On with Long Time Performance · 2019. 10. 22. · Functional Classes A, B, C According to DSTU IEC 61226:2007. Transmitters Correspond the Requirements for 1E Class Equipment EMC

On‐line Monitoring and Experience with Long Time Performance of Safety Related Pressure and Differential Pressure Transmitters

in Ukrainian Nuclear Power PlantsDr. Sergiy Lebedynskyy, Priv. JSC „Manometr‐Kharkiv“

TRADITIONAL INTERNATIONAL NUCLEAR CONFERENCEBULGARIAN NUCLEAR ENERGY – NATIONAL, REGIONAL AND WORLD ENERGY SECURITY

7th June – 9th June, 2017, Riviera Holiday Club, Varna



Experience with Long Time Performance of Safety Related Pressure and Differential Pressure Transmitters in Ukrainian Nuclear Power Plants

Pressure Transmitter Sapphir‐22Was Developed by Moscow Institute Teplopribor in the Middle of the 1980s. Is Still Used in Many NPP’s of Russia, Ukraine, Bulgaria, Czech Republic, Slovakia etc.

Sensing Element: Silicon‐On‐Sapphire Lever Scheme of the Measuring Block in Differential Pressure Transmitters

Pressure Transmitter Manufacturers in the USSR:

“Manometr” (Moscow)‐Leading Manufacturer “Teplopribor” (Ryazan)“Pribor” (Tchelyabinsk)“Teplocontrol” (Kazan)

Historical Background

Goal: Development of a New Modern Pressure Transmitter for Ukrainian Market

Ukraine: 4 NPPs, 15 Units

Rivne NPP

Khmelnitsky NPP

South Ukrainian NPP Zaporizhdzhya NPP




Private JSC «MANOMETR‐KHARKIV»Founded in 1997Specialization: Design, Manufacturing, and Service of Pressure, Level, Flow TransmittersTarget Markets: Nuclear Power Industry, Energy Generating Industry, Metallurgy, Chemistry and Machine BuildingStaff ‐ 100 EmployeesProduction Capacity: >1000 Units Per MonthQuality Management System is Certified According to ISO 9001:2008




Manometr‐Kharkiv in Nuclear Industry

Transmitters «Safir» on the Zaporizhzhia Nuclear Power Plant

Official corporate supplier of the National Nuclear Energy Generating Company "ENERGOATOM" (Ukraine).

• Begin of Cooperation in 2000

• Begin of Supply Since 2001

• New Developments are Coordinated with NNEGC Energoatom and SNRIU, Qualification Tests andExperimental Exploitation at NPP‘s areCompleted

• Quality Control System is Certified by NNEGC Energoatom

• All Nuclear Grade Pressure Transmitters areControlled By Specialists of the Conformity Assessment Body «CERTATOM» Before Shippment

• Annual workshops for NPP personnel




References

UkraineZaporizhzhya NPPRivne NPPSouth‐Ukraine NPPKhmelnytsky NPPMedical Nuclear Reactor at Kharkov Institute of Physics and Technology

Bulgaria Kozloduy NPP

SlovakiaMochovce NPP

ArmeniaArmenian NPP




Manometr‐Kharkiv Activities in Nuclear Industry:

1. Development and Manufacture of Pressure Transmitters

2. Re‐equipment of NPPs with Pressure Transmitters

3. Development and Implementation of Solutions for Pressure Measurement in Accident Environments

4. Service of Pressure Transmitters in Nuclear Power Plants

5. On‐line Monitoring of Pressure Transmitters




Nuclear Qualified Pressure Transmitters SAFIR :

AnalogAccuracy: 0,25% FSTurndown: 1:16Output 4‐20 mA, 0‐5 mAWarranty period 60 months, Inter calibration period 24 months

DigitalAccuracy: 0,1% FSTurndown: 1:16Output 4‐20 mA, 0‐5 mAWarranty period 60 months, Inter calibration period 36 months

SmartAccuracy: 0,05 % FSTurndown 1:40Output 4 – 20 mA, 0 – 5 mA, HART 7.0Warranty period 60 months, Inter calibration period 36 monthsSelf‐diagnostic




Nuclear CertificationTransmitters can be Used Both in Systems of Normal Operation and in Systems Important for Safety.SAFIR Transmitters are Certified for Usage in the I&C Systems as Components with Safety Classes 2, 3, 4 as per NP 306.2.141‐2008, Functional Classes A, B, C According to DSTU IEC 61226:2007. Transmitters Correspond the Requirements for 1E Class Equipment EMC Certified According to IEC 61000‐4‐X; Standards 2,3,4,5,6,9,10,11,12,16,18

Special Solutions Developed for Accident Environments:

