7/27/2019 000000000001010270 http://slidepdf.com/reader/full/000000000001010270 1/120 Fifth EPRI International Conference on Maintenance Proceedings Hyatt Regency Jersey City on the Hudson Jersey City, NJ August 8–10, 2005 Maintaining the Balance Between Maintenance Costs and Plant Reliability Sponsored by EPRI’s Maintenance Management and Technology (MM&T) and Technology for Equipment Assessment and Maintenance (TEAM) Programs Hosted by: Effective December 6, 2006, this report has been made publicly available in accordan with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S. E Administration Regulations. As a result of this publication, this report is subject to on copyright protection and does not require any license agreement from EPRI. This no supersedes the export control restrictions and any proprietary licensed material notice embedded in the document prior to publication.
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Fifth EPRI International Conference on Maintenance Proceedings: Maintaining the Balance Between Maintenance Costs and Plant Reliability. EPRI, Palo Alto, CA: 2005. 1010270.
Final AgendaEPRI International Conference on Maintenance
Hyatt Regency Jersey City on the Hudson, Jersey City , NJ, USA August 8-10, 2005
Sunday, August 7, 2005
4: 00 pm-6:00 pm Pre-Registration
Monday, August 8, 2005
7:00 am Continental Breakfast and Registration
8:00 am Welcome, Ray Chambers, Technical Manager, Maintenance Management & Technology, Electric Power Research Institute (EPRI)
8:30 am Keynote, Carl Fricker , Plant Manager, PSE&G Nuclear, LLC, Salem Generating Station
Plenary SessionDecision on Maintenance as a Cost Center or a Profit Center
Session Chairperson – Ray Chambers, EPRI
9:00 am Establishing a Fleet Approach for Equipment Reliability, James Stanley, David Sonnett, ConstellationGeneration Group
9:30 am The Business Case for Reliability, John Schulz, Allied Services Group, Inc.
10:00 am Break
10:30 am Surprises are not Acceptable, Peter Hessler, Construction Business Associates LLC
11:15 am Reliability Centered Leadership, Terrence O’Hanlon, Reliabilityweb.com
12:00 pm Lunch
Improvements in Fossil Maintenance TechnologiesSession Chair – George Van Der Horn, Innovative
Maintenance Solutions, Inc.
Improvements in Nuclear MaintenanceTechnologies
Session Chair – Joe Curley, The Accuro Group, Inc.
1:15 pm Advanced Erosion Protection Technology ProvidesSustained Burner Performance and Reliability,Chris Harley, Conforma Clad; Douglas Goebel,Michael Sarri, We Energies; Corby Valentine,Dynegy; Bonnie Courtemanche, Riley Power Inc.
Experience with Mid-Wall Weld Repairs forPressurizer Heater Sleeves, Pedro Amador, JimPuzan, Welding Services Inc.; Michael Lashley,Dick Mattson, Structural Integrity Associates
1:45 pm Yates Meter, Michael Mancini, HydroAire ServiceIncorporated
Advanced Pipe Replacement Procedure for aDefective CRDM Housing Nozzle Enables Continued
Normal Operation of a Nuclear Power Plant, Jerker Stötsberg , UDDCOMB Engineering Helsingborg AB(Sweden); Geoff Gilmore, Ph.D., Climax PortableMachine Tools, Inc.
2:30 pm Break
3:00 pm Case Studies of Quantitative Acoustic EmissionNon-Destructive Inspection Method in PowerIndustry, B. Muravin, G. Muravin, L. Lezvinsky,Margan Physical Diagnostics Ltd. (Israel);Presented by Dan Ezra, Margan, Inc.
Browns Ferry Unit 1 Restart Cobalt Reduction PlanUpdate, John Underwood, Tennessee Valley
Authority (Browns Ferry)
3:30 pm SiEMPre: A Step Forward in PredictiveMaintenance, Daniel Bri ff , Central Termoeléctrica
Genelba
Update on Preemptive Weld Overlay (PWOL)Activities, Pete Riccardella, Robert Hermann,
Structural Integrity Associates; Greg Frederick, ArtiePeterson, Jr ., Electric Power Research Institute(EPRI); Presented by Jim Puzan, Welding ServicesInc
4:00 pm Using Real Time Temperature, Stress and FlowReadings to Determine Equipment Damage,Maintenance Costs and Operational Strategy inPower Plants, Steven Lefton, Phillip Besuner,Dwight Agan, Jeffrey Grover , APTECHEngineering Services, Inc.
Past Operability Assessment of TDAGWP due to Turbine Bearing Oil Orifice Feed Plug by Debris,Mammar Maghraoui, Tahsin Dogan, Michael Kelly,Joseph Spencer , Framatome ANP, Inc.; Roger Wink, Wade Claspil l, AmerenUE (Callaway Plant)
Final AgendaEPRI International Conference on Maintenance
Hyatt Regency Jersey City on the Hudson, Jersey City , NJ, USA August 8-10, 2005
Tuesday, August 9, 2005
7:00 am Continental Breakfast
Current Issues in Fossil Processes and Financial MethodsSession Chair – George Van Der Horn, Innovative
Maintenance Solutions, Inc.
Cost and Reliability Techniques for Nuclear Power Session Chair – Joe Curley, The Accuro Group, Inc.
8:00 am Fossil P lant Maintenance – An OperationsPerspective, Wayne Crawford, Electric Power Research Institute (EPRI)
Equipment Reliability Process – A Case Study of aNorth American Nuclear Generating Station, SandraDiMatteo, Ivara Corporation
8:30 am Transformation to Knowledge Based Maintenance:Challenges of Change Management in a LargePower Utility, Mr. S.C. Deo Sharma, PankajBhartiya, Anil Mittal, National Thermal Power Corporation Ltd. (India); Patrick Abbott,EPRIsolutions.
Laser Scanning Offers Significant Benefits for thePower Market, Eric Hale, Quantapoint, Inc.
9:00 am Automating the PM Template and MaintenanceStrategy Development Process at ConEdison, MattWalther , Consolidated Edison Co. of New York,Inc.; Evan Niemkiewicz, Insert Key Solutions
Writing and Implementing Packing Procedures –Lessons Learned, Ron Frisard, AW Chesterton
9:30 am Gray Water Cooling in Surface Condensers and HeatExchangers – Trend or Aberration, DennisSchumerth, VALTIMET, Inc.
10:00 am Break
Current Issues in Fossil Processes and Financial MethodsSession Chair – George Van Der Horn, Innovative
Maintenance Solutions, Inc.
Cost and Reliability Techniques for Nuclear Power Session Chair – Joe Curley, The Accuro Group, Inc.
10:30 am New Business Model for Leveraging TechnologicalAdvancements to Achieve the Market DeterminedPrice for Power Ageing Power Plants, D.S. Sharma,
C. Subramaniam, National Thermal Power Corporation Ltd. (India)
PM Database Web Version, Marty Br idges, ElectricPower Research Institute (EPRI)
11:00 am Condition Based Maintenance PlantViewKnowledge Management, Paul Gwizdala, DTEEnergy; George Lum, Southern Company
Where has all the “Tribal Knowledge” Gone?, MarkGoodman, UE Systems, Inc.
11:30am Value Engineering: Strategy for IncreasingPerformance and Reducing Costs in Utilities, A.K.Tripathi, National Thermal Power Corporation Ltd(India)
Issue Gathering on Recent CMMS Installations,Marty Br idges, Electric Power Research Institute(EPRI)
1:30 pm Using Risk Informed Maintenance Strategies for High Voltage Networks, Paul Hendrix, MaintControl
International (The Netherlands); Edward Abbott, ABZ, Inc.
2:00 pm Low-Cost SF6Gas Monitor, George Rhodes, Tristan Fin, Avistar, Inc.
2:30 pm On-Line and Off-Line Testing as Part of a Predictive Maintenance Program, Timothy Thomas, Baker Instrument Company
3:00 pm Break
3:30 pm Increased Productivity, Reliability and Accuracy at Lower Cost: Applying the Proven Benefits of ElectronicPerformance Support Technology to Power Plant Maintenance, Roger LaPlante, Anna Liisa VanMantgem, REI Systems, Inc.
ESTABLISHING A FLEET APPROACH FOR EQUIPMENT RELIABILITY
James J. Stanley, Manager, Corporate Engineering
David E. Sonnett, Technical Consultant
Constellation Generation Group
ABSTRACT
INPO AP-913, “Equipment Reliability Process Description”, states one objective of an
equipment reliability program is to establish uniform processes among all plants in anorganization. In the last few years, Constellation Generation Group has acquired
substantial generating stations, increasing generation capacity to 12,000 MW, with 107
generating units at 35 locations. This includes 5 very different and diverse nuclear plants.With this increase, sufficient nucleus was available to justify establishing a dedicated
corporate engineering group, with one of the primary goals being to satisfy the AP-913
objective for process uniformity. This paper will present the Constellation Generation
Group’s Corporate Engineering organization, including core value, focus, role, structure,
approach, and accomplishments.
The core value of CGG Corporate Engineering is to improve fleet performance,capturing synergies and leveraging scale.
Our initial primary focus is equipment reliability for CGG’s nuclear fleet, with voluntaryfossil fleet participation in elements that are common to all generating units.
Our initial role is to provide governance with oversight in standardization of programs, policies and implementing best practices across the fleet.
The Corporate Engineering core organization is composed of seasoned experts with CGG
and other utility fleet experience in developing and managing major elements of
equipment reliability programs. Matrixed to this core organization are Equipment
Reliability Program owners at each site, Technical Subject Matter Experts from our plants and other organizations, and Strategic Alliance Industry Partners.
Our approach is to benchmark industry best practices, identify gaps and shortfalls,
prioritize areas identified for improvement, and engage our sites for input and support todevelop and implement the improvements. Our goal is to achieve results, as opposed to
process adherence. Areas where we are making substantial progress include component
classification, PM templates, single point vulnerability, troubleshooting, performancemonitoring, health reporting, prioritization, performance indicators, and equipment
reliability software support.
Engagement and communications between Corporate Engineering and our fleet have been enhanced by daily O&M Fleet Conferences, periodic Peer Group and Management
Review Meetings, and Challenge Board and Assessment participation.
This paper will present the accomplishments of the CGG Corporate Engineering
organization to date, some difficulties experienced, and some expected future direction.
