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Costantino Lanza, CEO INOVx Solutions, Inc.

3-D visualization streamlines flow-accelerated corrosion and other nuclear plant inspection programs. Costantino Lanza, CEO INOVx Solutions, Inc. Introduction. 3D as valuable component of plant operations and maintenance Improves asset management

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Costantino Lanza, CEO INOVx Solutions, Inc.

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  1. 3-D visualization streamlines flow-accelerated corrosion and other nuclear plant inspection programs Costantino Lanza, CEO INOVx Solutions, Inc.

  2. Introduction • 3D as valuable component of plant operations and maintenance • Improves asset management • Best practice for certain tasks; expanding to other uses • Best practice in Engineering and Inspection • Explore its use for Flow Accelerated Corrosion

  3. Flow-Accelerated Corrosion (FAC) • Major cause of catastrophic piping failures at power stations • Mitigation programs includes standardized, formal, and rigorous inspection and documentation for nuclear units • FAC susceptibility and severity has been correlated to geometry and “flow singularities” • expansions, contractions, orifices, tees, & elbows Physical context is critical!

  4. 3D visualization • Laser scan the actual plant equipment, accurately captures as-built environment • Convert scan data into high-fidelity 3D object model • Integrate with existing databases • Anchor all data, information, and knowledge to the as-built objects Virtual Reality Models of the actual plant

  5. Getting to 3D As-built / As-is 1 Globally Registered Point cloud Individual Laser Scans Survey Grid Model As-designed 2 CAD Model

  6. Petroleum Refinery example Risk-based inspection at National Cooperative Refinery Association (McPherson, Kansas) • 85,000 Bbl/day processing facility • 50% of the facility in 3-D models • Entire piping circuits are assessed “as a system” • Number of inspection points reduced by 50%, inspection hours reduced by 20-30% • Being integrated into CMMS, DCS, condition monitoring system, and outage planning processes and procedures • Improved compliance with OSHA, API standards Improve plant reliability and utilization

  7. Streamlined Inspections • Inspection teams receive a booklet with everything they need to inspect a circuit • Location • Piping • Test routines • Thickness monitoring locations (TMLs) • Corrosion monitoring locations (CMLs) • Testing procedures • Procedures are available in 3D, dynamically connected with plant data • AVOID OUTDATED LEGACY DRAWINGS, P&IDS, PIPING RECORDS, DATA SHEETS; ELIMINATE NEED TO CREATE NEW ISOMETRICS

  8. Potential Benefits for Nuclear Plants • Reduced worker RAD exposure in the field by reducing inspection hours • Improved insurability profile • Improve accuracy of CFD predictive codes • Avoid interpolating from approximate 2-D models • Direct access of data from FAC management software • Color code to show trouble spots, hot spots, etc. • Avoid use of generic models for components • Moisture separator reheaters • Inlet/outlet piping headers • Condensers Improve ANALYSIS; perform IT safely

  9. Illustration Benefits Color-coded piping circuit • Higher FAC susceptibility shown as higher temperature colors • Intuitive understanding of spatial extent of FAC • Better communicate threats and recommendations • Suggest solutions – e.g., eliminate short-coupled ells, change geometry of piping junction, increase size of the combined line

  10. Going beyond…Refinery crude unit

  11. Boiler plant – world’s largest crude oil processing facility

  12. Crude Tower Outlet…

  13. Piping run to/from crude tower

  14. From this…

  15. To this…

  16. EPRI Recommendationsfor FAC programs • Ease training of backup personnel and maintain continuity of program when experts are lost to attrition and retirement • Formalize sharing of data – ensure all staff operate from same “picture of reality • Ensure high level of quality assurance in documenting procedures and preparing tasks • Facilitate periodic review of all phases of the program • Simplify management practices by which analyses, predictive models, and documentation are kept current • Facilitate updating or revalidating records 3D Visualization assists with all the above!

  17. Summary • 3D technology emerging as best practice • Already proven in other industries • Many uses and applications • Flow Accelerated Corrosion management and analysis greatly improved with 3D • All aspects of physical asset management improve with 3D visualization

  18. Questions? • Contact me at: clanza@inovx.com

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