Pressure Transmitters Safir‐ACc (LOCA qualified)

Pressure Transmitters Safir with Remote Sensor Design for Harsh Environments

Spent Fuel Pool Level Measurement (Harsh Accident Qualification)

Pressure Transmitter Panels and Valves




Pressure Transmitter LOCA Qualification

Medium: Steam Gas Mixture, 16 g/kg Boron Acid, 3 g/kg KOHMaximal Temperature 150°C, t=30 minMaximal Pressure 5 barThermal and Radiation Ageing Corresponds to 12 Years

Test conditions: T=150 °С and pressure 5.1 bar (abs) during 30 minT = 125 °C and P = 2.3 bar for 180 minT= 115 °C, P = 1.7 bar for 420 min.

0,0

1,0

2,0

3,0

4,0

5,0

6,0

0

20

40

60

80

100

120

140

160

10:34 12:12 14:12 17:08 19:08 21:08

Pres

sure

[bar

]

Tem

pera

ture

[°C

]

Time [h:m] Setup For Modelling LOCA Accident




Safir Transmitter after the Test

SAFIR transmitters have shown operability under the severe conditions, measurement error did not exceed 10% FS (meets the requirements of IEEE Std. 497‐2010).Transmitters restored their initial performance after testing.

Test Result







Design for Harsh Environments with Remote Sensor

Sensor Electronics

Area with normal environmentArea with possible harsh environment

Up to 250 °СRadiation:20 kGy/hour, 72 hours +160 kGy/hour, 9 hoursTID 2,88 MGy

300 m

Spent Fuel Pool Level Measurement




3x Combined sensor module

Up to 25 m deepCable length up to 300 m

Temperature up to 250 °С

Medium density change calculation




Transmitter Panels, Valves

Application conditions:Temperature 300 °СSeismic qualification: 1 category according to ПНАЭ Г‐5‐006Radiation: 20 kGy/h for 72 h, TID 1,44 MGy

Pressure Transmitter Service at NPP







Planned Maintenance Procedure for Pressure Transmitters

• Every Year (Cycle)

• Work Under Time Limit

• Big Quantities of Transmitters (>1000) to be checked

• Procedure: 1. Transmitters are Being Dismounted2. Brought to the Labortory (Another Building)3. Being Checked4. Brought Back5. Installed




Transmitter Characteristics

Accelerated Thermal Ageing+ 80 °С (98 days)Equivalent exploitation term: 30 yearsThe main error of a new transmitter doesn‘t exceed 0,05% FS

0

0,02

0,04

0,06

0,08

0,1

0 5 10 15 20 25 30 35

Main Error [%]

Years

Digital 1

Digital 2

Digital 3

Pressure Transmitters On‐line Calibration Monitoring

Safety ImprovementIncrease of Inter‐Calibration Interval (up to 8 years)Transition to Condition Based Maintenance

Condition Based MaintenanceStandards:

IEC 62385:2007 Nuclear power plants ‐ Instrumentation and control important to safety ‐Methods for assessing the performance of safety system instrument channels

IEC 62765‐1: Nuclear power plants ‐ Instrumentation and control important to safety ‐Management of ageingof sensors and transmitters ‐ Part 1: Pressure transmitters




1. Data Selection, 10 sec Interval. - During the Startup and Shutdown;- Steady State Data, every month, one day data

2. Data Validation3. Data Processing4. Result: the List of Transmitters to be Validated

Online Calibration Monitoring




Pressure and Temperature Transmitters Online Calibration Monitoring. 3 Years Experience




Group name

Rivne NPP-1 Rivne NPP-2

Rivne NPP-4

Khmelnitsky NPP-1

All units

groups transm. groups transm. groups transm. groups transm. groups transm. Pressure over reactor active zone 3 18 3 18 2 6 2 6 10 48 Pressure steam collector 1 10 1 9 2 19 Prassure steam generator 2 12 2 12 4 24 Pressure in pressure compensator 1 4 1 4 2 8 Pressure drop in the main steam

collector 6 32 6 38 12 70

Pressure total 12 66 12 72 3 16 3 15 30 169 Pressure drop Main Circulation Pump 6 48 6 48 8 24 4 16 24 136 Pressure drop active zone 1 3 1 3 Delta P total 6 48 6 48 9 27 4 16 25 139 Water flow to high pressure heatener 1 4 1 4 Water flow to steam generator 1 8 6 18 7 26 Flow total 1 8 7 22 8 30 Pressure compensator level 2 6 2 6 Steam generator level 12 45 8 24 20 69 Level total 12 45 10 30 22 75 Temperature 3 12 3 11 6 23 Total 22 134 28 153 24 88 17 61 91 436

