Webinar managing instrument obsolence in nuclear edited

© Yokogawa Electric Corporation
Nuclear Industry
Managing Instrument
Obsolescence
Clayton Wilson and Tim Scott

1
Event Logistics
Email Link with
Recording
Shortly after the event, you will receive an email containing
a link to the recording, a slide download, and access to all
resources
Short Survey
As you exit the webinar, you will have the option to
participate in a short survey. Your feedback is very important
to us, so please take a minute to complete
Questions
If you have any questions for this Webinar topic, please
send them to webinars@us.yokogawa.com

2
Presenters
Host
Clayton Wilson
Product Manager, Industrial
Data Acquisition and Control
Clayton.Wilson@yokogawa.com
Gerald Hardesty
Product Marketing Manager
gerald.hardesty@yokogawa.com
Presenter
Tim Scott
Sr. Manager of Nuclear
Engineering and Testing Services
Tim.Scott@nts.com
Presenter

Managing Instrument
Obsolescence
3

© Yokogawa Electric CorporationCopyright © Yokogawa Corporation of America
4
Brief History of Yokogawa
Started as an electric meter
research institute in Tokyo.
First electric meter
in Japan
First portable magnetic
oscillograph in Japan
First electronic
recorder in Japan
1915 1917 1924 1950
1975
World’s first Distributed
Control System (DCS)
‘CENTUM’
1984
Released analog LSI
test system
Entered the high-
frequency measuring
instrument business
with digital oscilloscope
1988 20152012100th
anniversary
Our company has a long history and innovative technologies.

5
World Wide Nuclear Customers
 Yokogawa has a significant footprint in the global nuclear fleet.
Yokogawa Recorders are installed in every US nuclear plant.
Single Loop Controllers
Romania
Controllers, Recorders
Field Instruments
Canada
Recorders
Mexico
Recorders, Controllers,
Field Instruments
USA

6
National Testing Systems
 National Technical Systems (NTS) provides Third Party Qualification testing
and certification for Yokogawa controller, recorder and DAQ products
NTS TPQ program is located in Huntsville, AL
 NTS has provided these services for Yokogawa since 2000
 All qualification questions, product report requests, and product quotation
requests should be sent directly to NTS

Recorder Products

Paperless Recorder Innovation History
8
For the non-stop evolution of your plant
management and operations.
Digitizing
Networking
Enhancement
Advanced
μR1000/1800
The first recorder
with no
moving
contact
1992
VR100/200
Yokogawa’s 1st
Paperless
recorder
1996
1999
DAQStation DX
A new Paperless recorder
being at the forefront of
the recorder with
Ethernet I/F
2001
DAQStation DX
Networking Enhancement
Foundation Fieldbus
MODBUS Master
Web, E-Mail
2001
DAQStation DXP
Enhanced model for
pharmaceutical
needs; FDA 21
CFR 11
2003
DAQMaster MX
High-speed (10 msec)
DAQ with
module layout,
PC Front end
2005
DAQMaster MW
Stand-alone DAQ
With Web
monitoring
service
μR10000/20000
New flagship for Strip-Chart
Recorder VFD Dot-Matrix
Display, Fully
Contact-less
Technology, Ultra-
Small Servo Unit
2004
2001
DAQStation CX
Enhanced model
with Embedded
PID controller
2009
DAQStation
DX-Advanced
New flagship for
Paperless
Recorder
2005 2008 R3 2010 R4
SMART
Usability
2012
SMARTDAC+
Touch panel
Smart User Interface
Smart Architecture
Smart Functionality
Data Acquisition unit
by module structure
2014
Data
Logging
software
GM
GA10
Special
Purpose
Commercial
Use

9
Current Nuclear Recorders
 DAQSTATION DXAdvanced data acquisition stations replace most popular paper chart
recorders with no panel modification requirements. Advanced display, archiving, and
connectivity functions support a wide range of plant monitoring and recording applications.
 Recorders in Nuclear industry 10000+ units, out of 160,000 units sold.

