Applying Advanced Technologies to Improve NPP Productivity

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1 Applying Advanced Technologies to Improve NPP Productivity Lew Hanes, Consultant Joe Naser, EPRI Plant Productivity Improvement Through Advanced Technology - Group Kickoff Meeting June 29-30, 2010

2 Presentation Overview Why apply advanced technologies? Aviation and medical case studies Overview of EPRI projects involving advanced technology visualization tools 2

3 Why Apply Advanced Technologies? Make usable huge increase in data/information Sensors Data base access Computers Communications 3

4 Why Apply Advanced Technologies? Help reduce information overload and support decision-making (improve situation awareness; avoid errors: mode, fixation, keyhole, etc.) 4

5 Why Apply Advanced Technologies? Overcome information overload, e.g., visualization technology can show views and relationships not possible otherwise View of Core By 2-D or 2.5-D Picture By 1000 Words? 5

6 Why Apply Advanced Technologies? Workers will be retiring or going to new plants, and incoming and next generation workers will expect this technology - many are using it now 6

Case Study: Applying Advanced Technology in

technology to modernize aviation airspace

Performance (RNP) Many airlines have or will

7 Case Study: Applying Advanced Technology in Aviation Industry FAA implementing NexGen technology to modernize aviation airspace system Performance-Based Navigation (PBN): a key NexGen component providing Area Navigation (RNAV) Required Navigation Performance (RNP) Many airlines have or will upgrade aircraft and procedures to take advantage of this technology 7

via waypoints to point-topoint flights Shown: ORD to

8 Area Navigation (RNAV) Description RNAV enables aircraft to fly any desired flight path: From flights via waypoints to point-topoint flights Shown: ORD to MEM Before RNAV: Via waypoints After RNAV: Point-to-point 8

9 Required Navigation Performance (RNP) Description RNP is RNAV with the addition of Performance monitoring and aircraft control: aircraft track accuracy 10 meters; time of arrival accuracy at any flight point 10 seconds Capability to alert crew to deviations Provides automated descents and approaches After RNP: Automated continuous descent arrival profile Before RNP: Manual drive and dive arrival profile 9

Investment, Cockpit Upgrades, and Other Changes invested $175

cockpits: FMCs, GPS, Displays Before upgrade After upgrade

for 6000 pilots: ground school, flight simulator, PC-based

10 Investment, Cockpit Upgrades, and Other Changes invested $175 million to take advantage of FAA PBN technology Upgraded cockpits: FMCs, GPS, Displays Before upgrade After upgrade Provided automation, procedures, and RNP scenario training for 6000 pilots: ground school, flight simulator, PC-based simulation program Worked extensively with pilots to gain acceptance 10

11 Changed Concept of Operations and Pilot s Role Implementation changed concept of operations from manual to primarily automated flight control Pilot s role and tasks changed From manually flying to programming FMC, monitoring flight conditions and aircraft status, and taking over when needed or wanted Workload reduced, but with potential to lose some alertness and manual skills Manual flying reduced with greater attention to situation awareness and decision-making 11

12 Benefits: Safety, Fuel, and Environment Improved safety benefits Precise guidance reduces risk of hitting obstacles, such as mountains or structures Improved situation awareness results in faster pilot response and fewer errors Fuel consumption and environment benefits Each trip leg reduced by 3 miles (1 minute) saving 88 gallons fuel, 275 lb CO2, 1 lb NOx Test flight showed 6% fuel and CO2 savings 12

13 Benefits: Passenger and Economic Passenger benefits Shorter flight durations Smoother ride due to continuous descent Economic benefits due to annual reductions 90.6 million gallons across fleet with savings of $207 million (based on 4th quarter 2010 cost) CO2 emissions by 1.9 billion pounds $207 million fuel savings will recoup $175 million investment in less than one year 13

14 1- Lessons Learned from Aviation Industry Case Study Consider opportunities for improvement when changes are made (FAA PBN upgrade occurred independent of Southwest Airlines) Identify what is most important that could be achieved (safety and economic gains) Identify and evaluate change options, e.g., Limited ( s only with low costs) Across fleet ( upgrades expensive) User input and buy-in essential but difficult (pilots strongly resisted upgrade at first) 14

15 2- Lessons Learned from Aviation Industry Case Study Many issues must be considered in making decision about actions to take, if any Obtain OE from others (e.g., Alaska Airlines) Conduct tests to develop data (e.g., flight) Identify positive and negative impacts (e.g., on safety--loss of manual skills, alertness) Identify and evaluate required infrastructure changes and impact (e.g., training, procedures) Perform cost-benefit and ROI calculations 15

