Five Years (by Tube Bundle Totals) ,036 Inlet Outlet

10 Foreign Objects Detected Foreign Object Detection Over Ten Years 10 1,200 1, , (29 SG) 2008 (38 SG) 2009 (33 SG) 2010 (39 SG) 2011 (48 SG) 2012 (29 SG) 2013 (33 SG) 2014 (32 SG) 2015 (34 SG) (8 SG) Year

11 Average Number of Foreign Objects Detected per Steam Generator Foreign Object Detection Over Ten Years (29 SG) 2008 (38 SG) 2009 (33 SG) 2010 (39 SG) 2011 (48 SG) 2012 (29 SG) 2013 (33 SG) 2014 (32 SG) 2015 (34 SG) 2016 (8 SG) Year

12 Foreign Objects Detected Foreign Object Types Over Five Years Weld Slag Scale Misc Metal Objects Machining Remnant Sludge Rock Gasket Wire On average Wire makes up 35.6% of foreign objects found on a yearly basis. Wire foreign objects are trending upward. Majority of the wire located was Moisture Separator Reheater wire. On average Gasket makes up 18.0% of foreign objects found on a yearly basis. Gasket foreign objects are trending downward FME barrier failure, intrusion of auxiliary feed water header modification machining remnants.

13 Total Number of Foreign Object Types Over Five Years

14 Agenda 14 Foreign Object Detection Update Operating Experience Best Practices Summary

15 Palo Verde Work Scope and Objectives 15 Flow Distribution Plate FOSAR Remote preheater foreign object search and retrieval Inspect the tube bundle at the Flow Distribution Plate (FDP) elevation Annulus Divider plate region In-bundle region up to 5 tube pitches in depth Inspection system Shell Wrapper Annulus Transport System Low Profile (SWATS LP) Designed for FDP services

16 Flow Distribution Plate FOSAR Shell Wrapper Annulus Transport System Low Profile (SWATS LP) Capabilities Remote robotic steam generator annulus inspections in the FDP region Two color camera s, navigation and Inspection Panning camera 60, 90 and inch (38.1mm) chassis height, 1.71 inch (43.4mm) annulus gap Benefits Reduced radiation exposure ~80% dose reduction Increases data quality Reduces schedule time Annulus Divider Plate In-bundle 16

17 Flow Distribution Plate FOSAR Images 17 Video Probe SWATS LP In-bundle Region

18 Flow Distribution Plate FOSAR Images In-bundle Region 18 Divider Plate Region FDP Key obstruction for video probe, not SWATS Shroud Lip obstacle for SWATS LP, custom wheels fabricated to adjust to lip Annulus Region Annulus Region

19 Palo Verde Work Scope and Objectives 19 Jacking Screw Inspection Water box jacking screw inspection Inspect for anomalous conditions Planned access through water box hand hole Adapted access through water box flow holes from the top of tubesheet annulus region Inspection system Planned using SWATS PT Adapted to: SWATS PT as a delivery platform Guidetube attached to deliver a video probe Video probe used to inspect screws

20 Jacking Screw Inspection 20 Shell Wrapper Annulus Transport System Pan & Tilt (SWATS PT) Capabilities Remote robotic steam generator annulus inspection system Pan, tilt and boom camera Delivery platform for guidetube and video probe Benefits Reduced radiation exposure ~50% dose reduction Increases data quality Reduces schedule time Access Point

21 Jacking Screw Inspection Images 21

22 Experiences and Lessons Learned 22 Flow Distribution Plate FOSAR Consistent views into the tube bundle up to 5 tube pitches deep Viewing into the 60, 90 and 120 angles for complete coverage Significantly reduced inspection time and radiation exposure Increased quality of inspection as compared to video probes Jacking Screw Inspection Full remote inspections can only access limited number of jacking screws via the water box hand hole Combination of remote delivery platform and manual video probe deployment Next set of inspections will use modified SWATS vehicle for simplicity of operation

23 Agenda 23 Foreign Object Detection Update Operating Experience up to Spring 2016 Best Practices Summary

24 Palo Verde FDP and Jacking Screw Inspections 24 Remote robotic inspection systems Safety Reduced personnel radiation exposure Increase foreign object detection coverage, reduced risk of missed foreign objects Quality Increased inspection coverage FDP superior image verses video probes Production Provided consistent, repeatable inspection schedule

25 Agenda 25 Foreign Object Detection Update Operating Experience up to Spring 2016 Best Practices Summary

26 Summary 26 Foreign objects continue to present a challenge Foreign object detection is proportional to the amount of inspections Multiple angled inspections provide complete coverage of high flow region Recommendation to reduce personnel exposure, increase quality, reduce schedule and errors Remote robotic inspection systems

27 Thank You 27