Consumable management apparatus and consumable management method

Abstract

To provide a consumable management apparatus and a consumable management method capable of appropriately managing consumables used by equipment in maintenance activity of a nuclear power plant.SOLUTION: A consumable management apparatus 100 which manages consumables used by equipment constituting a system function in a nuclear power plant includes: a consumable importance determination unit 11 which determines a degree of importance of consumables; a consumable performance monitoring unit 12 which monitors the performance or reliability of the consumables while modifying monitoring frequency and monitoring content based on the degree of importance of the consumables; a consumable soundness evaluation unit 13 which predicts remaining life of the consumables from state information related to the performance or reliability of the consumables, to evaluate the soundness based on the predicted remaining life of the consumables; and a preventive maintenance planning unit 14 which plans preventive maintenance on the basis of the evaluation by the consumable soundness evaluation unit.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a consumables management device and a consumables management method for equipment in a nuclear power plant or the like. [Background technology]

[0002] Nuclear power plants are made up of hundreds of systems and numerous pieces of equipment. In order to maintain safety and maximize the performance of the power plant, maintenance activities are carried out to maintain and improve its reliability.

[0003] The equipment maintenance planning support system in Patent Document 1 discloses that it includes an equipment importance evaluation support system which inputs plant design and operation information and risk information, evaluates the importance of plant equipment and devices, and outputs importance rank information for the plant equipment and devices; a risk information evaluation system which inputs plant design and operation information and risk information, determines whether online maintenance can be performed, and outputs information on whether online maintenance can be performed; an equipment failure information processing system which inputs operation history information of plant equipment and devices and outputs it to an equipment failure database, while inputting equipment failure database information, calculates an equipment failure rate, and outputs equipment failure rate information; and an equipment maintenance method selection support system which inputs importance rank information of plant equipment and devices, information on whether online maintenance can be performed, and equipment failure rate information, selects a maintenance method for the plant equipment and devices, and outputs equipment maintenance method information. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2006-252311 A [Patent Document 2] JP 2019-007852 A Summary of the Invention [Problem to be solved by the invention]

[0005] In Patent Document 1, in order to determine the maintenance method for the facilities and equipment, various importance and risk information related to safety and power supply function are used as the criteria for determining the importance of the facilities and equipment, and the importance of the facilities and equipment is determined. However, the technology for evaluating the importance and reliability of consumables is not disclosed.

[0006] In general, for consumables (parts whose performance deteriorates over time and need to be replaced at regular intervals) used in equipment at facilities such as nuclear power plants, the replacement cycle is described in the instruction manual, etc., and the list of parts to be replaced is determined based on the results of periodic inspections. The replacement cycle for these consumables is determined based on estimated values ​​from life tests, empirical values, etc.

[0007] For example, Patent Document 2 discloses that for EQ (Environmental Qualification) equipment, which is required to have environmental resistance performance in nuclear power plants, the lifespan and replacement timing of EQ equipment are determined from the results of environmental measurements, and the equipment is appropriately managed and maintained.

[0008] Conventionally, consumables that have a finite lifespan have been inspected and replaced periodically. However, for parts with a wide variation in lifespan, setting a short replacement interval not only reduces reliability due to excessive maintenance, but is also uneconomical, so an average replacement interval is set based on experience. As a result, there are problems such as failures occurring shortly after replacement and parts being replaced even though they still have a remaining lifespan.

[0009] The present invention is an invention for solving the above-mentioned problems, and has an object to provide a consumables management device and a consumables management method that can appropriately manage consumables used in equipment during maintenance activities of a nuclear power plant. [Means for solving the problem]

[0010] In order to achieve the above object, the consumables management device of the present invention is a consumables management device that manages consumables used in equipment constituting a system function in a nuclear power plant, and is characterized by having a consumables importance determination unit that determines the importance of the consumables based on the importance of the equipment constituting the system function, a consumables performance monitoring unit that changes the monitoring frequency or monitoring content based on the importance of the consumables to monitor the performance or reliability of the consumables, a consumables health evaluation unit that predicts the remaining life of the consumables from status information related to the performance or reliability of the consumables and evaluates the health of the consumables based on the predicted remaining life of the consumables, and a preventive maintenance planning unit that plans preventive maintenance based on the evaluation by the consumables health evaluation unit. Other aspects of the present invention will be described in the embodiments described later. Effect of the Invention