10
Removable Chassis Units
 DX1000N and DX364 models utilize an inner chassis that can be removed
 All internal components can be accessed from the front of the control panel.
 No need to access the rear of the control panel or disturb any field and
power supply wiring.

Controller Products

12
History of Yokogawa’s SLC
1965
YS80
Micro processer
Analog meter
display
1980
1991 2007
For the non-stop evolution of your plant
management and operations.
Networking
ADVANCED
2010
1970
200920041996
YS100
Digital display
YS1000
Single loop controller
Versatile screen format
Ethernet
Open network
I series
Analog controller
Green series
Active color
display
EBS
Analog controller
UT351E
UT551E
Ethernet
Modbus/TCP
UP35A/UP55A
Program controller
Ladder sequence
Ethernet
Open network
1987
UT10/30/40
UP20/30/40
Full line up
Universal input
Communication
1983
M2000
LED numerical
display
UT32A/UT35A
UT52A/UT55A
Ladder sequence
Open network
Ethernet
2010
UM33A
2013
UT75A
Carbon Potential
calculation
Panel Indicator

13
YS1000 series
 Controllers in Nuclear industry - 850 units, out of 45,000+ units sold globally.
YS1000 series
-3x6 controller replacement
-5 inputs
-3 outputs
-Hard Manual
-Color TFT LCD 120 * 320 pixels.
Overview and Problems
Perform safe and stable control at low cost
Solution
Simple programming by Function Block wiring method
Cascade primary direct control
Cross limit control calculation
Feed forward control
Benefits
Reduced debugging time
Improvement of the reliability of programs
Safe and stable control at low cost

Maintaining Fit, Form, & Function

Commitment to Nuclear Products
 Continue to modernize nuclear qualified products.
 Upgrade unit displays to modern equivalents.
 Maintain fit, form & function.
 Update firmware to support new components.
 Maintain part compatibility with previous models.
 Maintain user experience.
 DX100/200 to DX1000/2000
 YS170 to YS1700
15

Current Recorder Models – Modernizing Projects
 Upgrade bezel and LCD display (In Progress / Completed)
 Qualification
 Upgraded Ethernet Assembly (In Progress / Completed)
 Qualification
 Power switch replacement (In Progress / Completed)
 Engineering Evaluation
 DX364 case weld enhancement (Complete)
 Qualification
 Firmware update (In Progress / Completed)
 Software Validation
16

Current Controller – Modernizing Projects
 Upgrade LCD display (Complete)
 Qualification
 Upgraded Ethernet Assembly (Complete)
 Qualification
 Firmware update (Complete)
 Software Validation
17

Backward Compatible Hardware
 Current hardware is designed to fit into the all legacy controller
platforms.
 Maintain existing wiring.
 Maintain existing panel engineering.
 Significant savings in instrument upgrades
 Investment in future hardware upgrades.
18
Backwards compatible to all Yokogawa’s legacy SLC models

Backward Compatible Software
 Current controller is designed to run engineering code from legacy
platforms.
 Application engineering can be reused.
 Maintain existing panel engineering.
 Significant savings in instrument upgrades
 Investment in future software engineering.
19
SLPC ROM
Program Upgrade
YS100 data conversion
SLPC data conversion
Components Function （Subprogram)
SLPC ROM conversion
tool

Product Modification for Replacing Pre-
installed Equipment

Product Modification
 Product modification is a tool Yokogawa uses to help plants
upgrade instrumentation with minimal panel disruptions.
 Significant engineering and labor costs savings.
 Significant time savings for installation.
 Most times, Yokogawa engineering is quite a bit less than complete
instrument change out.
21