“It’s OK to get Excited about Maintenance” is the introduction we use for every presentationwe give related to maintenance, reliability, and asset management. The reason for this is the
overwhelming business case associated with doing maintenance and reliability right. Asset
Management initiatives have been documented to have Returns on Investment (ROI) ranging
from 4:1 to 50:1. In fact, many organizations have found that a Total Equipment Asset
Management (TEAM) initiative has proven to be the best investment that they have ever made intheir facility. In this paper we will discuss and explore the “Business Case for Reliability” from
several different angles:
1. What is ROI?
2. What are the elements of a successful TEAM initiative?3. What are the typical costs associated with each element?
4. Where are these costs offset with savings?
5. What areas can expect to see the most significant savings?
6. What types of saving are likely in each area?
7. What is the “typical” Rate of Return (ROR)
8. What elements control ROR?
9. Where do you start?
Readers will gain a fundamental understanding of why a Reliability initiative makes financial
sense for their business, what elements are essential for their success, what they can control, and
how to start. If a plant already has a reliability initiative in place, but the results are not meeting
expectations, calculating the business case may provide insight into why results are not beingachieved.
To be successful, power plant outages require excellence inproject management and project controls
ABSTRACTOutages are tough to master. It is inevitable that they will not follow a scripted plan and there willlikely be many changes. There will be changes to personnel, scope, material schedules andbudgets. Quality and safety issues will create diversions that were never envisioned. However,none of this is new; these challenges have always been there. What is new is the demand tomanage these changes on behalf of the stakeholders - they do not want surprises!
So often, once the site work starts, it seems to take on a life of its own. Suddenly, themeticulously planned schedule bears little resemblance to what is actually happening on the job.Budgets are revised and scopes are readjusted, and the immovable start-up date looms closerand closer. Chaos sets in. But it doesn’t have to be this way.
Today, outages must be diligently managed and they must be proactively controlled - there’s a lotof money at stake. J ohn T. Long, Constellation Energy’s senior vice president for powergeneration, puts it this way: “The ability to accurately track project financial commitments as wellas physical completion is critical in today’s world. Surprises are not acceptable. In this competitiveenvironment, we must plan for them and be prepared for anything. The successful powergenerators are those that can consistently meet and beat their forecasted earnings. Excellence inproject management and project controls is vital to achieving those goals.”
A set of good management tools, and the ability to use them, is the key. They can be used tointervene when costs head in the wrong direction and they can be used to manage the outage.
This paper discusses those tools and how their use can help avoid the surprises that are nolonger acceptable.
Author Bio
Peter Hessler is the president of Construction Business Associates LLC, a provider of businessmanagement services to the power plant construction industry. He has almost 30 years of experience in managing the field construction of power plant outages and new plant work. Mr.Hessler is a graduate of Virginia Tech and an author of numerous papers on the subject of construction management. He has written a book on the economics of power plant construction,to be published by PennWell Corp. in the summer of 2005. Peter can be contacted [email protected].
Vattenfall AB, ServicesS-444 87 Stenungsund, Sweden
ABSTRACT
Maintenance is a prerequisite for high enough utilization of physical assets for energy production,transmission, and distribution, low enough spending over time, and long enough life lengths (and tosome extent even high enough residual values) of our energy systems. Maintenance is performed inorder to uphold the properties and functions of a physical asset and to assure availability and capacityto perform at its specifications – simply to be able to use the physical assets as intended.
Technical lifetimes of energy systems (or parts of them) are long. In some cases hundreds of years.
Values are great. The effects from, for example, decisions to shift in maintenance investment levelsnormally show up several years ahead and our kind of businesses offers a unique trade-off opportunity between short and long-term profits.
Many of us seek the optimum levels of maintenance spending. The deregulation and privatization erahas created a strong pressure to improve RONA and other short-term accounting based measures, and
in many energy companies, maintenance has been the instrument to reach desired targets, since marketstend to be stiff.
In this paper, some important elements for design and steering of maintenance of physical assets will be discussed based on experiences from an ongoing attempt to increase the efficiency of maintenance processes within the Vattenfall group. The experiences cover four countries and many more performance cultures. Basic business fundamentals will be exemplified and their inherent coupling and
effect on customer-supplier relationships as well as end-customers discussed around three themes:
The correct economic footprint of maintenanceToday, the maintenance strategical, tactical, and operative processes are spilt up in and in between
organisations. The focus on maintenance spending often only incorporate the operative part (the currentcosts), but the prerequisites for operative work are a result of the performance of the two former processes. What is included as maintenance costs also differ since organisations rather arbitrarilychoose what could be capitalized, and what to regard as maintenance activities. In addition to this fuzzy
picture of the resource consumption the capitalized part is normally not considered maintenance but“reinvestments”, “renewals”, and similar.
What are the maintenance design parameters?The end-customer focus and influence is still not fully developed in many energy companies. The
former business conditions have created a culture where what is acceptable not is determined by business offers, but from the general consensus among energy companies. Upon that, the uncertaintyaround what will be important seen from regulators and other stakeholders views, a “wait and see”
attitude develop instead of business based actions trying to develop the necessary work and processesneeded.
The need for better long-term steeringIn order to optimize profit levels over time today’s short-term financial targets, expressed as return
on net assets (or similar ones), should be balanced off with a more “long-term measure and target”reaching beyond business plan horizons.. A good achievement in maintenance should be to maximizethe value of the expected total discounted cash-flows and hence keeping the value of the assets at
reasonable levels. In the paper, some alternative approaches are discussed and compared.
ABSTRACTPresenter: Terrence O'Hanlon, Certified Maintenance and Reliability Professional Publisher of RELIABILITY®Magazine and Reliabilityweb.comDirector of Strategic Alliances for the Society of Maintenance & Reliability Professionals (SMRP)
For the past 27 years, maintenance & reliability management strategies, techniques andtechnologies have become very well defined and are more process based than ever. There areno secrets as to the elements that are included in Tier 1 or World Class Maintenance. Somecompanies use pyramids to represent Maintenance Excellence, others use an arch and othersuse block diagrams. If we already know what elements we need for effective maintenance whydon’t we all simply enjoy high levels of plant reliability?
In my work, I have the privilege to communicate with a large number of maintenance andreliability professionals from around the world. Many of them are involved with some type of maintenance improvement program. Some of these programs get implemented and have verypositive effects on company operations. More often I hear of others that seem to get stuck, fail togain acceptance and momentum and eventually fade away under the category of another“corporate program d’jour” or “flavor of the month”. Some companies make a few of the
improvements stick and are doing well but sense they could be doing things much better. Whydo some programs succeed and other fail?
A New KPI
This paper will explore a a new Key Performance Indicator (KPI) or Maintenance Metric, a definiteleading edge indicator to predict the health of almost any maintenance organization and thelikelihood that new improvement programs will take hold. It is called the Reliability LeadershipIndex or RLI.
Conforma Clad Inc.501 Park East Blvd.; New Albany, IN 47150
Douglas Goebel
Engineer, We Energies
333 West Everett Street; Milwaukee, WI 53203
Michael Sarri
Senior Mechanical Engineer
We Energies2701 Lake Shore Blvd.; North, Marquette, MI
Dave Weber
Sr. Metallurgist, Dynegy
1 Chessen Lane; Alton IL 62002
Bonnie Courtemanche, P.E.
Senior Engineer; Riley Power Inc.
5 Neponset St.; Worcester, MA 01615
Abstract
After a coal-fired electric power generator invests in NOx reduction technologies toachieve conformance, it is faced with maintaining the equipment to ensure that the NO x rates remain within specified tolerances. Pulverized coal traveling at high velocities
through coal burners and burner tips typically produces significant component erosion,
causing owners to repeatedly replace internal components, make operation adjustmentsand even replace entire burner assemblies. During the period between repairs, changes in
burner geometry caused by excessive erosion can impact combustion characteristics,
resulting in upward trending NOx emissions.
The most advanced Low NOx burner technologies utilize erosion-resistant materials to
protect against wear, in an attempt to increase burner geometry retention and maintaincombustion characteristics for sustained low NO
xperformance. This paper will discuss
an exhaustive laboratory analysis to evaluate erosion protection solutions for this extreme
application. Tests per ASTM G73 method, utilizing Black Beauty Coal Slag as the
erodent material, were performed on commonly used wear resistant materials: Stoody101, SA1750 CR, Conforma Clad WC219, Stellite 31, Stellite 6, A560 Grade 50Cr-50Ni,
A532-82 Type 2 class C, A532 type 1 class A and Silicon Carbide. In addition to the
qualification of the lab tests, this paper will discuss actual field test results comparingwear resistant materials on components subjected to the high-erosion environment of
burners and similar applications.
The combination of sophisticated burner designs and the utilization of the highesterosion-resistant materials ensure homogenous, non-turbulent coal mixing and
maintenance of controlled burn rates over extended periods of operation. Retaining thegeometries of the advanced burner technologies will not only test low at initial start-up,
but can be expected to remain low throughout the majority of burner life, between major outages. The net result of geometry retention through erosion resistance is prolonged
compliance with NOx emissions with a reduced risk of unplanned downtime, as well asan increase in overall unit productivity, predictability and reliability.
This paper introduces a method for recovering lost process data using auto-associative neural
networks. In auto-associative neural networks, the neural networks are trained to recall the inputdata. In this paper an error equation with missing inputs as design variables is constructed fromthe trained network. A genetic algorithm is then used to solve for the missing input data entries.
The proposed method is tested on prediction of missing data from a process monitoring system of a power generation plant. On prior tests conducted by Marwala and Mdlazi on a faultclassification in the presence of missing data, it was found that the method used in this paper wasable to estimate missing data entries to an average accuracy of 92.5%. It is therefore postulatedthat the method should yield similar results in the recovery of lost process data. This method willassist in the incident investigation in cases where some of the sensors have malfunctions and thedata has been lost.
The Yates meter is a testing device that was designed and perfected in the UnitedKingdom in 1983. The Yates meter has completed several rigorous design reviews byinternational accreditation agencies, such as ISO, BS, NEL & SIRA, to ensure that theservices we offer are of the highest caliber. To date, the Yates Meter has been utilizedin over 6,000 pump tests to various markets including fossil power, nuclear power,refinery, pipeline, steel, and water/wastewater.