[0011] According to the present invention, consumables used in equipment during maintenance activities of a nuclear power plant can be appropriately managed. [Brief description of the drawings]

[0012] [Figure 1] 1 is a diagram showing a configuration of a consumables management system according to an embodiment of the present invention. [Diagram 2] 1 is a block diagram showing a configuration of a consumables management device according to an embodiment of the present invention. [Diagram 3] FIG. 2 is a diagram showing the relationship between element functions, devices, and consumables. [Figure 4] FIG. 2 is a diagram showing examples of consumables used in the device. [Diagram 5] FIG. 13 is a diagram illustrating an example of a class classification determination table. [Figure 6] FIG. 11 is a diagram illustrating an example of configuration data of a device management DB. [Figure 7] FIG. 13 is a diagram showing an example of configuration data of a maintenance activity / monitoring item DB. [Figure 8] FIG. 11 is a diagram showing an example of configuration data of a sensing DB. [Figure 9] FIG. 13 is a diagram showing an example of configuration data of an FMEA DB. [Figure 10]FIG. 11 is a diagram showing an example of configuration data of a field data DB. [Figure 11] FIG. 13 is a diagram illustrating an example of a correspondence table between systems, functions, and components. [Figure 12A] FIG. 13 is a diagram showing an example of an A class determined by a consumables importance determination unit. [Figure 12B] FIG. 13 is a diagram showing an example of class B determined by the consumable importance determination unit. [Figure 12C] FIG. 13 is a diagram showing an example of C class by a consumables importance determination unit. [Figure 13] 13 is a diagram showing an example of a consumables monitoring classification table used in a consumables performance monitoring unit and a consumables health evaluation unit. FIG. [Figure 14A] FIG. 13 is a diagram showing an example of remaining life evaluation data of a consumables health evaluation unit. [Figure 14B] FIG. 13 is a diagram showing corrected remaining life evaluation data of the consumables health evaluation unit. [Figure 15] FIG. 13 is a diagram showing a method for selecting a threshold value for the life of consumables in the corrective action unit. [Figure 16] FIG. 13 is a diagram showing consumable life threshold data for each class of consumables. [Figure 17] FIG. 13 is a diagram illustrating a routine inspection interval extension process performed by the preventive maintenance planning unit. [Figure 18] FIG. 11 is a diagram showing a process flow for determining the importance of a consumable item. [Figure 19] FIG. 11 is a diagram showing another processing flow for determining the importance of a consumable item. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment for carrying out the present invention will be described in detail with reference to the accompanying drawings. In this embodiment, in order to promote maintenance activities in nuclear power plants, a consumables management device and a consumables management method capable of appropriately managing consumables used in equipment are proposed. First, the terms used in this embodiment, features, etc. will be described.

[0014] In the present invention, the term "element function" is used to describe the system function of the system to be maintained. In the present invention, the functions of the system are first decomposed into "element functions" such as pressure resistance, cooling, and flow control. Then, instead of classifying the importance of only the functions required of the system, weighting is performed based on the importance of the "element function" of the system that corresponds to the functions required of the system. Meanwhile, the equipment that constitutes the system is weighted from the perspective of its necessity in fulfilling the "element function."

[0015] An example of weighting is shown in Figure 11. Details will be given later, but the element functions of the system are broken down into cooling function, isolation function, flow control function, etc., and the importance of each function is weighted as H (High), M (Middle), or L (Low). Meanwhile, the necessity of the component for the equipment is weighted as H (High), M (Middle), L (Low), or no contribution. In this way, one of the features is that the relationship between the system and equipment can be clarified using the "element functions" as an intermediary.