Case Study: Applying Advanced Technology in Medical Industry Medical industry introducing many new systems incorporating advanced technology Most systems extremely beneficial for patients, but some

16 Case Study: Applying Advanced Technology in Medical Industry Medical industry introducing many new systems incorporating advanced technology Most systems extremely beneficial for patients, but some may create new avenues for errors, with devastating consequences New York State analyzed 621 incidents ( ) involving radiotherapy systems Radiation missed all or part of target: 46% of cases Wrong dose administered: 41% of cases Wrong patient involved: 8% of cases 16

17 Serious Incident with Varian Linear Accelerator System Automated system delivers Intensity- Modulated Radiation Therapy Computer-controlled X-ray accelerators distribute precise radiation doses to malignant tumors Radiation delivery pattern determined by software that performs optimization and treatment simulation Customized radiation maximizes tumor dose while protecting surrounding normal tissue resulting in better tumor targeting and lessened side effects System uses smart-beam technology provided by 120 computer-controlled metal leaves (multileaf collimator) to shape and modulate radiation beam 17

18 Preparing Linear Accelerator System Medical physicist has key responsibilities Creates treatment plan based on radiation oncologist prescription o Programs and saves instructions: beam radiation dose, treatment area digital image, instructions that guide multileaf collimator o Checks machine calibration, verifies correct dose delivered to proper location, system safety o May run test before treatment to verify computer programmed correctly (customary but not mandatory at hospital where incident occurred) 18

19 Administering the Radiation Treatment Patient typically receives several treatments spread over several days Radiation therapists Prepare patient and position patient on treatment table Operate system from behind shielded enclosure Watch patient on closed-circuit TV during treatment 19

20 Incident Scenario (1) Patient successfully received four treatments for tongue cancer, as prescribed Treatment plan revised to protect patient s teeth Medical physicist created a revised plan Tried to save plan when computer displayed error message asking if changes should be saved before program aborted answer was yes Radiation oncologist approved the new plan During plan revision patient arrived; therapists prepped patient and placed a mask over his face 20

21 Incident Scenario (2) After 30 minutes and two computer crashes several radioactive beams turned on Treatment repeated on each of next two days Medical physicist then ran test to check if patient was being radiated as prescribed Results were horrifying: multileaf collimator that should focus beam on tumor was wide open, and patient received 7 times prescribed dose Patient s entire neck, from base of skull to larynx, had been exposed 21

Incident Scenario (3) Remaining treatments were cancelled, and patient and wife told of serious overdose and that no cure existed Patient given pain

22 Incident Scenario (3) Remaining treatments were cancelled, and patient and wife told of serious overdose and that no cure existed Patient given pain medicine; was barely able to sleep or swallow; and endured incessant hiccupping, vomiting, a feeding tube, etc. Patient died in less than 2 years 22

23 Possible Causes (1) ( guesses based on newspaper reports; official records sealed) Design errors Software required three instructions to be entered in correct sequence and saved; no alert or alarm that input not saved with computer crashes No fail-safe mechanism or alarm--computer sent corrupted commands to control unit resulting in collimator completely open (worst possible position) Organizational errors Did not require treatment plan to be verified as accurate, or radiation therapist to monitor display Inadequate procedures, checklists, and training 23

24 Possible Causes (2) ( guesses based on newspaper reports; official records confidential) Medical physicist human errors Did not verify that instructions successfully saved, or treatment plan accurate before use Continuation bias or press-on-it is perceived time pressure to prepare revised plan since patient being prepped, and radiation oncologist waiting to review and approve plan revision before treatment Radiation therapist (2 present) human error Lack of situation awareness, fixation error therapists fixated attention on patient concerned about him vomiting in mask and choking, and ignored display showing collimator wide open 24

25 Consequences Investigators blamed both hospital for failing to catch the error, and Varian for flawed software New York City fined hospital $1,000, and financial settlement negotiated with family Radiation oncologist no longer treats patients (case drove him to retire, according to a friend) Extensive media coverage resulting in greatly increased FDA and manufacturer attention (based on this and many similar incidents) Fail-safe design and procedures included by

26 1- Lessons Learned from Medical Industry Case Study Advanced technology may be extremely beneficial, but also may create new avenues for errors, with devastating consequences Manual input often required to program automation, and errors must be found and corrected in advance of system operation Different and sometimes new personnel functions, tasks, and actions may be created resulting from new concept of operations, maintenance, planning New high-risk scenarios may be created based on advanced technology capabilities and applications 26

27 2- Lessons Learned from Medical Industry Case Study OE in other industries can provide valuable insights to consider when applying advanced technology, e.g., new types of errors and how they can be handled Important to apply HFE during all phases of design, evaluation, V&V Important to provide personnel with adequate procedures, checklists, training Should apply recent guidelines applicable to advanced technology rather than traditional guidance alone (e.g., NUREGs 0711 and 0700) 27