Product Modification
 Yokogawa has been successful in several modification projects for nuclear qualified applications.
 Our Engineered Solutions team offers turn-key integration based on the Yokogawa product
portfolio.
 Solutions may be as simple as a data acquisition system in an enclosure to a full well pad
automation solution.
 We offer pre-engineered solutions for power, heat treating and product testing.
 Yokogawa’s maintains 170,000 Sq. foot of manufacturing space with an in-house machine shop,
SMT PCB manufacturing, 3-D printing for prototyping, injection molding, laser engraving and
calibration facilities. An engineering staff of 25 and manufacturing staff of 125 run the facility.
22

Nuclear Modification Projects
 DX364/S24
 This was an L&N replacement for a pilot project at a new England plant. We extended case
to fit the existing L&N shelf. This was a 1E qualified application.
 DX364/S29
 We replaced existing Bailey 762 recorders. The case was extended to fit into Bailey Shelf.
We added RS-485 Modbus communications for compatibility. The initial shipment was 9
units.
23

 DX364/S28
 This is a standard retrofit for standard Foxboro cases. This was designed to fit into one of
several Foxboro cases and shelves.
 DX1000N/S80
 Yokogawa redesigned the case and front panel of DX1000N to replace Honeywell
recorders.
24

 YS1700/S18
 This project was a control modification to replace existing F&P 53MC5000
Scan Line controllers. The case was extended; a custom fail over circuit
added, input and output isolation were added and rear terminations were
modified.
25

 Redesign of a programmable controller to imitate a manual setting station.
 Programmable capability
 Minimal qualification efforts
 The /S61 is a YS1700 /S14 controller with a manual station display.
26
YS1700 Display Manual Station Display
Keys intentionally left
blank to indicate no
functionality

Adapter Plates
 Adapter plates allow us to install current products into oversized existing panel
cutouts without modification of the panels.
 Plates can be commercial or safety related.
 Yokogawa has designs for over 100 recorders and controller cutouts.
27

Simulator Versions
 Simulator versions of recorders and controllers are available for installation into simulators for
operator training.
 Used primarily as a dumb terminal.
 PID control is available
 Signals can be sent to control as analog or digital.
 Simulate fail screens
 Start and stop simulated process
 Soft reset for new initial conditions
 Erase trend screen and unacknowledged alarms
 Audit trail for operator actions
 Simulated power fail
 Operator functions shall work normally
28

Custom Solutions

30
Dry Cask Monitoring
 Yokogawa has provided solutions for multiple Dry Cask ISFSI-TMS
 Sample project completed in 2018
Existing site has 105 installed casks.
This project will add 59 new casks.
Each channel requires 2 alarms
 High limit
 Rate of change
No quality requirements.
Cyber security required.

31
Dry Cask System
New Main
Panel
New
Local
Panel
New
Local
Panel
Existing
Panel
Dry Cask Pad
Expansion
Box 1
Box 1
Existing
Panel
Existing
Panel
Box 2
Box 3
Box 4
Box 5
Box 2Box 3Box 5Box 4
Existing
Main
Panel
40 T/C
Inputs
Existing
Dry Cask Pad
New main panel will have the ability
for future expansion. Required to
accept 105 additional inputs from the
existing panels as they are replaced.
Inputs from future
panel replacement
19 T/C
Inputs
42 T/C
Inputs
42 T/C
Inputs
21 T/C
Inputs
100 ft 250 ft

32
Diesel Generator
 Yokogawa created a system that will measure Diesel Generator process
variables such as:
Starting speed
Fuel level
Cool-down
Incomplete sequence control
Maintained speed
Fuel rack position
Oil pressure
Temperature
 Resulting in
Enhanced troubleshooting
Decreased timeframe for startup
Increased online availability

33
Other Solutions
 General purpose enclosures for fields mounted instruments
 Generator temperature monitoring systems
 Independent Spent Fuel Storage Installation - Temperature Monitoring
System
 Heater Drain control panels
 SCRAM panel for air handling.

