Reduce Pump Maintenance Costs through Online Monitoring - MTA-MA-009

Administrative Items
Date	12/15/2020
Functional Area Where Benefits Will Be Realized	Maintenance Engineering
Reference Implementation Guidance	Online Monitoring Guide for Equipment Diagnostics and Reliability— Nuclear Generation (EPRI 3002010577) EPRI Preventive Maintenance Database (PMBD) (EPRI 3002005428) Continuous On-Line Monitoring (COLM): Vertical Pump, Vertical – Deep Draft – Radial Flow – Product Lube (EPRI 3002012763) Continuous Online Monitoring (COLM): Horizontal Pumps, Horizontal – Multistage – Split Case Pump (EPRI 3002012768) Continuous Online Monitoring (COLM): Horizontal Pumps, Horizontal – Single Stage – Single Suction (EPRI 3002012769) Continuous Online Monitoring (COLM): Positive Displacement Pump (EPRI 3002012773) Continuous Online Monitoring (COLM): Horizontal Pump, Horizontal Pump – Multistage – Barrel Type (EPRI 3002012780) Continuous On-Line Monitoring (COLM): Horizontal Pumps, Horizontal – Single Stage – Double Suction (EPRI 3002013864)
Industry SME	EPRI – Mike Taylor Contact: NuclearPlantMod@epri.com
Previous Implementation	Please contact EPRI for implementation examples and contacts.
Implementation Enablers	MTA-MA-003 - Implement Wireless Network Infrastructure Using a Distributed Antenna System (DAS) MTA-MA-004 - Implement Wireless Network Infrastructure Using WiFi
SWEEP Score	Cost – Level 3 – procurement and installation of wireless sensors in combination with other software and infrastructure necessary should be limited to $1 million or less. Savings – Level 1 – Savings achieved through the changes in PMs are generally expected to be $1 million or less. Payback – Level 2 – Based upon estimated cost and savings information, the payback period would be between one and five years. Licensing Readiness – Level 3 – This technology has already been implemented at nuclear power plants and requires no licensing changes if associated changes do not affect safety‑related functions. Technology Readiness – Level 3 – The technology is ready for wide operational deployment. Advanced OLM programs have been implemented in fossil generation and at nuclear facilities. Implementation Proficiency – Level 2 – The implementation of this technology is site‑specific and may warrant a comprehensive design change process. This depends on experience related to wireless data infrastructure, data transmission for monitoring, cyber‑security protocols, etc.
Applicability	All reactor types All geographic regions
Keywords	Condition-based maintenance; equipment reliability; online monitoring; pumps; sensors; quick guides
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 preventative maintenance (PM) to condition‑based maintenance (CBM), 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 pump components and the associated time‑based tasks that can be replaced, partially replaced, or have their intervals extended with the use of condition‑based maintenance.

Pumps considered in this MTA are various vertical, horizontal, and positive displacement pumps. These components require routine inspection and maintenance (e.g., boroscopic inspection and refurbishment) which are historically performed periodically, regardless of operating history. Implementation of pump COLM could allow for the extension or elimination of existing maintenance activities. COLM of essential pumps can protect plant health due to their critical functions and high energy consumption (e.g., circulating water pumps).

The MTA excludes: Motor, Motor/pump coupling, Seal water injection systems (if applicable), and External bearing cooling systems (if applicable).

Benefits

Benefits Estimate

Level 1 – Savings associated with one unit implementing pump COLM are less than $1 million per year from reducing or partially eliminating PM tasks.

Additional benefits (> Level 1) may be experienced if COLM aids in successfully avoiding a component failure.

Benefits Description

• Reduction of maintenance costs through eliminating or extending PM tasks by transitioning to CBM. As an example, boroscopic inspections and refurbishment could be done based on pump condition as opposed to set intervals.
• Early detection of pump degradation (e.g., packing or seal wear), resulting in reduced equipment forced outages and corrective maintenance (CM) costs.
• Improved visibility to the condition of the pump(s) and associated system(s) through more frequent data collection and real‑time monitoring.
• Maintenance error reduction in the form of avoided costs.
• Reduction of radiation exposure by reducing frequency of instrument calibration.

Costs and Schedule

Cost

Level 3 – Implementation cost is less than $1 million, including sensors (up to 30 sensors recommended for each pump), installation, and software. This cost can be shared site or fleet‑wide if other components implement OLM.

Schedule

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

Scope Context

The scope of the cost and benefit estimates assumes 40 pumps per unit. Efficiencies gained from larger deployments, such as multi‑unit sites, will increase savings.

Risks

IT risks associated with integrating the existing plant network infrastructure, data storage, and 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 cost.