ABSTRACT

The project deals with the Reliability and Maintainability analysis of a nuclear power plant. As part of the project we have studied various reliability techniques adopted widely in the industry today. We have studied various components used in a nuclear power plant with respect to failures.

We have first prepared a root cause analysis report as to the various components
We have prepared a RBD which gives us MTBF of components. We have also prepared a failure mode and effect analysis ( FMEA) worksheet to determine the failure of the heat exchanger We have prepared a Fault tree analysis of the Heat Exchanger and the pump. Prepared a preventive maintenance planning for a pump and turbine overhauling using CPM

CONTENT

Introduction
LITERATURE REVIEW PROBLEM DEFINITION RELIABILITY ANALYISIS TECHNIQUES

WORK WE DID
REASONS FOR FAILURE REFERENCES

INTRODUCTION

What is reliability?

Reliability can be defined as the probability that an item will perform its intended function without failure for a specified period of time under stated conditions. Performing a Reliability analysis on a product or system can actually include a number of different analyses to determine how reliable the product or system is.

Need for reliability and maintainability analysis

R&M is a Systems Engineering discipline that provides tools and techniques for: Establishing requirements. Monitoring design and development. Assessing the risk.

Improving Reliability and Maintainability.

Results R&M characteristics affect the continuous delivery of the capability in the field and are major drivers of the cost of ownership through life.

LITERATURE REVIEW
YEAR
1985 1986

AUTHOR
Lincoln and Guba Kurk and Miller

WORK
Neutrality or confirmity, consistancy or dependability applications Identified 3 types of reliabilty referred to in quantitative research

1991
1996 1999 2000 2001 2008

Eisner
Campbell Seale Joppe Patton Dr. Rajiv Kumar Sharma

Stressed on qualititaitive study to understand complex situations

Consistancy of data through examination of raw data Endorsed the concept of dependibility with consistancy and reliability Test Re-test method Validity and reliability are 2 factors to be considered while designing PERT modelling and RAM analysis

PROBLEM DEFENITION

With increasing demand for power supply every year, many countries are resorting to nuclear power as a resource to meet the energy requirements. Keeping in view the high magnitude of life loss that can occur in case of a failure in a NPP, Reliability and Maintainability studies of a nuclear power plant become extremely essential. Market pressures drive management to achieve higher and higher levels of availability and reliability. Our project focuses on studying various reliability and maintainability techniques which can be directly applied to reduce the problem of failures and downtime within the NPP as well as prevent leakages. Enhancing NPP reliability has many advantages. Cost effectiveness can be increased; plant assets management can be improved. Component lifetime can be extended, and leakages can be detected prior to shutdown.

Reliability Analysis Techniques

Techniques used:

RCA Root Cause Analysis

RBD Reliability Block Diagram

FMEA Failure mode and effects analysis

FTA Fault Tree Analysis CPM Critical Path Method

Root Cause Analysis

Root cause analysis (RCA) is a class of problem solving methods aimed at identifying the root causes of problems or events By directing corrective measures at root causes, it is hoped that the likelihood of problem recurrence will be minimized. RCA, initially is a reactive method of problem detection and solving. This means that the analysis is done after an event has occurred. By gaining expertise it became a pro-active method which can be used for forecasting. Methodology - safety-based, production-based, process-based, failure-based, and systems-based.

CONCLUSIONS

Root Cause Analysis (RCA) Root cause analysis (RCA) is a class of problem solving methods aimed at identifying the root causes of problems or events. The practice of RCA is predicated on the belief that problems are best solved by attempting to correct or eliminate root causes, as opposed to merely addressing the immediately obvious symptoms. Using Root cause analysis we have categorized the various failure causes and modes for Heat exchanger and Turbine. Corrosion, tubing, operation above specified limits, lack of proper maintenance, lack of sufficient pre- treatment processes were found to be the main reasons for failure of Heat exchanger and Turbine. (Figures 4.2 and 4.3)

CONCLUSIONS

Fault Tree Analysis (FTA) Fault tree analysis (FTA) is a failure analysis in which an undesired state of a system is analyzed using Boolean logic to combine a series of lowerlevel events. This analysis method is mainly used in the field of safety engineering to quantitatively determine the probability of a safety hazard. The probability of failure of the heat exchanger using fault tree analysis is = 0.099

CONCLUSIONS

Failure Mode and Effect Analysis (FMEA) A failure modes and effects analysis (FMEA) is a procedure in operations management for analysis of potential failure modes within a system for classification by severity or determination of the effect of failures on the system. It is widely used in manufacturing industries in various phases of the product life cycle and is now increasingly finding use in the service industry. Failure modes are any errors or defects in a process, design, or item, especially those that affect the customer, and can be potential or actual. Effects analysis refers to studying the consequences of those failures.
We performed Failure Mode analysis on Heat Exchanger and have found high priority (Risk Priority Number) parts which should be maintained frequently: (Table 4.3.4)

Entry and exit tube sheet RPN = 168

Minimum tube wall thickness RPN = 343 Cooling water inlet flange gasket RPN = 210 Process inlet flange gaskets RPN = 729 (Highest RPN) Plugged tubes RPN = 294 Least RPN=1, was found for process, anode on shell outer diameter.

REFERENCES

D. H. Stamatis (2003) ,The Basics of FMEA, CRC Press, 2nd edition, 2009, PP 90-100 Automotive Industry Action Group (AIAG) (2008), FMEA -4 Potential Failure Mode and Effects Analysis, Fourth Edition, PP150-157 Heat exchangers for High Temperature Thermodynamic cycles. A.P.Frass, Energy Division. Oak Ridge National Laboratory. Charles Ebeling(2004),Reliability and Maintainability engineering, Tata McGraw-Hill. Sadik Kaka and Hongtan Liu (2002). Heat Exchangers: Selection, Rating and Thermal Design (2nd Edition ed.). CRC Press. E.A.D.Saunders (1988). Heat Exchangers:Selection Design And Construction Longman Scientific and Technical

Hewitt G, Shires G & Bott T,(1994) ,Various Types of Gas - Liquid Direct Contact Heat Exchangers
Laszlo Sikos, Jiri Klemes .Reliability, availability and maintenance optimization of heat exchanger network -. Research Institute of Chemical and Process Engineering, Centre for Process Integration and Intensification CPI2, Faculty of Information Technology, University of Pannonia, Egyetem u. 10, 8200 Veszprm, Hungary. J.L Rouvroye, E.G. Van den Bliek(2002) ,Comparing safety analysis techniques,volume 7, issue 3,pages 289-294. Geert Waeyenbergh, Liliane Pintelon ,Maintenance concept development : A case study. Centre for Industrial Management, Catholic University of Leuven, Celestijnenlaan 300A, Heverlee, B-3001, Belgium. K.S Wang, F.S.Hsu. ,Modelling the bathtub shape hazard rate function in terms of reliability - Department of Mechanical Engineering, National Central University, Chung-Li, 32054 Taiwan, ROC. Ramakumar,R(1993): Engineering Reliability: Fundamentals and Applications, Prentice Hall, Upper Saddle River. New Jersey Smith.D.J(1985), Reliability and maintainability in perspective : pratical,contractual,commercial and software aspect , 2n edition, john wiley & sons , New York Zack .S (1982). Introduction to reliability analysis , Springer verlag, New york

THANK YOU!!