Ageing Management, In Service Inspection and Exceptional Maintenance D. Dallery J.J. Nicolay (Nuclear Operations Division, EDF - France) 1
EDF PWR Fleet EPR site Gravelines Penly Paluel Flamanville St-Laurent Chinon Chooz Cattenom Nogent Fessenheim Dampierre Belleville Type Power Number Color CP0 CP1-2 900 MW 34 P 4 P 4 1.300 MW 20 N4 1.500 MW 4 EPR 1.600 MW 1 Civaux Bugey Blayais St-Alban Cruas Golfech Tricastin 2
EDF Generation Capacity in France Capacity (101 GW) 2006 Generation (485 TWh) 2006 Hydro 20 GW 20% 17% Thermal 18 GW Hydro 40 TWh 8% 4% Thermal 17 TWh 63% 88% Nuclear 63 GW Nuclear 428 TWh More than 95% electricity output is CO2 emission free 3
Life Time Management and maintenance policy NPP Maintenance Policy Objective Objective Objective Safety Level Improvement Nuclear Generation Competitivity Improvement Life Time Management (40 years and more) 4
Fields of maintenance CONTENTS ROUTINE MAINTENANCE (corrective & preventive) OPERATIONAL EXCEPTIONAL MAINTENANCE ANTICIPATION EXCEPTIONAL MAINTENANCE 5
Routine Maintenance Organization Maintenance Preventive Maintenance Corrective Maintenance Predetermined Maintenance Systematic replacement Lubrication Routine maintenance Condition Based Maintenance Monitoring External Inspection Internal Inspection Compliance tests Overload tests Reliability Centered Maintenance helps to select Maintenance strategy 6
Routine Maintenance : Health Check-up I& C and Electrical param eters m onitoring Chemical analysis M echanical parameters m onitoring (vibrations ) Experience feedback (previous inspection) HEALTH CHECK-UP M aintenance Schedule O peration D ata C ollection Trend analysis (1st level) O peration Departm ent Post-diagnosis checking Inspection 7
Operational Exceptional Maintenance Operational Exceptional Maintenance apply to generic hazards or degradations concerning the whole Fleet of NPPs or part of it, are decided and planned at national level, are implemented once on a large number of units, deal with high costs and/or industrial impacts, are planned/implemented on several years. Proactive Maintenance Strategies 8
Operational Exceptional Maintenance Examples EXAMPLES OF EXCEPTIONAL MAINTENANCE OPERATIONS Nuclear Island STEAM GENERATORS Replacement (600 MA tube bundle) from 1990 to 2016 RV HEAD Replacement from 1993 to 2009 RHR PIPING TUBES Replacement from 1999 to 2001 1300 MWe DEG CHILLERS Conversion in 2005-2006 ConventionaI Island TURBINE LP ROTOR Refurbisment 900 MWe till 2018 (including power uprate) CONDENSER Replacement from 1990 to 2015 GENERATOR STATOR Rewinding or Replacement from 2005 to 2025 Cooling Source SAFETY Upgrading and PUMPING STATION EQUIPMENTS Renovation 9
RVH Replacement Program 6 60 5 50 10 Number/Year 4 3 2 1 0 1 9 9 1 1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 900 1300 Total Projection 1 9 9 7 1 9 9 8 1 9 9 9 2 0 0 0 2 0 0 1 2 0 0 2 2 0 0 3 2 0 0 4 2 0 0 5 2 0 0 6 2 0 0 7 2 0 0 8 2 0 0 9 After Bugey 3 event in 1991 (leakage during Hydrotest on RVH adapter), replacement of all RVHs equipped with Alloy 600 adapters 40 30 20 10 0 Total Number
I&C systems long-term maintenance strategy 1999 2 nd 10Y 3 rd 10Y 4 th 10Y 2009 2019 First Of Kind First Of Kind First Of Kind R2C Project 1993/1995 OVCC VD3 Project 2002/2003 OVCC VD4 Project 2011/2012 Progressive renovation according to periodic I&C ageing review («R2C», «OVCC») Strategic stock of spare parts (for several decades) Close relationship with I&C Suppliers (Durability contracts) 11
Anticipation Exceptional Maintenance Objective : To anticipate ageing phenomena and to be ready to repair or replace components Examples : Inspection and replacement of CVCS charging line nozzle (anticipation of Thermal Fatigue in mixing zone) Reactor Vessel BMI penetration repair (anticipation of PWSCC in Alloy 600 zone) Insurance Files 12
Anticipation Exceptional Maintenance Destructive examination of Fessenheim 1 CVCS nozzle 13
In Service Inspection Objectives In depth defense : To confirm analysis results showing absence of risks (example : circular welds of main primary pipes) Potential ageing phenomena detection : To detect degradation at the earliest stage on zones identified at risk (examples : mixing zones, turbine blades, Alloy 600 RV BMI penetrations) Ageing phenomena management : To detect and characterize ageing defects (example : PWSCC on Alloy 600 RVH penetrations, FAC on carbon steel pipes) 14