The Yates Meter employs a thermodynamic testing technique that relies on measuringvery small increases in the pumped fluid temperature as it passes through the pump.
The Yates Meter process requires measurement of suction and discharge temperatureand pressure and motor power. No measurement of flow is required. The Yates Metercan be used to test nearly the full gamut of centrifugal pump configurations and sizes.
The Yates Meter has many advantages over conventional test methods that rely on theaccurate measurement of flow. These advantages include ease of preparation, limitedpipe-work constraints and highly accurate and repeatable results with little or nointerference in the day to day operation of the pumps. The accuracy of the Yates Meteris documented to be up to 10 times more accurate than any conventional test method.
The most common customer benefit derived from utilizing the Yates Meter is asignificant reduction in their energy cost. This is achieved by accurately measuringpump efficiency, calculating operating flow and horsepower, and comparing this data towhat would be the minimum energy usage if the pump were operating at its best
efficiency point (BEP) at the maximum efficiency for its specific speed design. Inaddition, continuous monitoring of customer installations having multiple pumping unitswill yield significant energy savings by identifying the optimum operating schedule of theindividual paralleling pumps.
The Yates Meter can also be used for performance based monitoring to effectivelyreduce O&M costs by trending pump inefficiency, thus allowing proper scheduling of pump refurbishment and avoiding catastrophic failure.
Some customers require accurate flow and head measurements when either validatingthat the pumping application is delivering minimum acceptable performance or when up-rating plant output.
The simplicity of the testing method and the elimination of flow measurementaccelerates the testing process over conventional methods. Speed saves significantdollars to customers when associated with downtime (forced or planned outages), orimproved safety considerations when dealing in hazardous environments (such as highlycontaminated nuclear applications – ALARA).
Finally, the Yates Meter is wholly owned by Hydro-Yates, Inc. The customer receivesnot only test data, but also the analysis and reporting befitting a total pump servicescompany having the experience, empirical data, and pump-specific engineeringexcellence to provide solutions for maximum benefit.
Aging of fossil power stations dictates increasing need in routine inspectionsof high energy piping and other systems of power plants. A number of non-destructive inspection (NDI) methods were developed for this purposeincluding different ultrasonic, magnetic particles, X-ray and replicationmethods. Although these methods are effectively applied for inspections, stillthere are multiple technological and economical limitations. Hence in manycountries of the world more and more utilities start to use Quantitative
Acoustic Emission (QAE) NDI method which allows global, overall inspectionof structures, detection of different flaws at early stages of their developmentand monitoring of revealed flaws.
In this article we present several case studies of QAE NDI method in powerindustry. This includes confirmation of QAE NDI findings (creep at differentstages, fatigue cracks, stress corrosion cracking, systems of inclusions andother flaws) by conventional NDI methods and metallurgical investigations. Iaddition we present the capability of revealing of non-uniform dynamic stressdistribution in the piping due to mal-performing hangers and supports.
SiEMPre: (In Spanish Always). Acronym for Expert System for Predictive Maintenance
This work presents a powerful tool called SiEMPre, software developed and implemented by Genelba
Combined Cycle Power plant maintenance staff, intended for management optimization of plant assets.
Actually it is considered that the most efficient way for maintenance asset management is achieved
through continuous monitoring and by intensive use of predictive maintenance techniques. Diagnosticsoftware SiEMPre is a tailor made tool that proposes a step forward in the evolution of these types of
Maintenance strategies.
The Idea that enforces SiEMPre development is to convert a big amount of available data into valuable
information to take decisions referred to equipment condition assessment, all this information collected in
a unique platform that takes data from different sources, as operating tracking data, Control systemcontrol database, Performance monitoring software stand alone equipment, and so on.
SiEMPre systematizes predictive and condition strategies, helping to find the most efficient time to
perform tasks, reducing unplanned or corrective maintenance, and producing an early warning when
abnormalities are being developed in a phase where corrective actions impact is minimized, added with a
valuable estimate defect root cause, all of this done through a continuous monitoring of field magnitudes,
A key aspect is to take advantage of maintenance staff experience and knowledge on finding defects, by
evolving it into mathematical models that are incorporated as modules into the program.The evolution is given by the determination of equipment status in real time, because the concept for this
tool is always –SiEMPre- in service, with a model developed accordingly to plant service characteristics
required for every equipment involved.
Utilization results in various benefits, as to say:
♦ Increase in plant availability.
♦ Reduction of maintenance costs.
♦ Decrease forced outages.
♦ Life extension of consumables/ reduction on warehouse costs.
♦ Detection of abnormalities not considered by Control System warnings and alarms,
♦ Development of new abilities in maintenance experts
♦ Centralized monitoring of plant assets♦ Knowledge distributed as a new active of the company
Analysis modules include gas turbine instrument monitoring (vibration, temperature, pressure), control
valves loops, pneumatic valves functioning, analytical parameters, electrical magnitudes and all
instruments used to measure combined cycle efficiency.
Using Real Time Temperature, Stress, and Flow Readings to Determine Equipment
Damage, Maintenance Costs and Operational Strategy in Power Plants
By Steven A. Lefton, Phillip M. Besuner, Dwight Agan and Jeffery L. Grover
This paper will discuss the concepts and some technical details of a real-time cost and damage computer program COSTCOM that is designed to calculate total power plants
maintenance costs. APTECH Engineering Services has developed and used COSTCOM
for COST Control of O perations and Maintenance. The program examines key readingsof temperatures, stresses, and flow rates for all major power plant subsystems and
components. Then it computes and accounts for the interaction of (a) cyclic damage from
transient operations and (b) creep damage from base loaded steady state operations. The program obtains data directly from the plant data acquisition system. It then displays in
real time some 13 to 15 key operational parameters including steam and metal
temperatures, turbine shell temperatures, flows etc. For these parameters, both values and
rates of change (ramp rates) are displayed. The Costcom display gives operators guidance
for all types of starts, shutdowns, and load following transients on all these keytemperatures, pressures, MW rates of change, flows and on resultant probable future
maintenance costs. A unique display of 13 to 15 “thermometers” use color bars toindicate normal, cautionary, and alarming values of reading values and ramp rates. These
key parameters have been correlated to boiler and turbine stress levels, damage, and then
calibrated to past maintenance costs. The COSTCOM code is in operation at a large800MW gas and oil peaking conventional steam unit and it is critical in deterring
improper operation, equipment damage and improving start up/shut down strategy based
on economic dispatch that includes Aptech’s estimates of cycling costs. The program has been used to demonstrate the effect of ramp rates on stresses and damage/costs as
discussed in the recent EPRI report on the “Effects of Flexible Operations on Turbinesand Generators.” Informing operators about probable future maintenance costs as a result
of real time operation is a key educational element to operate power plants at low cost.
Experience with Mid-Wall Weld Repairs for Pressurizer Heater
Sleeves
Pedro Amador, Welding Services Inc.
Jim Puzan, Welding Services Inc.
Michael Lashley, Structural Integrity Associates
Dick Mattson, Structural Integrity Associates
Abstract
After the completion of 99 half nozzle pad repairs in the refurbishment of three (3) CombustionEngineering-designed pressurizers in 2003-04, the team of Welding Services Inc. (WSI) and
Structural Integrity Associates (SI) continued their support of pressurizer heater sleeve repairs in
Spring 2005 using the new half nozzle mid-wall repair. The industry’s first repair occurred at
Arkansas Nuclear One (ANO) Unit 2 on an emergent basis in March 2005. At the time of thiswriting, WSI and SI are making final preparations to complete half nozzle repairs on 29 heater
sleeves at Waterford-3 using this same mid-wall weld repair approach. The schedule window
planned for the Waterford-3 repair project is approximately 20 days. A significant reduction indose over that associated with half nozzle pad repairs, which typically require a schedule of 30
days or more, is anticipated.
The completed ANO-2 repair and the planned Waterford-3 project are the culmination of a
development program completed by WSI, SI, Entergy and Arizona Public Service to support
mid-wall repairs of CE-plant heater sleeves. The program involved development of an array of tools and procedures to implement the repair. This included remote welding equipment and
procedures to complete the mid-wall weld without ‘triple-point’ root defects. In addition, the program addressed mechanical tooling that was provided to ensure alignment of the repair (required for heater reinstallation) as well as tools required for NDE (PT and UT) to document
weld quality in the field. The development program also included design and licensing activities
required to obtain NRC approval of the repair.
This presentation will review the mid-wall repair technology, including the toolset, the
procedures, the licensing process and the results of its first applications at ANO-2 and
Waterford-3. The presentation will also present lessons-learned, including tooling and procedure modifications to be implemented for planned pressurizer refurbishment applications
coming up in the near future. Lastly, the presentation will summarize other potential
applications for mid-wall repair technology including bottom mounted instrument penetrations(BMIPs).
AbstractWhile conducting a non-destructive examination (NDE) during a 2003 outage at the Ringhals Nuclear
Power Plant in Sweden, a leak was found in the vicinity of a Control Rod Drive Mechanism (CRDM)
housing nozzle at Unit 1. The leak in the nozzle was found approximately 20 mm from the welded
joint between the attaching SCRAM pipe and the nozzle. In order to obtain approval of the Swedish
Nuclear Power Inspectorate to re-start the reactor, the affected piece of pipe i.e. the nozzle and pipe
ends had to be replaced by a new section.
The SCRAM piping system consists of a large number of SCRAM pipes, each welded to a CRDM
housing nozzle. Due to the large number of CRDM housings and SCRAM pipes, accessibility was
very limited. Since an NDE of all CRDM nozzles was scheduled during the following outage, the risk of encountering leaks in other nozzles could not be ruled out. For this reason the new, unique repair
system developed for the pipe replacement, needed to be flexible and somewhat generic. It was critical
that the repair solution could be applied to the least accessible nozzle position to avoid a complex and
risky dismantling of the CRDM housing.
Based on the ALARA principle for radioactive contamination, a new, unique repair process was
developed. The repair system includes utilization of custom made, remotely controlled GTAW-robots,
a specialized CNC cutting and finishing machine, snake-arm robots as well as NDE equipment.