Pressure Transmitters On‐line Calibration Monitoring




‐1

‐0,8

‐0,6

‐0,4

‐0,2

0

0,2

0,4

0,6

0,8

1

03 04 05 06 07 08 09 10 11 12

Δ, кгс/см²

Месяц

PЦT1‐201a1

PЦT1‐201a2

PЦT1‐201a3

PЦTЛ201‐11

PЦTЛ201‐21

РАЭС‐1Канал 8 (давление в первом контуре над АЗ)Режим ‐ нормальная работаВид проверки: ОТКЛОНЕНИЯНачало 17.03.15 00:00Конец _______23:59Допуск 0,5 % от ВПИРабочий диапазон давления: 123..125 кгс/см²

ЧАО "Манометр‐Харьков"

Выполнил Гниденко А.А. "__" _______ 20__Проверил Семенцов Ю.Е. "__" _______ 20__

2015

РЦТ1‐201а1 ‐ Сафир‐2160 №08285456, 2007г (0...160 кгс/см²)РЦТ1‐201а2‐ Сафир‐2160 №07290234, 2007г (0...160 кгс/см²)РЦТ1‐201а3 ‐ Сафир‐2160 №07178207, 2007г (0...160 кгс/см²)РЦТЛ201‐11 ‐ Сафир‐2160 №08299555, 2007г (0...160 кгс/см²)РЦТЛ201‐21 ‐ Сафир‐2160 №08291452, 2007г (0...160 кгс/см²)

‐1

‐0,8

‐0,6

‐0,4

‐0,2

0

0,2

0,4

0,6

0,8

1

03 04 05 06 07 08 09 10 11 12

Δ, кгс/см²

Месяц

PЦT1‐201a1

PЦT1‐201a2

PЦT1‐201a3

PЦTЛ201‐11

PЦTЛ201‐21

РАЭС‐1Канал 8 (давление в первом контуре над АЗ)Режим ‐ нормальная работаНачало 17.03.15 00:00Конец _______23:59Вид проверки: ДРЕЙФ ДАТЧИКОВДопуск 0,5 % от ВПИРабочий диапазон давления: 123...125 кгс/см²



2015


‐1

‐0,75

‐0,5

‐0,25

0

0,25

0,5

0,75

1

20 30 40 50 60 70 80 90 100 110 120 130

Δ, kg

f/cm

2

P, kgf/cm2

PЦT1‐201a1

PЦT1‐201a2

PЦT1‐201a3

PЦTЛ201‐11

PЦTЛ201‐21

РАЭС‐1Канал 8 (давление в первом контуре над АЗ)Начало 26.01.16 00:00:00Конец 26.01.16 15:30:00Режим ‐ПУСКВид проверки: диапазонДопуск 0,5 % от ВПИРабочий диапазон давления: 123...125 кгс/см²


‐1

‐0,75

‐0,5

‐0,25

0

0,25

0,5

0,75

1

20 30 40 50 60 70 80 90 100 110 120 130

Δ, kg

f/cm

2

P, kgf/cm2

PЦT2‐201a1

PЦT2‐201a2

PЦT2‐201a3

PЦTM201‐12

PЦTM201‐22

РАЭС‐1Канал 9 (давление в 1м контуре над АЗ)Начало 27.12.15 16:00:00Конец 28.12.15 09:30:00Режим ‐ОСТАНОВВид проверки: диапазонДопуск 0,5 % от ВПИРабочий диапазон давления:



РЦТ2‐201а1 ‐ Сафир‐2160 Р‐Ф‐И №09837948, 2008г (0...160 кгс/см²)РЦТ2‐201а2‐ Сафир‐2160 Р‐Ф‐И №09767142, 2008г (0...160 кгс/см²)РЦТ2‐201а3 ‐ Сафир‐2160 Р‐Ф‐И №09836947, 2008г (0...160 кгс/см²)РЦТМ201‐12 ‐ Сафир‐2160 №08297489, 2007г (0...160 кгс/см²)РЦТМ201‐22 ‐ Сафир‐2160 №07184959, 2007г (0...160 кгс/см²)

‐2,0

‐1,5

‐1,0

‐0,5

0,0

0,5

01 02 03 04 05 06 07 08 09 10 11

Δ, кг

с/см

2

Месяц

10RA10P207B

10RA10P406B

10RA10P‐422B

10RA10P‐423B

10RA10P‐424B



2014

РАЭС‐1Канал 16 (скорость падения давления в ГПК‐2)Режим ‐ нормальная работаВид проверки: ОТКЛОНЕНИЯНачало 17.01.14 00:00Конец 16.11.14 23:59Допуск 0,5 % от ВПИРабочий диапазон давления: 43...44 кгс/см²Отбраковка: 10RA10P‐422B