[0016] Based on the class classification determination table 26 shown in Figure 5, the importance of the equipment for the maintenance of the system to be maintained is classified (determined) into classes (Class A, Class B, Class C) based on the importance of the system function of the system in terms of "element function" and the necessity of the component equipment to realize the "element function."

[0017] In Japan, the relative importance of functions necessary to ensure the safety of light water reactor facilities is determined from a safety standpoint, and the designs of structures, systems, and equipment are classified according to their importance into classes 1, 2, and 3. In conventional maintenance, the importance of maintenance is determined first based on the safety importance of the system, and then the importance of the maintenance of the equipment is classified according to the impact that the failure of the equipment would have on the system functions.

[0018] <Consumables Management System> 1 is a diagram showing the configuration of a consumables management system 300 according to this embodiment. The consumables management system 300 includes a consumables management device 100 and a database device 200, which is an external storage device. The consumables management device 100 includes a processing unit 10, a storage unit 20, an input unit 30, an output unit 40, and a communication unit 50.

[0019] The processing unit 10 includes a consumable importance determination unit 11 that determines the importance of the consumable based on the importance of the equipment that constitutes the system function, a consumable performance monitoring unit 12 that monitors the performance and reliability of the consumable based on the importance of the consumable, a consumable health evaluation unit 13 that predicts the remaining life of the consumable from the status information of the consumable and evaluates the health of the consumable based on the predicted remaining life of the consumable, a preventive maintenance planning unit 14 that plans preventive maintenance based on the evaluation by the consumable health evaluation unit 13, a corrective action unit 15 that corrects the life margin of the consumable based on the importance of the consumable, and a life cycle management unit 16 that aggregates the performance history, life history, margin change history, etc. of the consumable from the consumable performance monitoring unit 12, the consumable health evaluation unit 13 and the corrective action unit 15 to grasp the status of the consumable from installation to replacement.

[0020] The memory unit 20 stores a system / function / component correspondence table 21, maintenance activity extraction information 22, field data extraction information 23, FMEA extraction information 24, sensing extraction information 25, a class classification determination table 26 for determining the importance of consumables, a consumable monitoring classification table 27, consumable life evaluation data 28, consumable life threshold data 29, etc.

[0021] 1, the processing unit 10 is a central processing unit (CPU) and executes various programs stored in a RAM, a HDD, etc. The storage unit 20 is a HDD and stores various data for the consumables management device 100 to execute processes. The input unit 30 is a device for inputting instructions to a computer, such as a keyboard or a mouse, and inputs instructions such as starting a program. The output unit 40 is a display or the like, and displays the execution status and execution results of processes by the consumables management device 100. The communication unit 50 exchanges various data and commands with other devices via the network NW.

[0022] The database device 200 has a configuration management DB 210, a maintenance activity / monitoring item DB 220, a sensing DB 230, an FMEA DB 240, a field data DB 250, etc. In addition, DB means database. FMEA is an abbreviation of Failure Mode and Effect Analysis, and is a systematic analysis method of potential failures with the aim of preventing failures and malfunctions.

[0023] The data stored in each DB is explained below. The configuration management DB 210 is a database that includes design requirements for the power plant, design documents, reliability evaluation test results during construction, literature, and acquired physical property values ​​and entity data for each consumable. The maintenance activity / monitoring item DB 220 is a database including information on the maintenance activities and monitoring items of the power plant, that is, the contents, frequency, and target deterioration phenomena. The sensing DB 230 is a database including the degradation modes and measurement methods (principles, sensor installation locations, etc.) covered with respect to sensing technologies applicable to the power plant. FMEA DB240 is a database that includes the deterioration modes of equipment that constitutes a power plant, i.e., failure locations, deterioration mechanisms, effects of deterioration, severity of deterioration, frequency of deterioration, and effective maintenance activities and monitoring items. The field data DB 250 is a database that includes data acquired at the site, such as the results of maintenance activities (inspection results, test results, etc.), as well as data before inspection and maintenance, and daily monitoring data.

[0024] <Outline of consumables management process> 2 is a block diagram showing the configuration of the consumables management device 100 according to this embodiment. An overview of the consumables management process will be described with reference to FIG.