The success of the repair solution was based on performing the machining and welding operations
from the inside of the SCRAM pipe (ID 33.4 mm) through the CRDM housing (ID 160 mm) since
accessibility from the outside was extremely limited. Depending on the position of the nozzle to berepaired, manipulators, consisting of either snake-arm robots or mechanical gripping tools, were
utilized to provide cameras, cutters etc. from the outside. The robots were also used to deliver the
replacement pipe and to perform tack welding in order to keep the replacement pipe in place while
welding from the inside.
Before the actual pipe replacement procedure was performed, comprehensive training programs were
conducted. The training was followed by certification of the equipment, staff and procedures during a
number of qualification tests in a full scale mock-up of the housing nozzle. Due to the ingenuity of the
overall repair solution and to the comprehensive training programs, the actual pipe replacement
procedure was completed during the 2004 outage in less than half the anticipated time. As a result of
the successful pipe replacement, the nuclear power plant was returned to normal operation.
Update on Preemptive Weld Overlay (PWOL) Activities
Pete Riccardella, Structural Integrity Associates
Robert Hermann, Structural Integrity Associates
Greg Frederick, EPRI
Artie Peterson, Jr., EPRI
Luis Yepez, Welding Services Inc.
Abstract
In February 2005, EPRI contracted the team of Structural Integrity Associates (SI) and Welding
Services Inc. (WSI) to complete activities in support of Preemptive Weld Overlay (PWOL)
licensing. PWOL is one of several PWSCC-mitigation measures available for the mitigation of PWSCC in Alloy 600 butt welds in PWRs. This initial contract, funded by the EPRI Materials
Reliability Program (MRP), requires the performance of finite element analysis (FEA) to
determine the residual stresses induced by weld overlay in a configuration representative of a pressurizer surge-line nozzle. In addition, the project includes the design and fabrication of a
simulated surge-line nozzle mock-up that is subsequently overlaid with Alloy 52MS weld filler
metal based on a specified PWOL design. The overlaid mock-up will be evaluated for axial and radial shrinkage and chemistry (i.e., Chromium content). In addition, residual stress
measurements will be taken for comparison with and for validation of FEA results. This
presentation will provide the details of the approach taken to this EPRI MRP project as well as
the results obtained.
In addition to the EPRI MRP project discussed above, a status update for other related PWOL
activities will be provided. As a part of the project, a Topical Report will be submitted to the NRC to aid them in establishing in service inspection frequency for a susceptible dissimilar
metal butt weld and to provide a basis for maintaining leak before break status for the affected
piping. Importantly, the paper includes a recap of the March 2005 NRC kickoff meeting held tointroduce the contents for the proposed topical report. The discussion at the meeting included
the PWOL design approach and its related benefits, summarized the licensing submittal plans
and to discuss the NRC’s approval schedule. (NRC approval was requested to support Spring
2006 PWOL implementation). Lastly, an update on the status and implications of the PWOL patent application is also expected to be included in the presentation.
Past Operability Assessment o f TDAFWP due to Turbine Bearing Oil OrificeFeed Plug by Debris
Mammar Maghraoui, Tahsin Dogan, Michael W. Kelly, J oseph W. Spencer
AREVA, Framatome ANP
Roger C. Wink, Wade A. ClaspillCallaway Power Plant
Abstract
During a periodic test of the TDAFWP at Callaway, bearing temperatures trended higher thannormal. Subsequent inspection of the bearing revealed that a wear particle obstructed about50% of the bearing port orifice area. This finding initiated a plant corrective action.
A past operability assessment of the TDAFWP turbine was requested by the plant postulating a
completely plugged oil supply orifice to the coupling end (CE) bearing during a four-hour stationblackout (SBO) condition. Under this scenario, oil can only be provided to the bearing by theexisting oil ring.
A first assessment, using conservative assumptions on bearing dynamic load, oil-ring lubricationflow, and TDAFP room equilibrium temperature during the four-hour SBO showed that fullblockage of the CE bearing oil port would be expected to result in higher than normal bearingBabbitt temperatures. These temperatures were estimated to be in the 275 F to 300 F range.
A review of the findings prompted a request for a second assessment. This time, the SBOcondition was postulated to last eight hours. Other questions relating to maximum oil levels in thebearing reservoir and foaming effects were also addressed. A more accurate model of thetransient nature of the TDAFWP room heatup to determine the maximum bearing temperatureswas developed. Interestingly, predicted maximum Babbitt temperatures (255 F) are lower in thiseight-hour analysis than the initial, four-hour run estimates. The detailed bearing analysisperformed has also determined that bearing lubrication under these conditions remainsessentially hydrodynamic with full or partial film separating the shaft from the bearing.
This analysis required the development of (1) a starved bearing computer model, (2) input of geometric and operating parameters for the bearing and the oil, (3) determination of the oildelivery rate from the installed oil-ring, (4) and the evaluation of the heat transfer characteristicsthat add heat to or remove heat from the oil and the bearing in the fully blocked scenario.Iterative techniques were used to evaluate the changes from a baseline of existing ambientconditions up to the calculated conditions that would be reached over the mission time.
Because of very light bearing loads, the presence of ring lubrication, and the relatively shortduration of the required turbine run (eight hours), the CE bearing was predicted to provide its
main function of supporting the turbine shaft with no damage. Industry experience with thisturbine indicates adequate performance even with damage to the CE journal bearing.
Based on this analysis and industry experience the TDAFWP was declared past operable underthe postulated conditions.
ABSTRACT For plants to achieve excellent performance as determined by any number of measures
such as, reliability, production cost, personnel safety, environmental compliance, or other measure; the plant organization including operations and maintenance must perform as an
effective team. Often maintenance programs, processes, and technologies are addressed
without sufficient integration with plant operations. Since operations plays a key role inmaintenance activities such as deficiency identification, work control, equipment removal
and isolation; giving visibility to these topics as an integral part of maintenance should
contribute to more successful implementation of maintenance improvementefforts. Active participation of plant operators and their management in the efforts toachieve more effective maintenance coupled with plant goals that reflect the integrated
performance of both organizations will lead to higher levels of performance. Some of the
key areas of interaction are described from the operations view for your consideration.
Anil MittalNational Thermal Power Corporation Ltd.
7, Institutional Area, Lodhi RoadNew Delhi-110003, India
Patrick D AbbottEPRI Solutions, Inc., USA
Abstract
National Thermal Power Corporation, the largest power producer of India havingcapacities of over 24000 MW spread over 25 locations in the country, has initiated an
ambitious maintenance optimization effort. Management has set the maintenance goal
of ‘zero forced outage’ and implementing an integrated strategy for optimization of
routine maintenance, overhauling management, shared maintenance, work processmanagement and IT enabling for achieving optimum cost & reliability.
The biggest challenge faced by utility is transforming its maintenance practices from
deep-seated traditional time based preventive maintenance culture to ‘Knowledge-Based
maintenance’. Paper describes the ‘Maintenance Road-map’ for utility and corporatestrategy adopted for wide spread implementation by development of multi disciplinary
teams around Corporate, Regional and Station ‘Process Anchors’.
Through experiential learning, NTPC has customized various EPRI tools and evolved a
well-documented procedure for undertaking PM Basis evaluation of all units and tracking
its benefits in a coordinated manner. The PM Basis implementation is already inadvanced stage in about 25 units by in-house teams and will be covering over 100 units in
next few months. Once completed, it will be one of the biggest efforts in implementingPM Basis in a large utility in shortest possible time. This is an important step towards
introduction of Risk Evaluation & Prioritization (REaP) concepts for risk minimization &
cost optimization. Paper discusses the cultural challenges faced and programmaticelements put in place to implement this transformation ‘road-map’ named Project REAP
From a Silo Operated Maintenance Practice to a Fully Integrated
Maintenance
Azwi Mamanyuha, Pr Eng, MSAIEE
Maintenance Specialist
Eskom Resource and StrategyIndustry Association (Distribution Technology)
Cnr Lake and Power Road
Germiston 1400 South AfricaTel: (+2711) 871 3987
Fax: (+2711) 871 2372
ABSTRACT Eskom is a South African electricity company which has three divisions; Generation, Transmission and
Distribution. The company is responsible of generating, transmission and distribution of electricity in
South Africa. It also exports a certain percentage to the neighbouring states. All these three divisions are
managed by Eskom Management Board and are regulated by the National Electricity Regulator (NER).
The utility has been operating in a monopoly since inception. As a hundred percent shareholder owner,
the government has issued warnings that competition will soon be introduced. There are also speculations
that a certain portion of Generation will be sold to Independent Power Producers (IPP). Preparations are
in place to combine the Distribution division with Metropolitan distributors and Municipalities. Various
players in the electricity market are awaiting the unbundling of the electricity market. The challenges
facing the organisations are that it needs to start reducing the cost of production before competition is
introduced. These challenges escalate down to reduction of maintenance costs. The maintenance
engineers need to come up with maintenance philosophies which will optimize the assets and enhance the
bottom line of the company.
If Eskom's portion can be owned by Independent Power Producers, then new business goals will emerge.
The current maintenance engineers are faced with challenges of ensuring reliability and availability of the
aging assets, reduce risk of failure and at the same time make sure that the electricity generation is
profitable with increased performance and still meet new business goals.
Currently maintenance in Generation is divided into plants, e.g. Electrical maintenance, Mechanical
(Turbine and Boiler) and Auxiliary maintenance. Even in Electrical Maintenance department the
personnel are divided into sub plants like: electrical boiler, electrical turbine maintenance and electrical
out side plant maintenance. The challenges are that these departments operate in silos where each
department operates independent of the other. The result being that some of the defects are not attended in
time because one department may not be exactly sure which department has to do the job. Generation is
also still relying on old maintenance strategies suggested by original equipment manufacturers (OEM)
about thirty years ago which some of them did not even consider the South African conditions.
The author recommends newly researched technologies as well as introducing new ways of maintaining
the plant. This can be achieved through a fully integrated department composed of different skills either
electrical or mechanical. These will reduce the time to repair the defect and increase reliability of the
assets. The one integrated department will take advantage of the synergy by combining skills tapped from
different fields. The new maintenance technology can be applied on power station equipment and henceincrease reliability and availability and optimize the profits.
“Automating the PM Template and Maintenance Strategy Development
Process at ConEdison”
Matt Walther
Consolidated Edison Co. of New York, Inc.
