[PPT] - EDF TRAINING TO MNER CHARACTERISE AND MAINTAIN THE MEASUREMENT PowerPoint Presentation

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EDF TRAINING TO MNER

CHARACTERISE AND MAINTAIN THE MEASUREMENT CHAIN

JULY 2017

EDF Thermal Generation & Engineering Division

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1.

Characterise and maintain the measurement chain

EDF I 07/2017

1 Introduction 2 Characterise a measurement chain 3 Maintain a measurement chain 4 Example of organisation in a powerplant

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INTRODUCTION ~ 48(1) GW

Cédric CHALAUD (cedric.chalaud@edf.fr)

 5 years in a dispatching  5 years Instrumentation and control in a Powerplant in Germany (EnBW)  5 years engineering and maintenance I&C for the nuclear powerplant  4 years Maintenance Instrumentation & Control (I&C) for the thermal powerplant

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INTRODUCTION

Definition of a measurement chain Sensor I/O Card Monitoring

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INTRODUCTION

How to define a measurement chain : Define a measurement chain = define the process which is followed

 The hardware architecture of the measurement chain is a compromise between  Availability of the measurement (how long and how often is it acceptable to have a no

“acceptable” data)

 Easiness to maintain  Price (conception and maintenance)

With this compromise, we can define the acceptable time to detect and solve a default (MTR)

 For the process, determine the acceptable level of uncertainty for the measurement

(Quality of the measurement). That’s mean the difference between the real value and the value read

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2.

EDF I 07/2017

Characterise and maintain the measurement chain

1 Introduction 2 Characterisation of a measurement chain 3 Maintain a measurement chain 4 Example of organisation in a powerplant

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1) Hardware Architecture : one sensor for the measurement 1 sensor out STOP Sensor 0 sensor out OK Sensor

Advantages :

Easy to install
Cheap

Inconveniences :

Bad rate of disponibility
Not suitable for a safety system

=> Repair OK

CHARACTERISATION OF A MEASUREMENT CHAIN

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1) Hardware Architecture : 2 sensors for the measurement 0 sensor out OK Sensors 1 sensor out => Priority availability OK Sensors 2 sensors out Sensors

=> Repair OK => Repair OK

=> Priority security

CHARACTERISATION OF A MEASUREMENT CHAIN

Advantage:

Suitable for a best rate of

disponibility or security Inconvenience :

Not suitable for a best rate of

disponibility and security STOP

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1) Hardware Architecture : 3 sensors for the measurement Sensors 0 sensor out => Priority availability => if 2003 values = => OK Sensors 1 sensor out => Priority security => if 2002 values = OK 2 sensors out Sensors

CHARACTERISATION OF A MEASUREMENT CHAIN

Advantage:

Suitable for a best rate of

disponibility and security Inconvenience :

Price

STOP => Repair OK => Repair OK

=> if 2002 values ≠

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CHARACTERISATION OF A MEASUREMENT CHAIN

1) Hardware Architecture : Important parameters for the sensors

Process to follow

Temperature
Pressure
Flow
Level

Parameters of the process

Temperature (normal, minimum, maximum)
Pressure (normal, minimum, maximum)
explosive atmosphere (yes / no) => ATEX
Security Level required (SIL)

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CHARACTERISATION OF A MEASUREMENT CHAIN

1) Hardware Architecture : Important parameters for the sensors

Range

Difference between the maximum and minimum value of the sensed parameter

Resolution

The smallest change the sensor can differentiate.
For digital sensors, it is related to number of bits used
For analog sensors, it is limited by low-level electrical noise

Sensitivity

Ratio of change in output to a unit change of the input

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CHARACTERISATION OF A MEASUREMENT CHAIN

1) Hardware Architecture : Important parameters for the sensors

Linearity

Percentage of deviation from the best-fit linear calibration curve

Zero offset

A nonzero value output for no input

Zero Drift

The departure of output from zero value over a period of time for no input

Accuracy

Inversely proportional to the error
Sometimes related to the sensor’s linearity

Precision

Ability to reproduce repeatedly with a given accuracy
Sometimes called repeatability

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CHARACTERISATION OF A MEASUREMENT CHAIN