[0025] The consumable importance determination unit 11 determines the importance of consumables used in equipment that is the target of maintenance in the nuclear power plant based on the importance of that equipment. The consumable importance determination unit 11 extracts the relationship between the system, the element functions of the system, and the equipment that composes the system, and classifies (determines) the equipment into three classes (Class A, Class B, Class C) according to the necessity for the important element functions that the system performs. Class A is the most important class, Class C is a post-maintenance class that keeps the equipment in operation until maintenance is performed, and Class B is an intermediate class that is less important than Class A.

[0026] If the equipment to be maintained is class A, the consumables used for it are also determined to be the most important class. If the equipment to be maintained is class B, the consumables used for it are also determined to be an intermediate class with a lower importance than class A. If the equipment to be maintained is class C, the consumables used for it are determined to be the corrective maintenance class.

[0027] The consumable importance determination unit 11 may determine the importance of consumables by utilizing the importance of the consumables, information on the radiation dose of workers, work information from the loss of functionality of the equipment to its recovery and information on the time required for this, information on the impact on plant operation in the event of a loss of functionality, and information on the environment in which the equipment is installed.

[0028] The consumable performance monitoring unit 12 monitors the performance or reliability of the consumable based on the importance of the consumable. The monitoring method varies the monitoring frequency and monitoring content based on the importance of the consumable, and monitors the performance or reliability of the consumable accordingly. That is, the consumable performance monitoring unit 12 changes the monitoring frequency or monitoring content based on the importance of the consumable to monitor the performance or reliability of the consumable. For example, in the case of class A, the monitoring frequency is every △ days, and in the case of class C, the monitoring frequency is every 〇 months. The consumable performance monitoring unit 12 monitors the consumable performance by referring to the judgment result of the consumable importance judgment unit 11, the evaluation result of the consumable health evaluation unit 13, the maintenance plan result of the preventive maintenance plan unit 14, and the correction result of the corrective action unit 15.

[0029] The consumables health evaluation unit 13 predicts the remaining life of the consumables from status information related to the performance or reliability of the consumables, and evaluates the health of the consumables based on the predicted remaining life of the consumables. The consumables health evaluation unit 13 evaluates the health of the consumables based on the judgment result of the consumables importance judgment unit 11, the evaluation result of the consumables health evaluation unit 13, and the corrective action result of the corrective action unit 15.

[0030] The preventive maintenance planning unit 14 plans preventive maintenance based on the evaluation result of the consumables soundness evaluation unit 13. The preventive maintenance planning unit 14 makes a plan as to whether or not to extend the inspection cycle (see FIG. 15), for example.

[0031] The corrective action unit 15 corrects the margin of the life of the consumable based on the importance of the consumable. For example, the corrective action unit 15 determines the threshold of the life of the consumable based on the importance of the consumable. The threshold of the consumable is determined according to class A, class B, or class C (see FIG. 16).

[0032] The life cycle management unit 16 manages the life cycle of the consumables based on the evaluation results of the consumables health evaluation unit 13 , the corrective action results of the corrective action unit 15 , and the monitoring results of the consumables performance monitoring unit 12 .

[0033] 3 is a diagram showing the relationship between element functions, devices, and consumables. In this embodiment, the functions of a system are decomposed into "element functions" such as a cooling function, an isolation function, and a flow control function. Each element function is composed of multiple devices that are components of the system. Multiple consumables are used in the component devices. As described above, the importance is not classified based only on the functions required for the system, but is weighted based on the importance of the "element function" of the system that corresponds to the functions required for the system, and the devices that make up the system are weighted from the perspective of their necessity in performing the "element function." The importance is classified (determined) from both perspectives.

[0034] Fig. 4 is a diagram showing an example of consumables used in equipment. Fig. 4 shows a gate valve 70. The gate valve 70 is composed of a handle 71, a valve stem 72, an upper base 73, a lower base 74, a valve seat 75, etc. EPDM (ethylene propylene diene rubber) O-rings 76 and 77 are used in the gate valve 70 as consumables. The gate valve 70 is also called a gate valve, and since the flow path is straight, pressure loss is small, and it is used to either allow a fluid to flow forcefully when fully open, or to completely stop the fluid when completely closed.