10RA10P207B ‐ Сафир 2160 Р‐Ф‐И №07235965, 2007г (0...60 кгc/см²)10RA10P406B ‐ Сафир‐2160 Р‐Ф‐И №06228783, 2007г (0...60 кгc/см²)10RA10P‐422B ‐ Сафир‐2160 Р‐Ф‐И №08346784, 2007г (0...60 кгc/см²)10RA10P‐423B ‐ Сафир‐2160 Р‐Ф‐И №11907176, 2008г (0...60 кгc/см²)10RA10P‐424B ‐ Сафир‐2160 Р‐Ф‐И №11883180, 2008г (0...60 кгc/см²)

‐2,0

‐1,5

‐1,0

‐0,5

0,0

0,5

01 02 03 04 05 06 07 08 09 10 11

Δ, кг

с/см

²

Месяц

10RA10P207B

10RA10P406B

10RA10P‐422B

10RA10P‐423B

10RA10P‐424B



2014

РАЭС‐1Канал 16 (скорость падения давленияв ГПК‐2)Режим ‐ нормальная работаНачало 17.01.14 00:00Конец 16.11.14 23:59Вид проверки: ДРЕЙФ ДАТЧИКОВДопуск 0,5 % от ВПИРабочий диапазон давления: 43...44 кгс/см²Отбраковка: 10RA10P‐422B


‐0,4

‐0,2

0,0

0,2

0,4

0,6

0,8

1,0

0 5 10 15 20 25 30 35 40 45 50

Δ, кгс/см²

Давление, кгс/см²

10RA10P207B

10RA10P406B

10RA10P‐422B

10RA10P‐423B

10RA10P‐424B

РАЭС‐1Канал 16 (давление пара в ГПК‐2)Начало 24.12.14 00:00:00Конец 26.12.14 23:59:50Режим ‐ОСТАНОВКАВид проверки: диапазонДопуск 0,5 % от ВПИРабочий диапазон давления: 43...44 кгс/см²Отбраковка: 10RA10P‐422B




‐1,6

‐1,2

‐0,8

‐0,4

0

0,4

0,8

1,2

1,6

‐1,6

‐1,2

‐0,8

‐0,4

0

0,4

0,8

1,2

1,6

0 15 30 45 60

кгс/см

2

%

Давление на входе, кгс/см2

Отклонение по результатам проверки, %Отклонение после регулировки, %Отклонение по результатам мониторинга, кгс/см2

10RA10P‐422Bдорегулировки

ϒ=1,43%

Pressure Transmitters Online Calibration Monitoring




2,8

2,9

3

3,1

3,2

0 0,2 0,4 0,6 0,8 1

p [kPa]

t [s]

RAMP Test

ReferenceSAFIR analog

15 ms

P P

63,2 %

t tτ

Response Time Measurement RAMP Test in Laboratory




t

P

Response Time Measurement. Noise Analysis. Dynamic Data Collection







Dynamic Data Collection Analysis Summary for Khmelnitsky NPP

ITEM TRANSMITTER RESPONSE TIME (SEC)

1 YA20P15B1 0.09

2 YA40P15B1 0.08

3 YA10P15B1 0.08

4 YA30P15B1 0.07

LAB TESTS <0.10







Gathered Facts:

• Existing I&C Systems Allow to Accomplish On‐line Calibration Monitoring

• Existing Regulations Guarantee Safe NPP Operation With Old‐type Transmitters withinstable characteristics.

• Existing Regulations are also Protecting the Executor and the Manager From CriminalResponsibility

• Adaptation of IEC 62385:2007 Nuclear power plants ‐ Instrumentation and control important to safety ‐Methods for assessing the performance of safety system instrument channels

• For the Implementration of Standards on Transmitter Ageing Management ExistingRegulations must be renewed. (As an Example, a Simple Transmitter CalibrationProcedure Needs to Be Changed)

Summary

‐ Since 2001 Manometr‐Kharkiv successfully supplies pressure transmitters to all Ukrainian NPP’s. Over 20 000 transmitters are in operation in NPP 15 Units in Ukraine

‐ Priv. JSC Manometr ‐ Kharkiv has developed a line of technical solutions for pressure and level measurement for applications in PAMS which can be used for any type of NPP renovation

‐ 3‐year experience in On‐line Monitoring and Service of pressure and temperature transmitters in Rivne and Khmelnitsky NPP




THANK YOU!




Documents

On with Long Time Performance · 2019. 10. 22. · Functional Classes A, B, C According to DSTU IEC 61226:2007. Transmitters Correspond the Requirements for 1E Class Equipment EMC