(212) 460-3065
Evan Niemkiewicz
Insert Key Solutions, Inc.(610) 459-4400
ABSTRACT
ConEdison is optimizing maintenance at four of its fossil steam and power generation plants
across Manhattan, New York. This effort includes the development of PM Templates and their
implementation in the form of component-based Maintenance Strategies. MaintenanceStrategies include component classification, template association, comparison of the suggested
template tasks and frequencies to actual maintenance practices, and the addition of manual tasks.
In many cases, this is attempted with Microsoft Word, Excel, or Access PM Templates and acrude implementation process. This effort suffers from inefficiencies due to the inability to shareinformation between sites, to standardize the process and workflow, and to keep data
synchronized between revisions. The weak IT architecture results in poor application
performance, loss of data, and frequent outages. ConEdison has successfully implemented acentralized, web-based software application named IQReview which has provided many
benefits. A single instance of the application installed at corporate offices supports all four sites
in one database. The simple user interface improves process efficiency and key performanceindicators can be automatically generated to measure progress across the sites. This paper
discusses some of the lessons learned during the implementation at ConEdison and the benefits
National Thermal Power CorporationEngineering Office Complex, A-8A, Sector-24,
NOIDA – 201301, (UP) INDIAPhone: 91 120 2410294
Fax: 91 120 2410545 / 2410136
ABSTRACTNational Thermal Power Corporation (NTPC) is the largest power company in India. NTPC’s presentinstalled capacity is 23,435 MW consisting of 13 coal based and seven combined cycle gas basedpower stations. With only 19.1% of India’s total installed capacity it contributes 26.7% of thecountry’s power generation. NTPC plans to be a 40,000 MW company by 2012, so cost - effective
management of its assets is of key importance. The total capacity is made of up 103 machines comprising 71 thermal units of 60 / 110 / 200 / 210 /500 MW rating, 22 gas units and 10 Steam Turbines in combined cycle mode. The average age of NTPC units is 88,000 operating hours with respect to coal fired units and about 67,000 hours withrespect to the gas based units.
Over and above the periodic maintenance, NTPC has been carrying out specific maintenance /modernization activities in the plants which have crossed 100,000 hours of operation, which aremainly focussed on sustaining the current levels of efficiency and performance. These have beenmainly one-is-to-one replacement to cater to site specific problems, obsolescence and the changingenvironmental standards. When the initial series of Units which are of the ‘80s vintage completearound 200,000 Hrs. of operation, sometime around 2008 - 10, it would be necessary to consider
High End Solutions (HES) with the aim of bringing the efficiency and performance of the aging unitson par with the contemporary Units. This would involve major retrofits / up-rates of Turbine-Generator, Steam Generator and Auxiliaries as compared to one-is-to-one replacement done earlier.
This would not only have to leverage the technological advancements between 1980-2010, butshould also aim at driving down the Cost of Generation (COG) while factoring in the emergingbusiness scenario to meet the market determined price for power.
NTPC is developing a new business model to cater to its ageing fleet. Some of the factors beingconsidered for developing the model are:
• The emerging competitive scenario in the Indian Power Sector.
• The emerging scenario of carbon abatement.
• Leveraging current technology to reduce COG.
• Capacity building to develop HES and reduce dependency on Original Equipment Manufacturers.• Development of Perspective Rolling Plans identifying dates for carrying out these activities in the ageing
Units in a time bound manner as is being done for new builds.
• Strategic collaboration with reputed international agencies in this field.
Some of the activities being considered to lower the COG are:
• Feasibility Study for Retrofit of Advanced Super Critical Boiler and Turbine technology in the existing olderunits.
• Upgradation of Process parameters to enhance efficiencies.
• Retrofitting of Steam Generators to operate with low water mass fluxes.
• Retrofitting of turbine rotor trains incorporating the latest state of the art blading.
• Incorporation of the latest state of the art asset management system.
The paper will explain the New Business Model and NTPC’s approach for Leveraging TechnologicalAdvancements to achieve the market determined price for power in Ageing Power Plants.
The Condition Based Maintenance (CBM) process provides the production staff with the knowledge to
make condition directed run or maintain decisions. It enables identification of planned corrective
maintenance work directed by equipment condition in lieu of scheduled maintenance. Many sources of
equipment condition monitoring information; real time process data, technical condition diagnostic data,
operator and engineer rounds information, inspection and surveillance data, and operator log information are
used to perform a condition assessment. The objective of the CBM program is to provide condition directed
work identification before failure or occurrence of an “unacceptable” operating state drives unplanned
emergent work.
EPRI’s PlantView applications are being used to automate CBM knowledge management. This web-based
software provides access to information and process applications across the intranet for all production staff
using browser technologies. The applications automate the entry and capture of data, aid analysis, manage
knowledge processes, display reports and maintain a documented history as an integrated knowledge
management system. This paper will describe the knowledge applications for a condition based maintenance
program, how they are used by the production team, and the benefits of an integrated open access program
over traditional work process tools. The PlantView Predictive Maintenance Application is focused on CBM
condition status reports to guide condition directed maintenance activities. This application maintains the
program Equipment & Condition Indicator (E&CI) matrix, and provides an efficient process for diagnostic
data collection as PdM Tech Exams, documents equipment condition assessments, manages case histories,
compiles a condition status report, and captures performance measures of the CBM program effectiveness.The PlantView Electronic Rounds application escalates the value of collecting rounds data by enabling
viewing rounds data and managing the data for equipment condition analysis to create PdM Tech exams.
The PlantView Data Visualizer application is designed to access process data from process historians as a
condition indicator to support condition assessment. The PlantView Report Library Application provides the
infrastructure to capture and manage engineering assessments that are critical to O&M work process
optimization. This application enables documenting engineering assessments from inspections and NDE
analysis, creating equipment assessments, and compiling a Condition Status Report. The PlantView
Electronic Logbook enhances communication of equipment condition between production teams with access
to shift notes, organizational logs, operating concerns, and work around logs. The PlantView System Health
Report facilitates quarterly unit condition reviews where the production team and management participate in
conducting system health assessments to make operational and maintenance decisions.
Mailing Address and Phone NumbersSenior Manager (International Cell), NTPC Consultancy Wing,
NTPC, Sector-24, Noida
Ph: 0091-120-2597220 (O)Ph: 0091-120-2504240 (R)
Fax: 0091-120-2410608
GSM: 00919868391131
ABSTRACTRapid changes in Electricity Market world over have created an environment of fierce
competition in production of Electricity. Many countries have introduced sweepingderegulation and liberalization in electricity market. Power producers world over are
therefore faced with complicated and dynamic situation where the “Survival Of The
Fittest” theory is truly unfolding. India is no exception. Wide-ranging changes in tariff structure and Operating Norms are already under force in India. Leading Utilities like
NTPC in India are today encountering unprecedented challenges in maintaining
excellence and growth.
Modern concepts of performance enhancement along with cost reduction are therefore
dire need of the time. Serious thought must be given to control costs and at the same timemaintain pace with cutting edge technology. This is a difficult task. Controlling costs and
ABSTRACT Better asset performance through improved equipment reliability is being recognized as a key contributorto success by senior management at leading commercial nuclear power plants. By optimizing assetreliability, utilities are responding to important business challenges they face on a daily basis including:
• regulatory compliance
•
safety and environmental integrity• doing more with less
• capturing the knowledge of the aging workforce
To address these challenges, leading utilities are establishing strategies to transition into reliability-basedorganizations by implementing a total asset reliability solution. This solution combines advancedtechnology with strategic and functional reliability practices that support the equipment reliability processand ensure sustainable reliability improvements are realized. By focusing on the equipment reliabilityprocess, utilities are able to establish and sustain a proactive maintenance environment – optimizingasset reliability and driving business results.
See how a total asset reliability solution has helped a North American Nuclear Generating Station identifythe right work to do, on the right equipment, at the right time. This case study will focus on the company’s
equipment reliability process initiative to optimize equipment reliability while managing cost efficiencies. This session presents and discusses the reliability practices and technologies used by the nucleargenerating station to:
• focus employee roles and responsibilities on the equipment reliability process
• move to a proactive, condition-based approach to reliability and work management
• pull together the islands of data required to keep reliability and performance on target
• capture the reliability knowledge of the aging equipment experts
Equipment reliability is a key driving factor in nuclear asset management and utility performance today. This nuclear generating station’s progressive approach positions them at the forefront of the utilitiesindustry amidst restructuring and deregulation as well as political and public pressures.
Laser Scanning Offers Significant Benefits for the Power Market
Eric Hale
Quantapoint, Inc.
ABSTRACT
With an aging fleet and limited capital for new investment, power producers are seeking to maximizeexisting resources and assets. Plants must improve all aspects of operation and maintenance to be
competitive. Runtimes are increasing while outage durations are decreasing. Today, world class
generators are approaching 20-day refuel outages and are then going on to set records for capacity and availability. These power producers are only able to achieve world class performance by seamless
execution of maintenance and modifications.
A significant challenge for maintenance and modifications is that they have inaccurate “as-built”documentation. Teams engage in a time-consuming process of manually measuring equipment or facilities
dimensions in the field using the conventional tools of a tape measure, plumb bob, and note pad. Some
plants are beginning to capitalize on the benefits that laser scanning technology has afforded the processand refining industries for more than 10 years.
All project stakeholders – owner operators, engineers, designers, maintenance personnel, project managers,and equipment vendors – find that laser documentation provides benefits. Early adopters consider laser scanning to be more safe, fast, accurate, complete, and transportable than other options for capturing and
sharing dimensional details of existing facilities.
The tangible benefits of as-built documentation include:
• Quality improvements from greater accuracy and precision that improves engineering designs.
• Scheduling improvements by reducing time spent in plants collecting data, improving designefficiency, enabling prefabrication of components, minimizing construction durations, and less
rework.
• Safety and ALARA improvements by reducing the exposure to potential hazards within the
plant environment.
• Reduced costs resulting from quickly capturing as-built dimensions, eliminating construction
rework and field changes, and shorter outage durations.
The experience and benefits for several recent projects is presented. The key factors for planning an as-
built documentation project are presented. Several different technologies are compared and contrasted.
