Playbook

Pump & Motor Services

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When it comes to the heart of your motor, you need reliability. This utility called on AREVA to do a fleetwide replacement of its stators. Why? The utility had already lost approximately $20M in reactor coolant pump (RCP) motor failures. Our stators reduce power consumption and are built for the life of the plant. And none of our 220+ RCP motors have ever experienced an electrical failure. The amount of revenue the utility has lost due to RCP motor failures since our stators were installed? Zero.

Replacement Play #1Stator Replacement - Fleetwide

Challenge: Stator aging Solution: Replacement statorBenefits: Improved reliability; reduced electrical losses

Before After

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Challenge: Shaft damage Solution: GTAW weld buildup, nickel plateBenefits: Save cost and time over rotor replacement; restores critical fit

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How important is it for a rotor shaft and flywheel to fit? Critical. During site-performed disassembly, this rotor shaft was damaged — affecting the critical fit between the rotor shaft and flywheel. An unstable fit creates the risk of pump vibration — which could lead to a plant shutdown. The solution? Manual welding, machining, nickel plating, and grinding. The fit was restored without the cost of replacing the rotor — or shutting down the plant.

Before After

Repair Play #2Rotor Shaft Repair

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Two housings destroyed in service. No replacements available. Only 10 days left in the outage. Panic? No. The housings were expedited to the Pump & Motor Service Center (P&MSC) and precision machined and welded to the original specs (.001” tolerance) — and the outage was not even extended one day.

Repair Play #3RCP Seal Housing Repair

Challenge: Housings damaged Solution: Weld and machineBenefits: Reduced cost; quick response; no outage extension

Before After

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Challenge: Stator wear & tear Solution: Stator rewindBenefits: Reduces operating temperature; reduces cost vs. new stator

Before After

Everything old can be new again. Putting in a brand new stator costs more money — and produces more contaminated waste — than remanufacturing your current stator. Our remanufacturing process reduces the operating temperatures of your stator — increasing insulation life and saving money on power consumption. And we increase the longevity of your stator over a standard industry-supplied rewind.

Repair Play #4Stator Rewind

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Challenge: Primary system leakage Solution: In-situ machiningBenefits: Restores to original specifications; eliminates leakage

Welding Machining

How low can we go? With our AREVA-designed shielded foreign material exclusion (FME) plug, we can provide a low-dose environment for our machinists while maintaining triple-seal protection against foreign material incursion into the primary system. When this plant had a leak through the pump to the casing joint in the primary system, we were able to fix it using our low-dose environment for in-situ machining. The result? No leakage. Original specs restored to the pump. And low dose.

Upgrades& Modifications

Play #5RCP Casing Machining

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Challenge: Shaft wear Solution: Replacement shaftBenefits: Reuse impeller; economical repair; less risk of RCP vibration

Modification Result

When you need to replace a shaft, it often means you need to replace the impeller, right? Not necessarily. You don’t want to replace the impeller when you already know how the old one will perform. With our match machining capabilities, we can match a new shaft to the old impeller — so when you start up your pump there are no surprises.

Play #6RCP Internals Shaft Replacement

Upgrades& Modifications

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Challenge: RCP seal failure Solution: Mobilized field techniciansBenefits: Rapid deployment; rapid repair; saves money

Before After

A plant is down with RCP seal failures. With no time to waste, an expert team of 14 AREVA technicians is mobilized and in containment within 24 hours of notification. And within merely four shifts, the seals were replaced — saving the customer from a lengthy forced outage and minimizing loss of revenue.

Play #7Emergency RCP Seal ReplacementField Service

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Challenge: Loose laminations Solution: Custom tool compresses coreBenefit: Avoids new rotor expense; restores rotor to original condition

Before After

Would you turn back time if you could? How about for your plant rotors? We can restore your rotor to its original operating condition without the addition of materials used as fillers. A “good as new” rotor saves money and man-hours by avoiding costly and time-consuming manual tack-weld repair.

Repair Play #8Rotor Compression

Maintenance & Refurbishment

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Challenge: Wear and tear Solution: Re-engineering and refurbishmentBenefits: Support all OEMs; designed, fabricated, and installed by AREVA

Before After

From the moment of start-up, this plant was plagued by an oil leak issue. Thirty-three years later, one new stator, a redesigned oil lift system and a brand new oil enclosure — designed, fabricated and installed by AREVA — and the leak was fixed. Top that off with a level one coating of safety-related paint performed at the P&MSC, and concerns about meeting Appendix R Fire Protection requirements — gone.

Play #9Main Coolant Pump Motor Refurb & Mod

Field Service

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Challenge: RCP vibration Solution: Vibration specialist deploymentBenefits: Direct on-station inspection; avoid unnecessary outage time

Pump vibration threatens to shut down the plant. Plant decides to replace RCP internals to solve the issue. Within eight hours, AREVA has a vibration specialist and pump advisor on site. The result? Inspection and vibration modeling pinpointed a problem with the RCP motor bearing. No pump internals replacements were needed and 15 days of forced outage time were saved.

Play #10On-Site Vibration Analysis

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Challenge: Unusable spare parts Solution: Decon and repairBenefits: Refurbish to original specs; extensive cost savings

Before After

Even though this plant had RCP internal spare parts, they were unusable because of high contamination levels. After decontamination, an inspection revealed that only the shaft, radial bearing, bolting, impeller and coupling needed to be replaced. The RCP was repaired and reassembled, built to original design specs and ready for installation before the next outage. The rest of the spare parts were refurbished and re-used — a solution that was approximately 40% of the cost of a new pump.

Play #11RCP Decon and Refurb

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AREVA U.S. Pump & Motor ScheduleVisiting Teams: (equipment we service)

• Westinghouse • Reliance• Allis-Chalmers • Flowserve• General Electric • Sulzer• Siemens

RosterProducts•Motors•Pumps•Replacementparts

•Refurbishment•On-siterepairs•Replacementstators

Services•Shipping•Inspection•Statorrewind•Statortesting•Motortesting•Vibrationanalysis•Diagnostics

Solutions•Assetmanagement•Upgradedparts•Equipmentmodification

•Extendedwarranty

•Rotorcompression•Resistanceringreplacement

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AREVA supplies solutions for carbon-free power generation. Its expertise and know-how in this field are setting the standard, and its responsible development is anchored in a process of continuous improvement.

As the global nuclear industry leader, AREVA’s unique integrated offer to utilities covers every stage of the fuel cycle, nuclear reactor design and construction, and related services. The group is also expanding considerably in renewable energies – wind, solar, bioenergies, hydrogen and storage – to be one of the top three in this sector worldwide in 2012.

Every day, AREVA’s 48,000 employees cultivate the synergies between these two major carbon-free

offers, helping to supply safer, cleaner and more economical energy to the greatest number

of people.www.areva.com

AREVA Inc.

For more information, contact your VP, Key Accounts: 3315 Old Forest Road, Lynchburg, VA 24501Tel: 434 832 2723 – Fax: 434 832 3840 – regional.manager@areva.com – www.us.areva.com