NTS presentation

A HIGHER STANDARD
T E S T I N G | I N S P E C T I O N | C E R T I F I C AT I O N

UNMATCHED EXCELLENCE IN NUCLEAR TESTING
The primary supplier of safety-related
equipment, qualification testing, and services
for nuclear power plants and manufacturers.
• Qualified Equipment and Parts for Third-Party
Qualification/Commercial Grade Dedication
• Equipment Qualification Testing: Radiation Aging, Thermal
Aging, Cycle Aging, EMI, Seismic, and Accident (LOCA)
Simulation
• Safety Relief Valve Testing: ASME OM Code, Set Pressure,
Seat Leakage and Operability with Steam/Water/Air, and
Repair Support
• Valve Qualification/Flow Testing: ASME QME-1, Hot and
Cold Cycle Testing, Flow Interruption, Deflection and Modal
Testing, Steam/Water/Air
• Snubber Services: ASME OM Code, Removal, Installation,
Inspection, Repair, Refurbishment

v
THE MOST PROMINENT COMPANIES IN THE WORLD
TURN TO NTS

THE WORLD’S MOST TRUSTED AND RESPECTED COMPANY FOR TESTING,
INSPECTION, AND CERTIFICATION.
8,000 CUSTOMERS 57 YEARS OF INNOVATION 59 LOCATIONS| |

28 LABS IN NORTH AMERICA

• Supporting the U.S. and International Nuclear Industry for over 50 years with:
 Safety Relief Valve Testing and Certification Services
 Valve and other Fluid Component Testing Services
 Snubber Inspection, Testing and Refurbishment
Services
 Equipment Qualification Engineering and
Testing Services
 Safety Related Equipment Supply
(Third Party Qualification)
• Radioactive Material License
• 10CFR50 Appendix B QA Program
 Audited By
 US Nuclear Regulatory Commission
 Nuclear Procurement Issues Committee
 Nuclear Industry Assessment Committee
NUCLEAR ENGINEERING & TESTING

• Full service third party dedication organization to supply
safety related equipment and parts to the nuclear utility
industry.
• 6,000 sq. ft. office and documentation storage system
• 50,000 sq. ft. test lab and equipment storage
• Test report and materials library
• TRAD Software – material database with computational
routines
• Program meets the requirements of:
 10CFR Part 21
 EPRI 3002002982, Revision 1 to EPRI NP-5652
 TR-102260
NUCLEAR THIRD PARTY QUALIFICATION (NTPQ)
SAFETY RELATED EQUIPMENT SUPPLY
How is obsolescence managed?

• Continuous oversight of Yokogawa’s design process as applied to safety-related
instruments.
 Commercial-grade surveys, design review meetings, routine design updates.
• Requalification programs when required (SEI, EMC, FV).
• Strong partnerships with medium voltage circuit breaker manufacturers, relay
manufacturers, etc.
• Controlled storage supplies of hard to find parts like terminal boards, breaker over-
current coils, safety-related lubricants, and specialized repair parts like anti-pump
relays (52Y).
• Ability to qualify new models of old parts and qualify new items makes NTS a well-
rounded leader in safety-related components.
• Always alert for CFSI or substitutions (counterfeit, fraudulent, and suspect items).
• Plus, support from the rest of NTS HSV!
Managing Obsolescence

CERTIFICATION AND COMPONENT TESTING
• SRV Services
 Valve Certification testing for operability, set pressure and
seat leakage using saturated steam, gaseous nitrogen, air, and
water.
 Valve refurbishment support including assembly/disassembly,
decontamination, visual and non-destructive inspections,
machining/welding activities, and heat treating.
• Valve and Fluid Component Testing
 Full service engineering and test group to support all types of
valve design and testing.
 Capabilities include design analysis, failure analysis, flow loop
testing, flow interruption testing, ASME QME-1 qualification
programs, heat exchanger, pump, and custom fluid
components testing.
SAFETY RELIEF VALVES (SRV)
SRV FACILITY

