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FeaturesIntegrated Valve MaintenanceConcept at NeckarAt Germany’s twin-unit NeckarNuclear Power Station, themaintenance of motor-operated valves(MOVs) is particularly crucial to plantoperation. In the past, MOVs wereinspected and overhauled at fixedintervals (determined on the basis ofoperating experience) and accordingto detailed maintenance specifications.The Integrated Valve MaintenanceConcept now being employed atNeckar is founded not only on soundequipment design but also on baselinemeasurements taken during initialplant startup and subsequentmaintenance work as well as on theresults of systematic data analysis andtrending. The specialists in the outageplanning department and mechanicalworkshop who are responsible forMOVs at both power plant units haveachieved a very high level of operationalreliability using this approach.The joint efforts undertaken by theplant operator GemeinschaftskernkraftwerkNeckar GmbH (GKN)and Framatome ANP in developingand installing SIPLUG ® onlinevalve diagnostics modules at Neckarpursued the following objectives:• Cost reduction through optimizedmaintenance and deploymentof a standardized monitoring system• Prompt detection of anomaliesvia trending• Faster data analysis thanks toautomatic online evaluation• Better and quicker fault analysesdue to continuous data acquisition• Consideration of current processparameters (flow, pressure anddifferential pressure).The development of a drawout-typediagnostics module was only possiblethrough close cooperation betweenvarious departments at GKN andFramatome ANP. Significant extensionsand modifications to the existing plantsystems were required to integratethe SIPLUG online diagnostics systeminto the plant’s two units. Newinfrastructure had to be installed tocarry the necessary cables to theswitchgear modules, and the existingdiagnostics network also had to beexpanded. For processing and storageof the new data, additional computers(PCs) had to be integrated into thediagnostics network and long-termarchiving capacity increased.To manage the 1,500 onlinediagnostics modules that are to beinstalled at Neckar I and II, GKN andFramatome ANP developed a newsoftware program called “SIPLUGExplorer”. The program provides aneasy-to-generate uninterruptedMultilevel safety concept at Neckar Nuclear Power Station18 Advanced Nuclear Power N O 9 November 2003
overview of conditions throughout thedata acquisition system. Modules fromwhich there are currently no “signs oflife,” as well as malfunctioning ortemporarily deactivated modules, arespecially tagged, thus enabling modulefailures to be detected promptly.Another requirement to be met by themonitoring system was that measureddata be evaluated directly at their officePCs by the specialists responsible. Dueto the particular safety concerns ofa nuclear power plant, special measureshad to be taken in connection withnetwork topology, equipment hardwareand software infrastructures. Thefirst such step, for example, involvedseparating data acquisition and preprocessingfrom data storage. Users canonly access data that have been storedin a dedicated file server separate fromthe data acquisition system. The nextstep was to provide a separate PCon which the ADAM ® valve diagnosticsand evaluation software was installed.Authorized users can connect to thiscomputer from their office PCs througha firewall and use ADAM to analyzedata. Instead of downloading actualplant data, however, users only receivea graphical simulation of the applicationalong with the associated keyboardand mouse inputs. This ensures thatdata acquisition remains completelyseparate from data analysis.Moving TowardsCondition-BasedMaintenanceThe deployment of Framatome ANP’sADAM valve diagnostics and evaluationsoftware, together with Neckar-specificsoftware components for automatic dataanalysis, is paving the way for a transitionto condition-based maintenance. Thetrial run of the 200 SIPLUG modulesalready installed is progressing toeveryone’s satisfaction, data acquisitionis stable, transfer of old data has beencompleted and gradual progress is beingmade with data evaluation and trending.Qualification of the ADAM softwareand the plant-specific components isexpected to be finished by the end of2003. The last phase of the project willentail installing 1,500 SIPLUG modulesat the Neckar plant. ■DepartmentsNews in BriefJeumont CRDMs ReceiveN-Stamp CertificationCRDMs in the Jeumont S.A.workshop.SUSI to the RescueAuthors: Robert Friedl, engineer,department of mechanicalengineering, valves; RobertPantle, engineer, departmentof electrical engineering,actuators; Mathias Stein,physicist, department ofelectrical engineering, diagnostic.All are with the Neckar NuclearPower Station.Jeumont S.A., a Framatome ANPmanufacturing facility specializing incontrol rod drive mechanisms (CRDM)and reactor coolant pumps and motors,obtained the N-Stamp certification inDecember 2001. The first CRDMsmade to the ASME code were completedin June 2003 and accepted by the AIA(Authorized Inspection Agency), anorganization responsible for certifying thecompliance of the manufactured equipment,and by the American customer.The equipment bears the N-Stampand was shipped at the end of June.The N-stamp certification is animportant milestone for Jeumont S.A.A large proportion of their CRDMsare manufactured for the US market.In the course of this year’s annual refueling outage at Germany’s 1370 MWBrokdorf PWR plant, a Framatome ANP competitor that had been contractedto visually inspect the reactor coolant pumps and reactor coolantpiping from the inside was unable to inspect all areas of the reactor coolantpiping using the equipment at its disposal. Framatome ANP, contacted by theplant operator and inspection contractor, responded quickly and efficientlyto immediately deploy its service-proven underwater inspection vehicle “SUSI”to the plant. The results of the inspections performed with SUSI wereaccepted at once by both the independent inspectors and the authorities with noresulting delay in the outage time schedule. The operator of Brokdorf issueda special thanks to Framatome ANP for coming to the rescue so quickly .Advanced Nuclear Power N O 9 November 2003 19
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