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 Best practice for certain tasks; expanding to other uses –Best practice in Engineering and Inspection Explore its use for Flow Accelerated Corrosion

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!

3D visualization 1.Laser scan the actual plant equipment, accurately captures as-built environment 2.Convert scan data into high-fidelity 3D object model 3.Integrate with existing databases 4.Anchor all data, information, and knowledge to the as-built objects VIRTUAL REALITY MODELS OF THE ACTUAL PLANT

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

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

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locations (CMLs) –Testing procedures Procedures are available in 3D, dynamically connected with plant data AVOID OUTDATED LEGACY DRAWINGS, P&IDS, PIPING RECORDS, DATA SHEETS; ELIMINATE NEED TO CREATE NEW ISOMETRICS

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

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

Going beyond…Refinery crude unit

Boiler plant – world’s largest crude oil processing facility

Crude Tower Outlet…

Piping run to/from crude tower

From this…

To this…

EPRI Recommendations for 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!

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

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