1) Hardware Architecture : Important parameters for the sensors

Accuracy and Precision ? Precise but not accurate Accurate but not precise Neither precise nor accurate Precise and accurate

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CHARACTERISATION OF A MEASUREMENT CHAIN

1) Hardware Architecture : Important parameters for the sensors

Deadband

The range of input
for which there is no output

Saturation

Maximum output capability,

regardless of input

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CHARACTERISATION OF A MEASUREMENT CHAIN

1) Hardware Architecture : Important parameters for the sensors

Availability

Cost
Size and available space
Ease of use
Ease of maintenance
Required signal processing
Environmental conditions
Power available for sensing

Product to follow

Composition
Density
Viscosity
Concentration

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CHARACTERISATION OF A MEASUREMENT CHAIN

2) Process : Quality assurance for a measurement chain

 The quality assurance take into account the error of a part of the chain :  The whole error is the sum of : Error sensor + Error acquisition + Error Monitoring  This method can be simplify by using only the error of the sensor (in the example, 70% of the

whole error). Sensor

100.7 bar

Error Sensor 0,7%

Acquisition & Processing

100.9 bar

Error Monitoring : 0,1% Error Acquisition : 0.2%

Monitoring

101 bar

Process

100 bar

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2) Process : Define the acceptable error for the process 100 bar 101 bar Sensor I/O Card Supervision Process

CHARACTERISATION OF A MEASUREMENT CHAIN

EDF I 07/2017

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CHARACTERISATION OF A MEASUREMENT CHAIN

After the characterisation of the measurement chain, we can define 4 groups for strategic chains:

Intern
Extern : atmospheric fumes emission

Rules

Protection of the material
Important chains for the process

Material

Material
Human

Safety

Invoice

Contract

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3.

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Characterise and maintain the measurement chain

1 Introduction 2 Characterise a measurement chain 3 Maintain a measurement chain 4 Example of organisation in a powerplant

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1) Introduction : MTR

 Detection (Hardware or Process error) can be divided into two parts  Automatic detection with alarm  Human detection : a technician notices the default  Call : time for the skilled worker to be on site  Reparation : availability of the spare part and duration of the reparation  Test : guarantee that the default is solved

Begin of the default Resolution of the default

Detection Call Reparation Test

MAINTAIN A MEASUREMENT CHAIN

MTR = Time between the begin and the resolution of the default.

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MAINTAIN A MEASUREMENT CHAIN

1) Introduction : Requirement to maintain the chain

Human Organisation Spare parts Skilled workers

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~ 48(1) GW

2) Process : Definitions Verification

 Difference between a reference (calibrator) and the value given by the sensor.

If an error of 1 bar is accepted on the sensor, the sensor is OK .

calibrator indicates 50 bar Sensor read 50,5 bar

MAINTAIN A MEASUREMENT CHAIN

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The sensor error accepted ± 1 bar

EDF I 07/2017

2) Process : Definitions Calibration

 Take back the sensor in this original technical specifications.

After calibration

Calibrator indicates 52 bar Sensor read 50,5 bar calibrator indicates 50 bar Sensor read 50 bar

MAINTAIN A MEASUREMENT CHAIN

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Question : is it necessary to calibrate the sensor ?

Value read on the sensor Acceptable error for the process

MAINTAIN A MEASUREMENT CHAIN

Time

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CHARACTERISATION OF A MEASUREMENT CHAIN

After the characterisation of the measurement chain, we can define 4 groups for strategic chains:

Intern
Extern : atmospheric fumes emission

Rules

Protection of the material
Important chains for the process

Material

Material
Human

Safety

Invoice

Contract

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~ 48(1) GW

Define the check Frequency (example) Follow contract

r rules

Yes

Strategic Sensor ?

No

Contract

r rules?

No check Yes No

Safety (SIL) ?

Yes

Periodical test to maintain the SIL

See annex 1 See annex 2

MAINTAIN A MEASUREMENT CHAIN

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~ 48(1) GW

Define the check Frequency (example)

Periodicity = f(sensor, process)

Important for process

Yes No

More than one sensor ?

Yes

No test

No

Safety (SIL) ?

