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Using SmartPlant Technology to Support
Engineering and Radiation Survey for Nuclear
Decommissioning
A Case Study of the Beloyarskaya Nuclear Power Plant in Russia
Dmitry Dorobin
Alexander Semenov
NEOLANT distributed engineering process
Requirements
General
layout
P&ID and
other
schematic
(2D)
Collision detection (3D)
Civil and
structural
Equipment
design Process
design
DrawingsInformation model
Moscow
Krasnoyarsk
Kaliningrad Stavropol
2
Leningradskaya NPP Smolenskaya NPPKurskaya NPP
NEOLANT: Completed projects
3
Реализованные проекты
Beloyarskaya NPP Bilibinskaya NPP Novovoronegskaya
NPP
NEOLANT: Completed projects
4
Реализованные проекты
Kolskaya NPP Nuclear fuel
recreation
Nuclear fuel
creation
NEOLANT: Completed projects
5
INFORMATION MANAGEMENT SYSTEM
(IMS) FOR NPP DECOMMISSION
NPP typical life cycle in Russia
1966
Project start
1973
NPP work
start
2003
End of projected
life cycle
2018
End of prolonged life
cycle
2010
2023
Turning NPP to the
nuclear safe state.
Getting the license for
decommissioning.
Projecting and
building Projected life
cycle
Prolonged life
cycle
yearsyears
years
Decommission process (>50 years)
7
Russian nuclear plants
Status map for 2020:
legend:
In original operation license
Prolonged operation license
Plant shut down
KolNPP
LNPP
SNPP KaNPP
KNPP
NNPP
BiNPP
“MAYAK”
Siberian Chemical PlantBelNPP
Mining-chemical plant
BalNPP
RNPP
8
Original drawing example
9
3D-model
P&ID drawing
NPP component
Attributes
Design drawings
Physical component information model (IMS)
10
Integration process
InterBridge adapter
IMS – SPF based
SmartPlant Adapter
Autodesk
Civil 3DAutodesk
Civil
Autodesk Inventor/
Bentley MicrostationSP3D
Sm
art
Pla
ntA
dapte
r
SPPID, SPEL
11
IMS FOR SMOLENSKAYA NPP (SNPP)
DECOMMISSIONING
As-build process diagrams in SPPID
13
General layout in Autodesk Civil
14
Process physical design in SP3D
15
Civil and structural design in Autodesk Revit
16
Reactor detailed model in Autodesk Inventor
17
Combined SNPP decommissioning IMS
18
Physical breakdown structure
19
• NPP site
• NPP
• Building
• Structural unit
• Level
• structural components
(columns, slabs, walls, etc)
• Room
• process components
(equipment, pipes, etc)
Civil and structural part of information model
20
Plant physical location structure modeled in SPF
down to floor, level and room plans
21
PBS and physical breakdown structure meet at
component level
22
Component 3D and 2D representation
(schematics drawings) are interrelated
23
Visualization of queries and reports in 2D/3D
24
IMS USAGE IN OPERATION PHASE,
MAINTENANCE AND REPAIR, ETC
IMS functions and architecture for operations
IMS functions
Data exchange with
prime design contractor
using 3D
Data exchange with
existing systems
NPP
Change
management
EAM CMMS SCADA
Operational
tasks
HR management
Safety/security
Materials
Fire safety
Radiating safety
Trainings
Equipment models
Radioactive waste
volume
Engineering and
Radiation Survey
NPP
configuration
data
structuralization
Archive
As-build 3D
model
NPP
components
characteristic
26
Data exchange with prime design contractor using 3D
Changed 3D model and data
Modification or repair issue
NPP
Prime design contractor
Design IMS
Operation IMS
27
Operational and maintenance (for example weld
inspection management)
It's easy to access all engineering information and inspection's data through 3D model.
There are very important sources of information that require constant monitoring for NPP safety operation: weld conditions for tanks, radioactive drain headers, pipelines and other high-pressure equipment.
IMS based on 3D engineering model is a very powerful tool for collecting, storing and providing an intuitive access to all operational data.
On this slide you can see the result of automatic indication NPP welds based on operational data:
• green - an inspection was done, normal condition
• orange – missing inspection more than 3 days
• red – missing inspection more than 10 days.
28
Operational and maintenance (for example weld
inspection management)
29
There are very important sources of information that require constant monitoring for NPP safety operation: weld conditions for tanks, radioactive drain headers, pipelines and other high-pressure equipment.
IMS based on 3D engineering model is a very powerful tool for collecting, storing and providing an intuitive access to all operational data.
On this slide you can see the result of automatic indication NPP welds based on operational data:
• green - an inspection was done, normal condition
• orange – missing inspection more than 3 days
• red – missing inspection more than 10 days.
It's easy to access all engineering information and inspection's data through 3D model.
Operational and maintenance (for example
equipment inspection management)
30
On this 3D model you can see turbine island part
There is color marked information about equipment state, that was receive from inspections
Radiation safety (fixed and mobile radiation
management)
31
Radiation safety (fixed measurement points,
real-time measurement and visualization)
32
Radiation safety (mobile inspection and
measurement)
33
Fire evacuation routes modelling:
The room, where we have troubles, marked red (information was automatically receive from instruments)
Nearest rooms, where personnel works are marked blue.