Projects Involving Advanced Technology Visualization Tools Graphical visualization period began about 1500 Leonardo da Vinci created first use of visualization as a scientific tool to study a

28 Projects Involving Advanced Technology Visualization Tools Graphical visualization period began about 1500 Leonardo da Vinci created first use of visualization as a scientific tool to study a turbulent flow EPRI began Visualization R&D projects in 2003 Performed demonstrations with three utilities Showed results and obtained feedback from several utilities Free water jet issuing from a square hole into a pool 28

29 EPRI Projects Involving Advanced Technology Visualization Tools Technology supporting visualization allowing a user to interact with and thereby affect results of a computersimulated 3-D real or imaginary environment (in both 2.5-D and 3-D) 2.5-D: Created by perspective renditions 3-D: Created by stereo presentations 29

Facility Evaluation: Callaway Site Control Room Upgrade At Callaway site used VR tools to create photorealistic-appearing control room model showing planned upgrade Evaluated model in both 2.

30 Facility Evaluation: Callaway Site Control Room Upgrade At Callaway site used VR tools to create photorealistic-appearing control room model showing planned upgrade Evaluated model in both 2.5-D (on PCs and screen) and 3-D (in CAVE and on Visi-Wall) Evaluation determined how model might be used, if design met NRC human factors guidelines, etc. Utility personnel took part in evaluation, and identified numerous VR applications 30

familiarization and orientation Successfully applied a tool to evaluate against NRC

31 Facility Evaluation Results Model created quickly and at low cost--3-d CAD file was available Useful for conceptual design, evaluation, and to get feedback Valuable for familiarization and orientation Successfully applied a tool to evaluate against NRC guidelines Very favorable comments about use and value by plant personnel 2.5-D model adequate 31

Possible Benefits: Facility Design and Evaluation Virtual Models Eliminate or reduce need for expensive physical mockups Improve design quality by having virtual model available during conceptual

32 Possible Benefits: Facility Design and Evaluation Virtual Models Eliminate or reduce need for expensive physical mockups Improve design quality by having virtual model available during conceptual design phase Cheaply evaluate alternative designs Obtain user feedback early in design Verify against guidelines, e.g., human factors Not acceptable Evaluate and eliminate design deficiencies in virtual model rather than physical mockup Model may be used almost anywhere to support evaluations, for orientation, etc. 32

33 Work Planning and Training at Comanche Peak Site At Comanche Peak site demonstrated use of 2.5-D VR to support activities in pressurizer room prior to weld overlay work Work planning prior to room preparations Worker orientation and training before entry to prepare room and take radiation measurements Capture undocumented knowledge from experts to make available to others Welder training prior to weld overlay start 33

dose RP techs significantly less dose Reasons for dose avoidance: use for training; to obtain

34 Work Planning and Training Results Models created quickly and at low cost laser scans were available Pressurizer room VR model found cost-effective~$3k benefit Shielding workers~50% less dose RP techs significantly less dose Reasons for dose avoidance: use for training; to obtain data; to plan, e.g., shielding placement Fewer entries into pressurizer Hot spot knowledge 9.5 inch 34

Comments Provided by Site Personnel VR can effectively support outage, facility modification, maintenance and walkdown work planning Especially valuable for parts of the plant Inaccessible with the

35 Comments Provided by Site Personnel VR can effectively support outage, facility modification, maintenance and walkdown work planning Especially valuable for parts of the plant Inaccessible with the plant at power Containing radiation or other contaminants (can reduce or eliminate entries) Congested with equipment, piping, etc., requiring time to find location and take needed actions, e.g., make measurements Model reusable in future with additional benefits 35

Possible Benefits: Work Planning Virtual Models Eliminate or reduce need to enter parts of plant while at power, that contain radiation, are congested, etc.