No

Periodicity = f(sensor, process)

MAINTAIN A MEASUREMENT CHAIN

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We are not allowed to run.

EDF I 07/2017

MAINTAIN A MEASUREMENT CHAIN ~ 48(1) GW

Example : Regulatory measurement chain

Example : monitoring of atmospheric fumes emissions

STOP

Perimeter :

Gas analyser in the chimney (SO2, NO, CO, O2, CO2)
Dust analyser

Control every month :

Calibration of the sensor with a reference gas.
Control and send the sensor’s drift to the authorities
Preventive check (sensor’s temperature and seal)
Change if necessary the filters

Solution

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MAINTAIN A MEASUREMENT CHAIN

Example : Strategic process measurement - regulate the flow of fuel

Goal: Take good decisions in order to protect the material. How to achieve this goal :

Define the critical situations
Clear overview of the system

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MAINTAIN A MEASUREMENT CHAIN

Example : Strategic process measurement - regulate the flow of fuel

Flowmeter 100 t/h read = 100 t/h real (1) (+/- 2%)

regulation Efficiency Clogging boiler

Clogging Airheater

(1) CAUTION :The values

choosen are only an

example. It is not realistic

values.

INITIAL SITUATION

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MAINTAIN A MEASUREMENT CHAIN

Strategic process measurement : regulate the flow of fuel A sensor drift Calibration NO Calibration

WITH THE TIME …

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Strategic process measurement : Calibration

 First case :

a) Control b) Calibration c) Feedback (questions ?)

 The control was not correct  The calibration is made => Flowmeter OK  Question : reduce the time between two controls ?  Question : Is it a general failure for this type of sensor ?

d) Historical

MAINTAIN A MEASUREMENT CHAIN

100 t/h Flowmeter 100t/h CALIBRATOR 100 t/h

NOK : The flowmeter error accepted ±2 %

100 t/h Flowmeter 110 t/h CALIBRATOR 100 t/h

OK

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OK : The flowmeter error accepted ±2%

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Strategic process measurement : Calibration

 Second case :

a) Control b) Calibration not mandatory c) Feedback

 The control was correct.

d) Historical

100 t/h Flowmeter 101 t/h CALIBRATOR 100 t/h

MAINTAIN A MEASUREMENT CHAIN

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MAINTAIN A MEASUREMENT CHAIN

Strategic process measurement : regulate the flow of fuel

Risk of fire Bad thermal exchange

Flowmeter 100 t/h read = 110 t/h real. (+/- 2%)

régulation Efficiency Clogging boiler Clogging Airheater

(1) CAUTION :The values

choosen are only an

example. It is not realistic

values.

Consequence

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MAINTAIN A MEASUREMENT CHAIN

Strategic process measurement

Example of overview

Clear overview.

Flow of fuel oil Alarm

Only for expert on I&C.

Flow of fuel oil

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4.

EDF I 07/2017

1 Introduction 2 Characterise a measurement chain 3 Maintain a measurement chain 4 Example of organisation in a powerplant

Characterise and maintain the measurement chain

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EXAMPLE OF ORGANISATION IN A POWERPLANT ~ 48(1) GW

Rule of each player

 Operator:  Define the acceptable precision for the process (acceptable error)  Engineering:  Define the strategic sensors  Define the check frequency(check frequency)  Save the control report.  Make the feedback  Maintenance :  Check the sensors  Make the control report

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EXAMPLE OF ORGANISATION IN A POWERPLANT

Organisation for the maintenance in Porcheville

Precision for the process Check frequency Intervention Guide Sensor check Make the control report Historical Feedback

OPERATOR ENGINEERING MAINTENANCE

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ANY QUESTIONS ?

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THANK YOU

DPIT I 05/2015

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Annex 1 Example of contrat and rules

 The flowmeter for the quantity of gas must be checked every year (condition of the contract)  The analyser for the gas exhaust must be checked every year (environmental rule)  The sensors which follow the pressure of the boiler must be checked (intern and extern rules)

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Time (month)

SIL 3 SIL 2 SIL 1 SIL 0

Without check, the level SIL 3 is lost Time (month)

Without periodical test With periodical test

Test efficiency 100% Test efficiency 80%

Annex 2 Periodical test to maintain the SIL