[0035] Consumables used in nuclear power-related facilities are parts that deteriorate over time and need to be replaced at regular intervals, but maintenance parts replaced during maintenance work on facilities and equipment can also be treated as consumables in the embodiments. Specifically, consumables include resin products (packings, sealing materials, oil, coating materials, sheets, etc.) and metal products (bearings, etc.).

[0036] Next, examples of data constituting the class classification decision table and each DB in FIG. 1 will be described. <Classification decision table> 5 is a diagram showing an example of the class classification judgment table 26. The classes (Class A, Class B, Class C) are classified by a matrix of the importance of element functions and the necessity of component equipment to realize the element functions. The vertical axis represents the importance of element functions, and the horizontal axis represents the necessity of the equipment for the element functions. The importance of element functions is classified into three categories: H (High), M (Middle), and L (Low). The necessity of the function is classified into four categories: H (High), M (Middle), L (Low), and no contribution (-).

[0037] Class A is when the importance of the element function is "H" and the necessity of the equipment is "H". Class B is when the importance of the element function is "H" and the necessity of the equipment is "M" or "L", when the importance of the element function is "M" and the necessity of the equipment is "H" or "M", when the importance of the element function is "L" and the necessity of the equipment is "H". Class C is when the importance of the element function is "H" and the necessity of the equipment is "-" (no contribution), when the importance of the element function is "M" and the necessity of the equipment is "L" or "-", and when the importance of the element function is "L" and the necessity of the equipment is "M" or "L" or "-".

[0038] <Examples of configuration data for each DB> 6 is a diagram showing an example of configuration data of the configuration management DB 210. The configuration management DB 210 is composed of categories and their configuration data. The categories include design requirements, facility configuration information, and physical configuration. For example, the design requirements include laws and regulations, design criteria documents, calculation and analysis results, reliability evaluation test results at the time of construction, and physical property values ​​of consumables.

[0039] For example, the information includes consumable information indicating the contents of consumables to be replaced as part of the maintenance of the EQ equipment. The consumable information includes the consumable name, consumable model number, EQ equipment used, consumable specifications, consumable price, available period, replacement time, work procedure, last replacement date, recommended life, remaining life, limit test results, and compatible product names.

[0040] The consumable name is the name of the consumable to be replaced. The consumable model number is the identification information of the part to be replaced. The name of the EQ equipment used is the name of the EQ equipment that uses the consumable. The consumable specifications are information indicating the dimensions, shape, material, performance, environmental resistance specifications, etc.

[0041] The consumable price is the purchase price of the consumable. The availability period is the period during which the consumable is available. The replacement time is the replacement time of the consumable in the EQ device. The work procedure is information for indicating the procedure for replacing the consumable in the EQ device. It may be a procedure file or link information of a web page indicating the procedure.

[0042] The last replacement date is the date and time when the consumable was last replaced. The date and time elapsed from the last replacement date to the current replacement is the operating time of the consumable. The recommended life is the recommended operating time in a specified usage environment. Consumables are replaced so that the operating time does not exceed the recommended time. The remaining life indicates the remaining operating time in the usage environment. If the remaining life is longer than the period until the next maintenance work date and time, replacement does not need to be performed during the current maintenance work.

[0043] The limit test result is information for referring to the limit test result of the life characteristics of the consumables for each use environment. It may be link information of the test result file. The compatible product name is information indicating the name of the replaceable consumable.

[0044] Fig. 7 is a diagram showing an example of data configuration of the maintenance activity / monitoring item DB 220. The maintenance activity / monitoring item DB 220 has data such as maintenance activities, maintenance frequency, target deterioration events, etc., and data such as monitoring items, monitoring frequency, target deterioration events, etc. Specifically, when the target device is a XX valve, it can be seen that a XX non-destructive inspection is carried out every XX years as a maintenance activity.