36 Possible Benefits: Work Planning Virtual Models Eliminate or reduce need to enter parts of plant while at power, that contain radiation, are congested, etc. Obtain information from model to support outage, maintenance, and facility modification planning, e.g., design of shielding, scaffolding Reduce need for walkdowns Take measurements using model Perform equipment interference checks Train workers before entry, e.g., routes, hot spots to avoid Read tag ID Measure 36

37 AOV Maintenance Training at Comanche Peak At Comanche Peak site demonstrated use of 2.5-D to support Air- Operated Valve (AOV) maintenance training 37

38 AOV Maintenance Training Results Model cost high, but reduced to ~$865, if 3-D CAD files available and commercial authoring software used to add interactive features ~5-10% time savings to perform maintenance Reduced rad dose due to less time in room Huge savings possible if can eliminate Physical model used for training Major errors causing power reduction Model may be used repeatedly in future Useful for JIT, instructor and self-training Modelling software 38

Valve Maintenance Training Results Useful for inspection, preventive

Models may include conditions not possible with physical mockups

usable in future at ~ no cost Very useful for preparing for tasks in

39 Valve Maintenance Training Results Useful for inspection, preventive maintenance, repair, and equipment upgrade and removal activities Models may include conditions not possible with physical mockups Models may be used anywhere compatible computer is available Model usable in future at ~ no cost Very useful for preparing for tasks in radiation and difficult access areas Do not need an exact model to train on 39

40 Possible Benefits: Maintenance Training Virtual Models Eliminate need for physical mockups (e.g., valves, pumps); big $ savings Reduce time to maintain and reduce error occurence due to better training Animation shows how to perform actions Links to expertise and documents valuable Reduce exposure, if radiation present Virtual model may be used Almost anywhere providing training flexibility Reused when needed in the future Easily modified when equipment is upgraded 40

for work planning and training prior to weld overlay AOV model for maintenance technician

41 Knowledge Elicitation and Presentation at Comanche Peak At Comanche Peak site demonstrated use of VR models to elicit tacit knowledge from experts to support Pressurizer room model for work planning and training prior to weld overlay AOV model for maintenance technician training Video camera used to capture expert s knowledge while he interacts with virtual model 41

delivering expertise; users liked immediate access by label click Users saw value in ease of adding expertise and links to

42 Knowledge Elicitation and Presentation Results, and Possible Benefits Very effective and low cost tool for capturing and presenting valuable knowledge (~$900) Stimulated recall of valuable tacit knowledge not recalled with traditional methods Valuable for delivering expertise; users liked immediate access by label click Users saw value in ease of adding expertise and links to additional information sources Video delivery very well liked users could see and hear expert (preferred to written material) 42 High dose sources

completed showing endpoint vision Use models to visualize, interact, and evaluate plans before implementation

43 Current Power Plant VR Applications: Fort Calhoun Nuclear Power Plant Plant is planning to upgrade control room, and create four virtual models Current control room After two intermediate upgrades After upgrade completed showing endpoint vision Use models to visualize, interact, and evaluate plans before implementation Orient personnel to planned changes Obtain input about potential design problems Support finalizing interface specification 43

Possible VR Uses Identified by Nuclear Utility Personnel Listed in EPRI 1011303 Training and education in plant fundamentals Maintenance training and support Design and evaluate new and upgraded

44 Possible VR Uses Identified by Nuclear Utility Personnel Listed in EPRI Training and education in plant fundamentals Maintenance training and support Design and evaluate new and upgraded facilities Minimize exposure to radiation and other undesirable conditions Support capture and delivery of valuable worker knowledge Virtual tours and route planning, e.g., first time outage workers 44

Possible Additional VR Uses NDE training and testing

teams Support collaboration between sites Virtual

core visualization Personnel radiation tracking and

45 Possible Additional VR Uses NDE training and testing Virtual training for security and emergency response teams Support collaboration between sites Virtual maintenance and task proficiency evaluation Reactor core visualization Personnel radiation tracking and monitoring View and evaluate facility construction plan over time 45

46 Some Lessons Learned Choice of 2-D, 2.5-D or 3-D depends on task and user visualization needs Less costly 2.5-D adequate for most nuclear applications, but 3-D cost Cost of developing VR models Benefit Low, if 3-D CAD files or laser scans available, and commercial authoring software used High, if modeling software used to create 3-D files Important to perform cost-benefit analysis to determine if VR is justified Cost 46

Some Criteria for Selecting Tasks Justifying VR Use Large economic and/or safety benefits, if user performance improved (less work time, dose, probability of error, etc.

47 Some Criteria for Selecting Tasks Justifying VR Use Large economic and/or safety benefits, if user performance improved (less work time, dose, probability of error, etc.) Human performance is a problem Many Tasks Screen Select ones with most value Task requires visualization and human performance improved with VR Virtual models produced at acceptable cost Cost/ benefit justification for providing VR Need to train new workers and outage workers Utility has infrastructure to support VR use 47

48 Questions? 48

Application Note. ipix A Gamma imager to support various applications. Introduction. An easy to carry and deploy instrument

Application Note. ipix A Gamma imager to support various applications. Introduction. An easy to carry and deploy instrument Application Note ipix A Gamma imager to support various applications Introduction ipix is a unique gamma imager that quickly locates low level radioactive sources from a distance and estimates the dose