In today’s electricity generation industry world critical valve performance is
a key part of safe and reliable plant operation. How plants’ Packing
procedures are written and implemented is critical in today’s world of
shortened outages and extended up-time. There is no time for repetitive
gland adjustments or frequent packing installations because of poorly written packing installation procedures. This paper will focus on plants with well-
written procedures that have resulted in maintenance, engineering, and I&C
groups taking total ownership of achieving peak performance from critical
AOV / MOV Valves. This paper will also include discussions regarding
packing consolidation procedures and the misuse of stem lubricants to mask
packing friction. Today it is important to utilize new low friction packing
technology to enhance valve operability without sacrificing long-term valve
ABSTRACT In recent years, concern over the continued use of limited fresh water supplies or similarly,cooling towers and their essential makeup, high maintenance and associated chemicaltreatment requirements has spawned a crafty, yet dramatic change in powerplant surfacecondenser and heat exchanger cooling. The paradigm shift away from the more establishedand typical toward the more unconventional has produced an innovative and non-traditional
cooling water source for surface condensers and heat exchangers. Clearly, gray water-coolinghas come of age.
By definition, gray water is cooling water where all or part of the flow stream is made up of eitherpartially or fully treated sewage effluent. As you can well imagine, the use of sewage effluentprovokes a plethora of new issues. They are led by the voluminous unknowns that flow fromsociety to the sewage treatment plant and the economics of processing and transporting this“impaired water” from the municipal host to the ultimate user. The application of this relativelynew cooling medium suggests the potential impact of this “water” on plant metallurgy, chemicaltreatment requirements, corrosion abatement and other physical plant system needs, can beloosely categorized as both speculative and unproven. Without a clear understanding of legislative and political landscape issues, the regulative complexities that deal with this type of
cooling water could conceivably lead to an unattractive, environmental legacy.
Having duly noted the “trend or aberration” dilemma, this paper will further identify efforts by themunicipal wastewater treatment plants to economically process a usable product. We will alsoinvestigate the impact of ancillary add-on costs absorbed by the electric utility such assecondary filtration. Finally, the paper will evaluate new operational conditions, potentially newcorrosion activities, metallurgical changes, pollution considerations, maintenance issues andother mechanisms which have forced utilities to be innovative in seeking alternative coolingwater sources for the main surface condenser and other heat exchangers.
ABSTRACT Maintenance personnel at many US nuclear plants have an interest in reducing preventive maintenance
costs and improving equipment performance by more closely matching PM tasks with the functional
importance of equipment. For this to succeed, utilities require information on the most appropriate tasks
and task intervals for the important equipment types, while accounting for the influences of duty cycle
and service conditions. The need for the database information was originally pointed out by members of
the former EPRI Reliability Centered Maintenance Users Group during 1988-1994. The original data for
39 component types were assembled during 1996-98, have been published as a series of reports in EPRI
TR-106857, November 1998, as an electronic database described in EPRI Product 1001448, Preventive
Maintenance Basis Database Version 3.01, User Manual, January 2001, and as Version 4 of the database
released in December 2002. Making the information available as an electronic database has significantlyincreased its accessibility, and brings advanced analysis tools within reach. A fully integrated
Application Guideline advises users on making changes to PM tasks, on the deferral of tasks, and many
other technical aspects of managing a PM program. The Application Guideline was requested by utility
engineers at an EPRI workshop toward the end of 1998, and was first included in Version 3.01.
Objectives
The Preventive Maintenance Basis Database provides the nuclear utility maintenance community with an
essential reference for preventive maintenance task selection and evaluation for common major
components. It also provides the rationale for each task, and the influence of the equipment failure
locations, failure mechanisms, and the timing of failures, on task content and task intervals.
Major advances in Client/Server Version 1.0 include the update of component data, the addition of thecapability to semi-automate the building of the plant PM program, the capability to generate detailed lists
of as-found conditions specific to each PM task and component type, the expansion and automation of the
Vulnerability Evaluation, and the inclusion of modules to estimate economic risk for critical components
and to evaluate the balance between reliability and availability when making PM changes. In addition,
the software is now operates in a MS.NET environment utilizing MS SQL Server.
Approach
Expert panels composed of knowledgeable individuals from EPRI, EPRI member utilities, and
manufacturers, were employed to formulate the technical bases of PM task options presented for the
selected equipment. Most of the expert panels addressed a small number of closely associated component
types, e.g. three types of pressure relief valves. A utility oversight committee, the PM Basis steering
committee, was established to oversee and direct this process. Once the data had been reviewed and published, contractors loaded it into a Microsoft Access database, and designed forms to display the data
in useful ways. Experience from almost two decades of PM optimization studies with EPRI utility
members was embedded in the Application Guideline and in the Vulnerability Evaluation. Industry
working groups in many areas of maintenance technology and equipment reliability improvement,
contribute to the database by providing experts at ongoing industry meetings, who assist in keeping the
information up-to-date.
Results
The result of this work is a database containing over 200,000 data fields of utility PM information, which
represents several decades of utility experience of improving equipment reliability with cost-effective PM
ABSTRACT As demands on maintenance departments and inspectors have increased, some of the
“tribal knowledge” of how specific items in the plant and or production process has been
disappearing due to layoffs and early retirement of key people. There is a need to adoptmethods and technologies to assist a new generation of inspection personnel. New
advances in ultrasound technology are ideally suited for this demand. Ultrasound
technology now provides inspectors with a complete range if inspection, recording,
analysis and reporting capabilities.
Of the technologies available for condition monitoring, ultrasound inspection offers a
unique position as both an integrating technology and as an effective tool that can speed up the inspection/analysis process. Many inspectors are using ultrasound instruments as
their basic screening tool to identify anomalies and to help them determine effective
follow-up actions such as recommendations for more frequent monitoring, additionaltesting with other technologies or corrective procedures.
This presentation will describe the basics of the technology, how it has evolved, the latestadvancements in digital instruments and software, which will help assure asset reliability,
reduce unplanned downtime and improve system efficiencies.
Transmission System Operator (TSO) TenneT manages the 'expressways' of the Dutchhigh voltage network (380 and 220 kV). As network manager/TSO, TenneT isresponsible for the high voltage network that links all the regional electricity networks
and the European network. TenneT monitors the reliability and continuity of theelectricity supply in the Netherlands. TenneT makes its high voltage network availablein an impartial fashion for the transport of electricity and ensures the required balance
between supply and demand in the Netherlands. TenneT works together with EuropeanTSOs. Since October 2001, the national government is a 100% share owner of TenneT.
TenneT implemented maintenance plans based on risk analysis, supported by the useof Optimizer+. As a result, TenneT expects to realize yearly maintenance cost savings
between 10 and 25 percent. This paper describes the results of this optimizationprocess for a specific component, the rail separator in a 380 kV high voltage station.
Implementation of the optimized maintenance plan will reduce the costs by over 16percent and lower the hours of downtime by almost 24 percent.
This paper will discuss approach, specific use of Optimizer+, and the results achieved.
Illustrations in the form of screenshots and other visual presentations of the results inthe final paper will provide insight into how Optimizer+ aided the risk analysis process.
TenneT used Optimizer+ to map the relationship between risk on the one hand andoperational and financial performance on the other.
The following steps were carried out during implementation of the project:1. Collecting information on assets.
2. Building a library database.3. Modeling a station.4. Carrying out risk analysis.5. Formulating and simulating the maintenance concept.
With the help of Optimizer+, TenneT can model the entire installation, carry out riskanalyses, take the necessary preventive measures, and calculate the effects of variousscenarios. This enables TenneT to make decisions regarding maintenance strategies,
with the aim of optimizing the existing maintenance plan. The process provides the user with the required insight into the balance between maintenance, costs, performance
and risk in relationship to the overall company goals. In practical terms, TenneTdemonstrated that the use of Optimizer+ for a rail separator can reduce maintenancecosts by an average of 16 percent, as well as reduce downtime by 24 percent.
Submitted to “Fifth EPRI International Conference on Maintenance (Aug'05)”
Low-Cost SF6 Gas Monitor
George W. Rhodes and Tristan D. FinAvistar, Inc2401 Aztec N.E., Albuquerque, NM 87107
505.855.6499
ABSTRACT
The electric utility industry uses Sulfur Hexafluoride (SF6) as the dielectric gas for breaker switches. SF6 is 25,000 times more damaging to the environment than CO2 as a greenhouse gas.Gas containment systems have several mechanical seals that degrade with time allowingatmospheric release. Utilities need to monitor each of the containment sites, but the cost of
available systems has prohibited widespread deployment. The current EPRI camera offeringwould benefit if the measurements were focused on known leaking switches. To providecomplete surveillance, a pressure sensor, thermistor and PIC chip have been combined - keepingthe cost of goods sold under $250. Monitoring pressure levels of SF6 as a function of temperatureallows good scheduling of maintenance and repair. This relative measurement technique can bedeployed on any SF6 switch, independent of environment (0-100psi, -20-75 C) withoutreconfiguration. The system’s output is available through three channels: 0-5V, 0-1mA, and 8-bitdigital. The digital channel is configured for a variety of communication protocols to interfacewith SCADA, or other reporting systems.
Mailing Address: 7620 Little River Turnpike, Suite 500
Annandale, Virginia 22003
Phone Number: 703‐256‐2245
FAX number: 703‐256‐9372
ABSTRACT
Electronic performance support systems (EPSS) are web-enabled software applications that
provide maintenance technicians with standardized work procedures integrated with equipmentdiagrams, animated electrical schematics, part ordering information, assembly drawings,technical tips, Computer Based Training (CBT) clips, and other mission-critical information
resources. EPSS applications are rapidly gaining popularity in both commercial and military
settings due to their demonstrated success at optimizing maintenance effectiveness. Numerousindustrial and military tests have proven that electronic performance support systems increase
workforce productivity by 30% or more while concurrently increasing troubleshooting and repair
accuracy rates and boosting equipment reliability and availability levels. Furthermore, theElectric Power Research Institute, which has been active at the forefront of EPSS research and
development since the late 1990s, is focusing on performance support technology to help reduce
maintenance expenditures, provide technicians with refresher training at the point of need, and
manage organizational knowledge assets, among other functions.
This session will summarize the results of EPRI’s recent electronic performance support systemcase study performed at Bull Run Fossil Plant, a Tennessee Valley Authority facility, and will
present other results and metrics culled from performance support technology tests conducted in
2004-2005. Maintenance managers will be instructed how to apply performance supporttechnology effectively to achieve similar results within their own maintenance organizations.
