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Managing I&C Obsolescence for Plant Life ExtensionIAEA-CN-155/075

Larry ChiConsulting EngineerBin ZhangSenior Engineer

GE-Hitachi Nuclear EnergyOctober 2007

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�Background�I&C Obsolescence Issues�Challenges� GEH Approach�Six Sigma �Potential Upgrades�Long Term Strategy�Summary

Managing I&C Obsolescence for Plant Life Extension

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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 20TM

Background

Plant Life Extension changes the landscape for I&C upgradePlant Life Extension changes the landscape for I&C upgrade

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Instrumentation & Controls Products & Services GEH Scope of Supply: Over 40 years of design, manufacturing and service

of I&C for GE BWR

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Power PlantsCommercial

Operation DateLicense Expiration

Date Life ChartNine Mile Point 1 (213) - I 26-Dec-76 22-Aug-09Oyster Creek (213) - I 1-Dec-69 4-Apr-09Tsuruga (171) - I Mar-70 14-Mar-10Dresden 2 (251) - I 20-Feb-91 22-Dec-09Dresden 3 (251) - I 12-Jan-71 12-Jan-11Fukushima 1 (188) - I Mar-71 26-Mar-11Monticello (205) - I 9-Jan-81 8-Sep-10Santa Maria De Garona (Nuclenor) (188) - I 2-Mar-71 11-May-11Pilgrim (224) - I 9-Dec-72 8-Jun-12Quad Cities 2 (251) - I 10-Mar-73 13-Dec-12Browns Ferry 1 (251) - I 20-Dec-73 20-Dec-13Browns Ferry 2 (251) - I 2-Aug-74 28-Jun-14Browns Ferry 3 (251) - I 18-Aug-76 2-Jul-16Brunswick 1 (218) - I 12-Nov-76 8-Sep-16Brunswick 2 (218) - I 27-Dec-74 27-Dec-14Chinshan 1 (201) - I 15-Dec-78 14-Dec-18Chinshan 2 (201) - I 15-Jul-79 14-Jul-19Cooper (218) - I 18-Jan-74 18-Jan-14Duane Arnold (183) - I 20-Feb-75 21-Feb-14Fermi 2 (251) - I 15-Jul-85 20-Mar-25FitzPatrick (218) - I 10-Oct-74 17-Oct-14Fukushima 2 (218) - I Jul-74 18-Jul-14Hatch 1 (218) - I 13-Oct-74 6-Aug-34Hatch 2 (218) - I 13-Jun-78 13-Jun-18Hope Creek 1 (251) - I 25-Jul-86 11-Apr-26Muehleberg (KKM) (158) - I 15-Nov-72 14-Nov-12Limerick 1 (251) - II 8-Aug-85 26-Oct-24Limerick 2 (251) - II 25-Aug-89 22-Jun-29Peach Bottom 2 (251) - I 25-Oct-73 8-Aug-13Peach Bottom 3 (251) - I 2-Jul-74 2-Jul-14Susquehanna 1 (251) - II 12-Nov-82 17-Jul-22Susquehanna 2 (251) - II 27-Jun-84 23-Mar-24Vermont Yankee (205) - I 28-Feb-73 21-Mar-12Columbia (251) - II 13-Apr-84 20-Dec-23Fukushima 6 (251) - II Oct-79 24-Oct-19Laguna Verde 1 (201) - II 29-Jul-90 14-Jul-30Laguna Verde 2 (201) - II 10-Apr-95 14-Apr-35LaSalle 1 (251) - II 17-Apr-82 17-Apr-22LaSalle 2 (251) - II 16-Dec-83 16-Dec-23Nine Mile Point 2 (251) - II 2-Jul-87 31-Oct-26Tokai 2 (251) - II Nov-78 27-Nov-18Clinton 1 (218) - III 24-Nov-87 29-Sep-26Cofrentes (218) - III 11-Mar-85 10-Mar-25Grand Gulf 1 (251) - III 1-Oct-84 16-Jun-22Leibstadt (KKL) (238) - III 15-Dec-84 15-Dec-24Kuosheng 1 (218) - III 15-Dec-81 14-Dec-18Kuosheng 2 (218) - III 15-Mar-83 15-Mar-23Perry 1 (238) - III 13-Nov-86 18-Mar-26River Bend 1 (218) - III 20-Nov-85 29-Aug-25

1960 1970 1980 1990 2000 2010 2020 2030 2040 2050

FIG. 1. Current operating GE BWR NPPs and life status

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FIG. 2. Comparison of operated life vs .initial licensed life left

1 0 2 0 3 0 4 0

0

1

2

3

4

5

6

7

26.5 year

Years

Histogram of Years of Operation

3 02 01 00

7

6

5

4

3

2

1

0

11.8 year

Years

Histogram of Years of Licensed life left

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� 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

I&C Obsolescence Issues

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� 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

I&C Upgrade Challenges

Requires systematic approach to identify and prioritize I&C

upgrade for Plant Life Extension

Requires systematic approach to identify and prioritize I&C

upgrade for Plant Life Extension

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GEH Approach

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

Customer Satisfaction and Benefits�Minimal outage�Life extension�Power output uprate�Safer, more secured and reliable operation

Industrial and RegulatoryRequirements�Licensing process for safety related controls�Update of industrial standards�Plant process for implementing upgrades

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)

FIG. 3 Overview of GENE Approach in Dealing with I&C Obsolescence

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GEH Approach OverviewBenefit• 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

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

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Logic Architecture Code Design Resources•IP cores•Code libraries•Logic functional cells

Function Design

Design Results•Net list file•Pin configuration•Layout and routing•Define constraints

Result Verification• Simulations• Debugging • Testing • Final prototyping

Programming

FPGA

FIG. 4 Overview of design flow of FPGA devices

GEH Approach Example

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GEH Approach Example

FIG. 5 A programable device used to simplify and upgrade a design of BWR reactor rod control board

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�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

Six Sigma Methodology

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�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)

QFD Application to Plant Life Extension

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FIG. 6 Application of QFD tool for I&C upgrade

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• Wide Range Neutron Monitor (WRNM)– Replaces Source Range Monitor and Intermediate Range Monitor

Examples of Potential Upgrades (1)

Existing System Advanced System (WRNM)

Control RoomMonitor

Penetration

Control Room

Preamplifier

Reactor Pressure VesselFixed Incore Regenerative Sensor

CoreDryTube

Connector

Cable

ReactorBuildingDrywell

IRM

Penetration

Reactor Pressure VesselRetractable SensorCoreDry TubePositionSwitches

Flexible Cable

SRMElectronics

Motor

DriveControlFlexible

Shaft

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• Power Range Neutron Monitor (PRNM)– Replaces Average Power Range Monitor

Examples of Potential Upgrades (2)

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• Rod Control and Management System (RCMS)– Replaces Rod Position and Information System and Reactor Manual

Control System

Examples of Potential Upgrades (3)

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Examples of Potential Upgrades

See IAEA-CN-155-048PSee IAEA-CN-155-048P

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�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

Long Term Strategy

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Summary

Plan I&C upgrade to Improved Plant Reliability, Operation and Supports Plant

Life Extension

Plan I&C upgrade to Improved Plant Reliability, Operation and Supports Plant

Life Extension

�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

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GE’s Advanced BWR Control Room