[0045] Fig. 8 is a diagram showing an example of data constituting the sensing DB 230. The sensing DB 230 has data such as the device name, the faulty part, the deterioration mechanism, the cause of the deterioration, the measurement target, the measurement method, the sensor installation location, etc. According to Fig. 8, in the case of the XX valve, it can be seen that the faulty part is the seal part, and packing deterioration is expected.

[0046] Figure 9 is a diagram showing an example of data configuration of FMEA DB240. FMEA DB240 has data such as equipment name, deterioration mode, effective maintenance activities, monitoring items, etc. Deterioration mode includes failure part, deterioration mechanism, deterioration effect, deterioration severity, and deterioration frequency. According to Figure 9, in the case of XX valve, there is a possibility of leakage occurring due to resin deterioration of the sealing part.

[0047] Fig. 10 is a diagram showing an example of data constituting the field data DB 250. The field data DB 250 in Fig. 10 is data corresponding to the maintenance activity / monitoring item DB 220 in Fig. 7, and has data such as maintenance activities, maintenance frequency, and results (performance) of the maintenance activities, as well as data such as monitoring items, monitoring frequency, and monitoring results (performance).

[0048] <Consumables importance determination section> The consumable importance determination unit 11 (see FIG. 1) extracts information that organizes the relationships between systems, system functions that the systems have, element functions of the systems (system element functions), and the equipment that makes up the systems, from the configuration management DB 210 in order to assign priorities for optimizing maintenance activities, and outputs a system / function / component correspondence table 21.

[0049] 11 is a diagram showing an example of the system-function-component correspondence table 21. The system-function-component correspondence table 21 is composed of element functions performed by the system, the importance of the functions, the necessity of components (system constituent devices) for the functions, etc.

[0050] The element functions of the system include a cooling function, an isolation function, a flow control function, etc., and the importance of each element function is weighted as H (High), M (Middle), or L (Low). In addition, the necessity of a component for that function is weighted as H (High), M (Middle), L (Low), or no contribution (-). According to Fig. 11, for example, in the case of a cooling function, the importance of the function is "M," and it can be seen that the component with the highest necessity for that function is a pump.

[0051] According to Figure 11, for example, when the element function of a system is a "cooling function," the importance of that function is "M," and the necessity of a component for the function is "L" for a valve, while it is "H" for a pump. Also, when the element function of a system is an "isolation function," the importance of that function is "H," and the necessity of a component for the function is "no contribution" for a △△ valve, while it is "H" for a XX valve.

[0052] In this embodiment, the importance is not classified only based on the functions required for the system, but weights (H, M, L) are assigned to the importance of the system's element functions corresponding to the functions required for the system. On the other hand, one of the features is that the devices constituting the system are weighted (H, M, L, -) from the viewpoint of the necessity for performing the element functions.

[0053] The consumable importance determination unit 11 (see FIG. 1) performs class classification (determination) based on the system / equipment / component correspondence table 21 and the class classification determination table 26. Through the class classification (determination), the equipment is set as important equipment (Class A) required to maintain important element functions that the system should fulfill, equipment that is not essential to maintain the relevant functions (Class C), or other equipment (Class B).

[0054] FIG. 12A is a diagram showing an example of Class A based on consumable importance judgment 11. System / function / component correspondence table 21 is the same as the correspondence table shown in FIG. 11. In the case of the "XX valve" in FIG. 12A, the isolation function has a functional importance of "H" and the equipment necessity is also "H" (see the bold frame). Looking at the importance of function x equipment necessity, the others are the cooling function, M x M, and the flow control function, L x L, so they are judged based on the highest class classification, i.e., H x H. Therefore, it is classified (judged) as Class A.

[0055] Fig. 12B is a diagram showing an example of Class B by the consumable importance determination unit 11. The system / function / component correspondence table 21 is the same as the correspondence table shown in Fig. 11. In the case of "◇◇Pump" in Fig. 12B, in terms of the importance of function x necessity of equipment, the cooling function is M×H, the isolation function is H×L, and the flow control function is L×H (see the bold frame), and the function is classified (determined) as Class B based on the highest case.