Topics to be discussed include how electronic performance support systems can elevate
maintenance department productivity by 30% or more without altering the size or structure of theexisting workforce; how performance support systems can streamline parts inventories and stores
by increasing maintenance accuracy and reducing false removals of functional components; how
performance support systems serve as a core component of knowledge management and processimprovement initiatives; and more. Session participants will gain a thorough understanding of
the electronic performance support system concept, learn about the proven benefits of the
technology, and receive detailed guidance on how to successfully implement an EPSS program
Equipment Condition Assessment (ECA) is an emerging technology which can provide on-line
component health for further diagnostics, and/or prognostics. . ECA is based on an empirical
model of a component based on measured process variables and other information. Its
implementation is usually via automated, on-line methodology where input data to the model are
periodically collected (once a minute, hour, etc.). The model is able to detect “anomalies”—
deviations from normal operation using an anomaly detection algorithm, and a logic-rule-based
anomaly interpretation scheme.
The goal of ECA is to provide an early warning of equipment degradation or failure such that
proper actions can be taken to minimize the effects of that failure, including: parts inventory,
maintenance scheduling, maintenance planning, and load reduction to contain the failure or
reduce the rate of degradation.
The development of empirical models for ECA consists mainly of grouping together an
appropriate set of correlated process variables, and gathering historical data for those process
variables. Predictive maintenance data and qualitative “rounds” data may provide additional
information that can be input to the empirical model. The mechanics of how to couple disparate
sources of data remains a challenge; however, once a developed model is placed in-service, an
anomaly detection algorithm is coupled to the model which continuously evaluates the residual
differences between the process variable measurements and the empirical model estimations. Ananomaly is defined as a deviation from expected behavior, which in most cases is a deviation of
the residual values from a normally distributed density of known variance and a zero mean. The
final aspect of ECA is automating the interpretation of simultaneous anomalies such that a single
succinct diagnosis or prognosis can be announced.
EPRI is assisting in ECA deployment for a pilot study at a fossil power plant and for a large scale
fleet-wide monitoring implementation. Progress Energy’s Mayo fossil plant is the host site where
SmartSignal’s eCM software has been installed. The software performs ECA utilizing models
that are specifically tailored for this application based on the available process variables and
historical data from the process variable sensors. The scope of the pilot study initially includes
boiler feed pumps, induced draft fans, and forced draft fans. TXU Energy has undertaken the
development of a centralized Power Optimization Center which will carry out, among other things, thermal performance monitoring, vibration monitoring, and ECA for their fleet of plants.
The ECA implementations at the TXU Energy sites are plant-wide as opposed to the limited
breadth of the pilot study at Progress Energy. The experiences gathered through these efforts will
be documented in the form of descriptions, illustrations, and evaluations of the developed ECA
ABSTRACTAs power plants continue to age past their intended design life, several areas of the rawwater system will eventually require attention. Areas that require attention includepiping susceptible to preferential attack at welded joints, corrosion at flanged, bell &spigot connections, and steel to concrete transitions. Circulating water expansion jointshave also become susceptible to leakage and catastrophic failure as they age wellbeyond the intended design life.
Internal sealing of raw water piping to arrest corrosion has been utilized inmunicipal, industrial and power applications for over twenty-five years. This processconsist of an EPDM (Ethylene Propylene Diene Monomer) rubber seal that is positionedover the affected area and locked in place with two hydraulically expanded stainlesssteel retaining bands, located at each end of the seal.
Cooling water piping system leaks often suggest that large sections of pipe mayneed to be replaced. In many cases the deterioration is limited to the pipe joints.Preferential attack at welded joints is a common problem and deteriorated conditionscan also be found at flanged, bell & spigot connections, and steel to concrete pipetransitions. Typically, repairs range from complete excavation (if required) andreplacement of the affected area to welded patches and belly bands. The internal seal is
a relatively simple method to isolate or repair deteriorated areas in all piping materials indiameters ranging from 16 inches to 18 feet. As many as 100 smaller diameter sealscan be installed, inspected and tested during a 48 hour time period. To seal longerlengths of piping the seals can also be interlocked together to form a continuousprotective membrane. In addition, the seals can be specially formed for elbows tees andother fittings.
In the last few years the internal seal has successfully been used to repaircirculating water expansion joints. A repair technique utilizing a backing strip of stainless steel is installed over the existing expansion joint convolution to providereinforcement at the joint. The seal is installed on the inside diameter of the expansion joint and restrained by two bands at each end with an extra band provided to anchor the
backing strip on one end. This repair takes the place of the expansion joint andprovides the required flexibility while maintaining pressure boundary integrity. Theexisting expansion joints are not removed from the system. This new advance ininternal sealing design have led to the ability to repair expansion joints insitu and thuseliminating significant maintenance costs. It is the intent of this paper to demonstratethe capabilities of the internal seal repair methodology, the design basis and the rangeof plant components where this technology can be applied.
In the last decade, advancements in motor testing technology have brought forth
advances in online and offline testing. Online Current Signature Analysis (CSA) isquickly becoming a standard industry practice. Offline tests include advanced inductance
measurements to analyze rotor and stator health. Using a combination of online and
offline tests to form a six fault zone approach offers a more complete analysis of motor health. Power Quality focuses on the quality of the voltage and current. Power Circuit
focuses on the power circuit supplying power to the motor. The Stator Fault Zone focuses
on the turn-to-turn insulation and internal coil connections. The Air Gap Fault Zone
refers to the quality of the air gap between the rotor and the stator. The Insulation FaultZone refers to the winding to ground insulation. The Rotor Fault Zone refers to the health
of the rotor cage and laminations. All six fault zones should be analyzed to accurately
Use of the ORSIM Model for Improvement of Nuclear Power
Plant Operations
Michael W. Golay
Massachusetts Institute of Technology1617 253 5824/ [email protected]
ABSTRACT
During the past year the Operations Risk Simulator (ORSIM) model of nuclear power plant organizational performance has been used in a pilot project at a Four-unit CANDU
nuclear power plant. The purpose of the project was to determine whether use of this
model is feasible and compatible with the limited planning resources typical of nuclear power plants under current competitive conditions, and to determine whether it could
provide valuable insights for improving operational performance. The experience was asuccess in terms of both criteria. The resource requirements for adapting PWR-based
original version of the ORSIM model to a CANDU application were found to be modest
(< 1 man-month, and negligible computational costs), and the insights provided wereuseful to the plant managers in understanding the causes of observed performance
declines, and in choosing among alternative proposals for improving the efficiency of the power plant’s organization.
The ORSIM model was developed using the System Dynamics technique for capturingthe domain expertise of the team operating a two-unit PWR plant in the United States.
Briefly, this technique utilizes the methods of engineering control theory to describe theoperations of an organization as the result of the interactions of the organization’s groups
performing their individual tasks and supporting each other. It is especially capable of
describing the nonlinear amplifications (the “ripple” effect) of these interactions
depending upon the degree to which these interactions are harmonious. It is useful for identifying operational vulnerabilities, conditions that will lead to progressive-and-then-catastrophic decline and ways to improve performance. A major product of a simulation
using this model is the time-dependent material condition of the plant, and the
corresponding electrical production and associated risks. The ORSIM team plans next to
start another pilot project at a single-unit US PWR.
Doug Gipson has challenged the EPRI staff and me to provide additional value from existing EPRI products and
services with minimal or no additional cost to the membership. In responding to his request, one program I amconvinced we can extract enhanced value is EPRI’s Task Proficiency Evaluation (TPE) program. The TPE
program was designed to assist nuclear power plants in assuring that their internal and supplemental work force
have the required knowledge and skills necessary to safely and efficiently accomplish assigned maintenance tasks.
Given the replacement workforce issues being discussed in many forums across our industry, EPRI is rethinking
our approach to the present TPE program. But, EPRI’s efforts alone are not sufficient! The information below
provides a vision for an industry-wide collaborative that can address some aspects of the challenges your staff faces
today regarding:
z Work Force Aging and Turnover
z Supplemental Personnel Performance
z Cost effective training
We are working with our members, NEI, INPO, and others to identify what ‘next steps’ will be most helpful and
what the business case looks like.
Background
Before beginning independent work on a specific task in a nuclear plant, individuals must possess the required
knowledge and skills of that task. The skilled trades have historically prepared supplemental workers withspecialized skills and knowledge of nuclear plant maintenance tasks. To ensure that supplemental personnel have
the required qualifications (knowledge and skills), the plants options include items such as resume reviews,
subjective interviews, or pre-outage training and testing. The latter although effective, is costly and oftenrepetitive, from plant-to-plant and outage-to-outage. Costly on-site training is frequently the least timely and least
desirable.
The TPE program was designed and developed to assist nuclear power plants in assuring their internal and
supplemental work force have the required knowledge and skills necessary to safely and efficiently accomplish
assigned maintenance tasks. The program process identifies and develops critical maintenance related task
evaluation tools and maintains a task qualification registry. Program oversight and operation is maintained through
a chartered TPE Users Group made up of interested EPRI member utilities, national labor unions and associated
maintenance contractors.
Specific evaluation tools (written and performance tests) applicable
to each identified critical maintenance task were identified. A subset
has been fully developed, but it is about a third of the 147 total tasksidentified by the TPE Users Group. The main emphasis was placed on
outage related maintenance tasks routinely performed by contracted
personnel. This resulted in the program participants expanding to
include the major Building and Construction Trades Department
(BCTD) labor unions. Their involvement was a natural extension of
EPRI’s participation in the development and implementation of the
Nuclear Mechanic Apprenticeship Program (NMAP) where the bulk of
TPE Evaluation Process
•
Task-Specific Evaluation Modules• Knowledge – Written Examination
The power generation industry has changed significantly as a result of the competitive market and increased
electricity demand, requiring an elevated level of staff proficiency. Many companies in the industry have
indicated they are also confronted by retirement of an aging experienced workforce and creating competent
replacement workers. To meet these demands, it is critical to assure maintenance staff are prepared with the
knowledge and skills to perform their jobs effectively, and to accelerate the time to competency of
replacement staff. This paper will address the creation of a Maintenance Excellence Program (MEP) to meet
the craft training needs at Progress Energy and PSEG Power. There are three primary elements to a
successful implementation of an MEP program;
1. Capturing the knowledge of experienced workers before they leave. Creating an environment to
encourage workers to share their experiences, identifying and prioritizing knowledge to be captured
that is critical to success of the plant, and implementing processes to capture and convert
knowledge into useful training content.