SRV FACILITIES
• 20,000 ft2 Operations building – test/rework area, office/control room,
and warehouse.
 Test/rework area – test cells, non-radioactive and
radioactive work areas, and QA controlled storage area for
customer valve parts.
 Control room – 3 stations that control steam
(pressure/temperature) conditions and collect and store test
data.
• Warehouse – loading dock for shipping and receiving of valves.
• 2 – 3000 psi/6,000 lb/hr and 1 – 1500 psi/12,000 lb/hr boilers and a
de-mineralized feed water system.
• Office space for valve manufacturer representatives and customers.
• Radioactive work area – 2-1500 psi and 1-3000 psi test cells,
decontamination area, liquid waste room, machine shop, repair areas,
and nitrogen test stand.
SAFETY RELIEF VALVES
SRV FACILITY

TEST FACILTIES
• Saturated steam test system – 1500 psig, 2M lb/hr transient,
24K lb/hr steady state, 2 – 420 ft3 accumulator vessels, 1 – 450
ft3 ullage tank.
• Hot water test system – 1 – 3000 gallon pressure vessel with
maximum conditions of 2200 psig and 600°F.
• Cold water flow loop test system (valve test) – 60,000 gallon
tank, pump station – 8000 gpm at 220 psig, piping legs of 6,
10, and 14 inch in diameter.
• Hot water flow loop test system (pump and heat exchanger
test) – 30,000 gallon tank, 150 psig, 400°F.
• Air/Nitrogen testing – all systems except the flow loops can be
used to test valves flowing air/nitrogen.
VALVE & FLUID COMPONENTS
HIGH FLOW STEAM

SNUBBER SERVICES
• Turnkey services to support maintenance and surveillance
programs for all types and sizes of mechanical and hydraulic
snubbers.
• Capabilities include:
 Procedure and work package development
 Visual inspection, snubber removal and
reinstallation
 On-site and in-house functional testing
 On-site and in-house repair and overhaul
 Failure analysis
SNUBBER INSPECTION, TEST & REFURB
SNUBBER LAB

SNUBBER FACILITIES
• Snubber refurbishment and testing
• 7 small bore test machines (200 – 250,000 lb load capability)
• 2 portable large bore test machines (1.7 million lb load
capability)
• 1 non-portable large bore snubber test machine (2.0 million
lb load capability)
• 11 snubber trailers (8 test and 3 rebuild)
SNUBBER INSPECTION, TEST & REFURB
SNUBBER TRAILERS FOR ON SITE TESTING

FACILITIES
• Wide range of functional test equipment
• Wide range of electrical power loads
• 4 seismic simulation tables
 Bi-axial seismic table
 Tri-axial seismic table
QUALIFICATION ENGINEERING & TEST
BI-AXIAL SEISMIC TABLE

FACILITIES
• 6 accident simulation chambers up to 8’ x 12’ with 2
chemical spray injection systems
• 3300 lb/hr boiler at 150 psig
• 300kW super-heater
• Contract radiation testing
• And, the support from the balance of NTS!
QUALIFICATION ENGINEERING & TEST
ACCIDENT CHAMBER

WE’VE GOT YOU COVERED

BUILT TO SERVE YOU

53
Fully Stocked | Fully Staffed | Fully Safe
Yokogawa factories and warehouses are ready to ship!
Need it now?
Call us at (800) 888-6400
 Actively Shipping with
Standard 10 day Lead Times
 Get 2 day shipping with North
America Quick Ship Program
 Transmitters
 Flow Meters
 Gas Analyzers
 Liquid Analyzers
 Data Acquisition Recorders
 Controllers
 Most process instruments are
assembled in the United States.
YS1000

Q & A

Webinar managing instrument obsolence in nuclear edited

More Related Content

What's hot

Similar to Webinar managing instrument obsolence in nuclear edited

More from Yokogawa1

Recently uploaded

Webinar managing instrument obsolence in nuclear edited