Reduce Compressor Maintenance Costs through Online Monitoring - MTA-MA-010

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 3002010057) EPRI Preventive Maintenance Database (PMBD) (EPRI 3002005428) Continuous On-Line Monitoring (COLM): Compressor, Rotary Screw – Oil Flooded and Oil Free (EPRI 3002012779)
Industry SME	EPRI – Mike Taylor EPRI – Richard Pepin 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 are 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 warrants a comprehensive design change process. Implementation depends on experience related to wireless data infrastructure, data transmission for monitoring, and cyber‑security protocols, etc.
Applicability	All reactor types All geographic regions
Keywords	Condition-based maintenance; equipment reliability; online monitoring; compressors; fans; sensors; quick guides
Business Case Analysis Cross-Reference	Plant Modernization Business Case: Monitoring and Diagnostic Program Development (EPRI 3002018424).

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 and early‑life failures of replacement parts. 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 Compressor components and the associated time‑based task intervals that can be replaced, partially replaced, or extended with the use of condition‑based maintenance.

Rotary screw compressors (both oil flooded and oil free) are considered in this MTA. These components require routine inspection and maintenance (e.g., oil analysis and refurbishment) which are historically performed periodically, regardless of operating history. Implementation of compressor COLM could allow for the extension or elimination of existing maintenance activities.

Per EPRI’s Preventative Maintenance Database (PMDB), this MTA does not include monitoring of the following compressor components: air dryers, I&C components, solenoid valves, relays, and safety relief valves.

Benefits

Benefits Estimate

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

Benefits Description

• Reduction of maintenance costs through eliminating or extending PM tasks by transitioning to CBM. As an example, periodic compressor refurbishment could be deferred and periodic internal inspections could be replaced with the combination of online monitoring and alternate PM tasks.
• Improved visibility to the compressor condition and associated system conditions through more frequent data collection and real‑time monitoring. This could allow failure detection prior to occurrence.
• Reduction in maintenance‑induced failures due to less frequent maintenance.
• Reduction of radiation exposure by reducing frequency of instrument calibration and PM tasks.

Costs and Schedule

Cost

Level 3 – Implementation cost is less than $1 million, including approximately 12 high‑value sensors per compressor (e.g., temperature, vibration, etc.), 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 2‑4 non‑safety‑related compressors 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.

Administrative Items

(Administrative details are captured in the MTATemplate above.)