2. Creation of a knowledge warehouse as craft training content. The knowledge warehouse is crafted
as unit specific training content; and includes component knowledge descriptions, theory of how
equipment works, procedural based skills, associated references and procedures, and
comprehensive maintenance work packages for key components.
3. Automating training delivery with the PlantView Automated Training Manager (ATM). The ATMis a comprehensive learning management system for the economical delivery of training that also
provides progression profiling, training enrolment and delivery, competency evaluation, access to
associated references, and training administration. It empowers MEP coordinators with the ability
to create the knowledge and training content, copy it between plants, and edit them to be site
specific MEP packages. The ATM is simple to use for the Maintenance Managers to manage their
staff training and qualification progression from entry level to journeyman.
The MEP helps plant managers ensure maintenance staff are prepared with the knowledge and skills to
maintain its facilities at the highest level of reliability, efficiency, and safety.
We propose a presentation on a landmark workforce development initiative that PSEG has implemented here
in the State of New Jersey in partnership with some of our local community colleges entitled the Energy
Utility Technology Associate Degree Program. This is a fully accredited Associate Degree program in
Energy Utility Technology from Mercer County Community College or Essex County College, managed in
partnership with PSEG. The program has been recognized as a workforce development strategy that works.
The program was conceived in response to what some experts are predicting will be a major staffing crisis
for the energy industry due to a significant number of craft and technical workers becoming eligible for
retirement in the next decade, and a growing need for a more highly skilled and better educated workforce.
PSE&G, and now PSEG Power’s fossil generation business, have begun to realize the benefits of workforce
planning via this program launched 27 month’s ago to address the pending employment gap and generate
renewed interest in technical trade careers.
“When we started the Energy Utility Technology Associate Degree Program with Mercer County
Community College, we weren’t quite sure what the response would be,” explains Dana DeYoung, PSEG
director of Talent Management. “Now – two-years later, we have six graduates, 18 students hired, 40
currently enrolled, two community colleges and PSEG Fossil participating in the program. We‘re just
beginning to see the potential of this program.”
As a result of Fossil’s participation, four energy utility technology degree students will be getting an up close
and personal view of what it’s like to work in a power plant, when they participate in summer internships at
Mercer Generating Station in Hamilton Township. According to Alan Bassham, PSEG Power, manager – technical training, an introductory power plant operations and maintenance course developed by his training
staff, and approved as a program elective, will prepare the students for the experience by providing them
with the basic knowledge and skills they need for safe power plant operation and maintenance.
“We realized we needed to take a more aggressive approach to attracting and recruiting new talent into entry-
level technical positions within our power generation business,” says Bassham. “Like the utility, many of
our folks will be retiring and quite frankly – you don’t see a lot of young people pursuing employment in
power plants. I’m confident that this program will help start to bridge this gap by both educating and
exposing students to career opportunities that are available in our business.”
The creation and implementation of this program had enabled PSEG to create strategic Business/EducationPartnerships with select educational organizations in the state to increase the diversity and competence for
candidates in our job pool and provide a solution to the potential impacts of the aging energy workforce. The presentation for the EPRI Conference on International Maintenance will focus on:
* An overview of the Energy Utility Technology Associate Degree Program,
* Development and implementation of the program
* Highlights of the results achieved thus far through recorded testimonials from the program
participants,
* Expansion of the program within the generation organization in the operations and
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Insert Key Solutions, Inc. (IKS) delivers web-based solutions for businesses of all sizes, from Fortune 500 companiesto start-ups. IKS has developed a suite of web-based products that are designed to improve and automate PlantEquipment Reliability (ER). The ER Suite was developed by incorporating industry best practices, regulatoryguidelines, and input and experience from a broad customer base. The entire suite of products is web-based and
incorporates the latest technologies. The suite of products includes:
IQTemplatesTM – PM\PCM Template management including tasks, frequencies, ownership, and revision control.IQReviewTM – Component Classification, PM\PCM Template Association, Review against Current Practice, and an interface to the Computerized Maintenance Management System (CMMS).PlantIQ® – Component Health Reporting and Predictive Maintenance (PdM) integration including Performance Indicator automation.SystemIQTM – System Health Reporting, Action Plan Generation, and data integration including Quarterly Reporting Requirements.PAM ManagerTM – Just-In-Time Work Order Review and Proactive Maintenance Craft Feedback Review. Data integration and Performance Indicator automation.Ranking Index or Orders (RIO)TM – Work Order Prioritization and ranking through automated data integration.ER DashboardTM – Centralized Equipment Reliability Performance Indicators with drill-down into Supporting
Applications.SmartSealTM – Valve and Pump design, sealing and packing material, and maintenance management.
IKS has extensive experience in the power industry. Our Equipment Reliability Suite of products is installed in more than 60
nuclear and fossil plants across North America.
Exhibitor Booth #100
Name of Company STORK H&E TURBO BLADING
Contact Name: JOE WALKER Address: 334 COMFORT RD, ITHACA, NY 14850 USA
Stork H&E Turbo Blading is the largest and oldest independent turbo blading manufacturer in theworld. All OEM model steam turbines, gas turbine compressor, and axial compressor blades,
vanes, buckets, rotors, stators, nozzles and guide vanes are manufactured to ISO9000 & AS9000
standards. Stork supplies the global power generation industry, petrochemical, aviation, marine,
pulp & paper, and other process industry turbine users.
Quantapoint uses integrated laser scanning to provide the fastest, easiest and most cost-
effective solution for creating detailed and highly accurate as-built documentation for power plants. With nearly 700 as-built laser documentation projects, including fossil-fuel and
nuclear power plants, Quantapoint rapidly collects, integrates and verifies billions of highly
accurate measurements to provide a consistent and complete “digitized plant” of easily
shareable as-built laser documentation – without data handoffs, purchasing costly hardware or
time-consuming remodeling.
The digitized plant can include dimensionally accurate and photo-realistic 2D laser scans,
interactive 3D laser models and verified 2D drawings,
such as piping & instrumentation diagrams. It provides
more accurate and complete information for design,fabrication and construction decisions, with construction
The leader in insulation test technologies, Baker’s are industry standard for predictivemaintenance and motor rebuilders.
These instruments compile information via in-service and traditional static testing. In-service
equipment searches for power, torque, overcurrents, load, efficiency and other problems within the
running motor. This monitor can be connected via a safe connection at the MCC, quicklydetermining problems apparent within the motor process.
Static equipment tests for weaknesses in the windings, coils, or leads. They simulate spikesassociated with startup, finding problems that are above operating voltage. This allows time to
repair or replace equipment on your schedule not the machinery’s.
Analysts Inc is the nation’s oldest, most experienced commercial oil laboratory. They are ISO
9001 and NRC 10 CFR Appendix B approved. In addition to a wide range of standard testingcapabilities, Analysts is at the forefront of research on turbine oil degradation. They havedeveloped unique testing technologies specifically designed to maximize the life and performance
Name of Company: Conco Systems, Inc.Contact Name: Sharon L. Springer Title: Marketing AssistantAddress: 530 J ones Street, Verona, PA 15147Phone: 412-828-1166Fax: 412-826-8255E-mail: [email protected] Site: www.concosystems.com
Conco Systems is recognized throughout the power industry as the world leader forquality cleaning of condensers and heat exchangers. Conco supplies exclusivetechnology for; tube cleaning, tube cleaning services, leak detection services, EddyCurrent testing, condenser performance analysis, and tube plugging. In addition, Concois introducing the latest technology for cleaning air-cooled condensers: the j & w® cleaning system with a patented nozzle beam for optimal cleaning. Conco also has acomplete line of HydroDrills designed by Global Heat Exchanger Services for cleaningheat exchanger tubes in power, petrochemical, and refining facilities.
Exhibitor Booth #206
Name of Company: EST Group
Contact Name: Hank Brandenberger Title: General sales manager
EST Group provides a complete range of repair products, services and replacement parts,
(including replacement units) covering the life cycle of tubular heat exchangers and condensers;additionally EST Group provides products and services to facilitate pressure testing pipe, piping
Margan specializes in the online inspection of High Energy Piping by QAE NDI or QuantitativeAcoustic Emissions Non-Destructive Inspection. We listen to the integrity of High Energy Piping
during operation to detect flaws at their earliest stages, long before they become failures.
Exhibitor Booth #211
Name of Company Alaron CorporationContact Name: Steve Ferguson
Title: Vise President, Business Development & Marketing
Address: 2138 State Route 18, Wampum PA 16157Phone: 513-583-1744
Alaron, together with our teaming partners, has become a ‘one-stop shop’ for all your nuclear
service needs. Alaron provides a variety of services including; equipment storage, facility-spaceleasing, waste processing (wet and dry), asset recovery, service level one coatings and
refurbishment of both safety and non-safety related components (pumps, motors including
PdMA Corporation provides the equipment, services and training to support electric motor
reliability. Products include static and dynamic portable motor analyzers utilized in the conditionmonitoring of electric motors and circuits. The MCE static tester provides a detailed analysis of motor and circuit condition. The EMAX tester collects data while the motor is operating, giving you
the power and convenience only dynamic testing can provide. The MCEMAX integrates both
technologies into one comprehensive package. By combining the accuracy of motor and circuit
analysis and the convenience of power analysis, the user is given the information necessary toevaluate all six potential fault zones: power circuit, stator, rotor, air gap, insulation and power
quality. Services include oil analysis, motor circuit analysis and motor power analysis.
Babcock Power Inc., through its various subsidiaries, is a leading worldwide supplier of
technology, equipment, and aftermarket services for heat exchangers, HRSGs, steam generators,fuel firing equipment, and environmental products for the power generation, industrial, and waste-
Based in Oregon, C limax Portable Machine Tools is a full service provider of on-site
machining solutions. The Company offers spec ialized engineering consulting services,
customized training programs and a comprehensive line of portable machine toolsenabling customers to quickly perform a variety of on-site machining proc edures. Climax
offers a broad selection of standardized portable machine tools, as well as a range of
custom-built solutions based on extensive experience within the power generation
industry. Climax Portable Machine Tools serves domestic and international markets
through both its own international offices and via licensed representatives in 23 countries.