Evacuation route that personal should use is marked green.
We can quickly get information about every room: fire resistance characteristics, fire-fighting equipment, etc.
This visualization helps to get allinformation for decision to eliminate fire and personal evacuation.
Fire safety
34
Personnel training and simulators
35
AS-BUILD RADIATION INFORMATION MODEL
FOR DECOMMISSION AND WORK PLANNING
Creation of as-build and radiation
information model
1. As-build engineering 3D model with the
superimposed radiation situation
2. Actual physical structure of an object
3. Weight and dimensional characteristics, component
materials, other characteristics
4. 360-degree panoramic photo, other data of
comprehensive engineering and radiation survey
5. Electronic documentation archive
6. Intelligent process diagrams
Basic data:
As-build verification (laser
scanning)
Collecting topological
information with a
millimeter accuracy
Recreating as designed engineering
model from existing design and
operational documentation
Gamma scanning
Determining equipment “hot spots”
Radiation monitoring
Plant radiation condition
information
360-degree
panoramic photo
Visualization of real
condition of a plant
38
As-build radiation information model life cycle
Plant shut down
The beginning of
decommissioning
Comprehensive engineering
and radiation survey
As-build radiation
information model
Creation
Decommission activities (dismantle, radioactive waste utilization, etc.)
Information is available to all
participants of decommissioning
The model is applied for planning and
simulation of decommission work
Updating
39
AS DESIGNED ENGINEERING MODEL
CREATION
Main original documentation types
41
As designed model and electronic archive creation
The raster files
Electronic archive
As design 3D model
42
LASER SCANNING
The applied technologies:
Laser scanning
The main characteristics
Accuracy: from 1 мм
Range: to 2500 м
Scanning time: 2-3 min
Quantity of points: to several million
Laser scanning is a technology providing a people-independent way of obtaining actual reliable topological
information about a condition of an object within shares of millimeter.
It is active applied since the end of the 90th years in such branches as oil and gas industry and metallurgy
when collecting initial information to carrying out modernization and reconstruction of productions.
It was initially developed in France in the late eighties for recovery of documentation to nuclear objects.
44
Laser scanning.
As-build model creation technology
Initial object
Cloud of points
As-build 3D modelScan
Cloud of points creation
Binding to uniform
system of coordinates
Cleaning of low-quality
measurements
3D model
actualization
45
Laser scanning.
Topological information quality comparison
Leningradskaya NPP turbine island part 3D model
(on the basis of design documentation)
46
Leningradskaya NPP turbine island part 3D model
(on the basis of laser scanning)
Laser scanning.
Topological information quality comparison
47
In most cases existing plant documentation significantly differs from the actual configuration which causes considerable
disparities of design and actual volumes of the radioactive waste complicating decommissioning
Laser scanning.
Topological information quality comparison
48
AS-BUILD RADIATION
IMS AND DECONSTRUCTION WORK PLAN
OF THE BELOYARSKAYA NPP (BNPP)
As-build radiation IMS and turbine island deconstruction
work plan of Beloyarskaya NPP
The project characteristics
Plant:Turbine island of units
1,2 of Beloyarsk NPP
Customer:
Joint Stock Company
«Research &
Demonstration Center
Decommission Nuclear
Reactors»
Work time: 2013
Duration of scanning: 1 week
Duration of creation of
IMS of a turbine island
(including work plan):
3 month
Cost: ~2 million $50
Beloyarskaya NPP turbine island
51
Beloyarskaya NPP laser scanning
52
Beloyarskaya NPP turbine island as-build IMS
53
Beloyarskaya NPP turbine island as-build IMS
54
Beloyarskaya NPP turbine island as-build IMS
55
Beloyarskaya NPP turbine island real condition
(360 degree panoramic photo with hyperlink)
56
The gamma survey of Beloyarskaya NPP turbine island
57
Results of measurements of a radiation background in rooms of the turbine island on elevation level +3.800, +4.050, +5.500
Integration of comprehensive engineering and radiation survey data into 3D engineering model. Points of radiation control
58
Integration of comprehensive engineering and radiation survey data into IMS. Points of radiation control
59
Integration of comprehensive engineering and radiation survey data into IMS. Points of radiation control
60
Comprehensive engineering and radiation survey data
integration into IMS. Equipment “hot spots”
61
Based on all this data about equipment, piping,
structure and others the following calculation can be
done:
• radioactive waste volume according to
categories: high-level, middle-level and low-
level radioactive waste.
• radioactive decontaminant volume and liquid
radioactive waste volume.
• radioactive waste volume specifications.
Decommission scheduling and simulation using as-build
radiation IMS
Initial state - Before dismantle Final state – After equipment removal
Work plan to dismantle of the main equipment, pipelines and piping components of a turbine unit No. 1 of Beloyarsk NPP
62
THANK YOU
FOR YOUR ATTENTION!
Dmitry Dorobin:
Alexander Semenov:
neolant.com
twitter.com/NeolantGroupEN
facebook.com/NeolantGroupEN
lindkenIn.com/NeolantGroupEN
