AECL’s Use Of FMEA And OPEX for Field Service Tooling and Process Development, Implementation and Improvement: A Model for the Future

Abstract

Failure Modes and Effects Analysis (FMEA) is a systematic and rigorous process applied to new or complex systems to predict system failures and assist with the development of mitigating strategies. The process is especially beneficial when applied to higher-risk applications such as nuclear systems. FMEA may be used for design verification and maintenance program development. For field service tooling, FMEA is complimented well by operating experience (OPEX) and continuous improvement initiatives. FMEA is generally conducted while developing systems and processes to ensure safe and successful implementation, while OPEX is fed back into the system design and operation to improve those systems and processes for subsequent field applications. This paper will explore these techniques as they have been applied to AECL’s CANDUclean™ system. The portable CANDUclean system is employed to mechanically clean the inside of steam generator (SG) tubes in CANDU® nuclear power plants. During normal plant operation, the steam generator tubes in the heat transport system develop a build-up of magnetite on their internal diameter, which decreases heat transfer efficiency, impedes SG maintenance activities and increases the radiation fields in and around the boilers. As part of a regular plant aging management routine, the CANDUclean system is used to remove the magnetite layers. The nature of this work includes risks to personnel safety, however by continually applying FMEA and other improvement initiatives, safety and system effectiveness are maximized. This paper will provide an overview of the integrated continuous improvement approach applied to the CANDUclean system and consider the value of strategies when applied to field service tooling and CANDU systems.