MTA-MA-012

Administrative Items
Date	12/15/2020
Functional Area Where Benefits Will Be Realized	Maintenance Engineering
Reference Implementation Guidance	Continuous On-Line Monitoring: Main Condenser (EPRI 3002012767) Evaluation of Condenser Cleanliness Techniques for Thermal Performance and Condenser Integrity (EPRI 3002018338) EPRI Preventive Maintenance Basis Database (PMBD) (EPRI 3002005428)
Industry SME	EPRI – Kurt Crytzer EPRI – Tim Eckert Contact: NuclearPlantMod@epri.com
Previous Implementation	Please contact EPRI for implementation examples and contacts.
Implementation Enablers	MTA-MA-003 – Implement a Wireless Network Infrastructure Using a Distributed Antenna System (DAS) MTA-MA-004 – Implement a Wireless Network Infrastructure Using WiFi
SWEEP Score	Cost – Level 3 – Implementation costs should be less than $1 million. Savings – Level 1 – Savings are less than $1 million per year. Payback – Level 2 – Based on available cost and savings information, payback period for implementation would be greater than one year but less than five years. Licensing Readiness – Level 3 – Elements of this approach have already been implemented at nuclear power plants. Technology readiness – Level 3 – The technology is ready for wide operational deployment. Advanced OLM has already been implemented at fossil facilities and piloted at nuclear facilities. Implementation proficiency – Level 2 – Implementation proficiency is dependent on site‑specific experience related to wireless data infrastructure, wireless data transmission for maintenance and monitoring, cyber‑security protocols, etc.
Applicability	All reactor types All geographic regions
Keywords	On-line monitoring; main condenser; equipment reliability; condition-based maintenance; quick guides; thermal performance
Business Case Analysis Cross-Reference	N/A

Description

Data acquisition and processing tools have reached the point where Continuous Online Monitoring (COLM) of equipment is possible and cost‑effective. COLM can be used to transition from time‑based to condition‑based maintenance, which reduces maintenance costs by eliminating or reducing premature maintenance activities. COLM also provides valuable insights into equipment health that may help to detect incipient failures before major equipment damage. This MTA applies to the monitoring of main condenser components.

The main condenser cools exhaust steam from a turbine so that it can be returned to the heat source as liquid water. To function properly, condenser components require routine inspection and maintenance (e.g., descaling of condenser tubes). Historically, these inspections and maintenance have been performed periodically, regardless of condenser operating history or expected material condition of condenser tubes and other components. Properly implementing main condenser COLM could allow for the extension or elimination of existing preventative maintenance activities.

For the purpose of this MTA, the boundary of the main condenser is defined as follows per the EPRI Preventative Maintenance Basis Database (PMBD):

Includes:

• Condensers, including waterboxes
• Tubes and Tube Sheets
• Hotwell
• Hotwell Expansion Joint
• Inlet and Outlet Nozzles
• Turbine Exhaust Flange Connection
• Penetration Bellows

Excludes:

• Steam Turbine Expansion Joint or Dog Bone
• Feedwater Heaters
• Waterbox Vacuum Priming System
• Instrumentation
• Exhaust or Suction Piping and Penetrations and Vacuum Pumps
• Cathodic Protection (impressed and passive)

Benefits

Benefits Estimate

Level 1 – Savings for one unit implementing Main Condenser COLM are expected to be less than $1 million per year from reducing or partially eliminating PM tasks. Additional benefits (> Level 1) may come from restored generation due to thermal performance improvements.

Benefits Description

• Potential labor savings for eliminated preventive maintenance (PM) and inspection tasks and interval extension for other PM tasks by transitioning to condition-based maintenance. As an example, condenser tube cleaning could be performed when necessary rather than at a pre-defined interval. As another example, operator rounds could eliminate reading gauges that are continuously monitored with sensors.
• Early detection of equipment degradation, resulting in reduced equipment forced outages and corrective maintenance (CM) costs.
• Improved visibility to asset or system condition through more frequent data collection.
• Reduced risk of equipment unreliability caused by maintenance, because COLM replaces PM items or extends the maintenance interval.
• Improved thermal performance from prioritized, condition‑based maintenance (e.g., tube cleaning) can lead to restored generation. The thermal performance benefit would vary per unit.

Costs and Schedule

Cost

Level 3 – Implementation costs associated with sensors should be less than $1 million (up to 17 types of sensors recommended for each Main Condenser). These costs include the sensors, installation, and software. This cost can be shared site or fleet‑wide if other components implement OLM. Many condenser sensors may already be installed in existing plants.

Schedule

Six months to two years, which includes planning and implementing new sensors.

Scope Context

Per unit, with multiple condensers per unit. Each unit might have 1 – 3 main condensers.

Risks

IT risks associated with integrating with existing plant network, data storage, and analysis software. Addressing IT concerns at the requirements phase of the project (for example, how the sensor data will be gathered and used) will mitigate this risk.

Sensors can vary in implementation difficulty and costs.