[0056] Fig. 12C is a diagram showing an example of C class by the consumable importance determination unit 11. The system / function / component correspondence table 21 is the same as the correspondence table shown in Fig. 11. In the case of the "△△ valve" in Fig. 12C, in terms of the importance of function x the necessity of the equipment, the cooling function is M x L, the isolation function is H x -, and the flow control function is L x M (see the thick line frame), and the function is classified (determined) as class C based on the highest case.

[0057] <Consumables monitoring classification table> Fig. 13 is a diagram showing an example of a consumables monitoring classification table 27 used by the consumables performance monitoring unit 12 (see Fig. 1) and the consumables health evaluation unit 13 (see Fig. 1). Fig. 13 is a consumables monitoring classification table for sealing members. In Fig. 13, EQ test data is test data for the environmental performance assurance (EQ) of equipment in a nuclear power plant. As found data refers to data obtained by patrols and in-operation tests during operation, and data obtained during regular inspections and from consumables removed during regular inspections.

[0058] When the sealing material is static, the confirmation of the wear amount is classified according to whether it can be confirmed from the outside or not. If it can be confirmed from the outside, the life evaluation uses the initial value data, EQ test data, data acquired during operation, and As found data after use. On the other hand, if it cannot be confirmed from the outside, the life evaluation uses the initial value data, EQ test data, and As found data after use.

[0059] When the sealing material is dynamic, the confirmation of the wear amount is classified according to whether it can be confirmed from the outside or not. If it can be confirmed from the outside, the life evaluation uses the initial value data, EQ test data, data acquired during operation, and As found data after use. On the other hand, if it cannot be confirmed from the outside, the life evaluation uses the initial value data, EQ test data, and As found data after use.

[0060] <Consumables Health Evaluation Department> Fig. 14A is a diagram showing an example of consumables life evaluation data 28 of the consumables health evaluation unit 13 (see Fig. 1). The consumables life evaluation data 28A in Fig. 14A shows data on the compression set of the sealing member over time. There is a large difference in the value of the compression set over time between the harsh environment data (EQ test data) and the normal environment data.

[0061] The consumables soundness evaluation unit 13 obtains limit test results indicating life characteristics related to operating time from the dimensions (initial dimensions), shape or physical properties of the consumables before use and dimensional changes such as compression set, shape changes or physical property deterioration at the end of use.Then, the remaining life of the consumables is predicted from the state of the equipment based on the limit test results.

[0062] The consumables health evaluation unit 13 evaluates the remaining life taking into account the effects of degradation according to the usage conditions of the consumables. Usage conditions that have an effect of degradation include temperature, radiation dose, characteristics of fluids in contact with the consumables (gas, water vapor, water, pH), or the use of chemicals that accelerate the corrosion of the consumables (alkali metals, lanthanides, actinides, transition metals, halogens, chalcogen elements).

[0063] FIG. 14B is a diagram showing consumable life evaluation data 28 after correction by consumables health evaluation unit 13. Consumables life evaluation data 28B in FIG. 14B shows data corrected to enable an estimation that is more appropriate for the actual equipment (corrected values ​​shown by dashed lines). Consumables health evaluation unit 13 uses the EQ test results, data during operation, and As found data to correct the initial EQ test results and make an estimation that is more appropriate for the actual equipment. At this time, it is advisable for consumables health evaluation unit 13 to group the data by environment and evaluate the same materials used in different devices across the board by looking at the data.

[0064] In the example of FIG. 14B, the correction value for the harsh environment is corrected so that the compression set is larger than the data before correction, so it is expected that deterioration will tend to be large and the lifespan of the material will be shortened.

[0065] In addition, the consumables soundness evaluation unit 13, for example, measures the dimensions of the consumable parts as actual machine data and evaluates the remaining life based on the amount of change from the initial dimensions. At this time, it is desirable for the consumables soundness evaluation unit 13 to take into account the dimensional variation of the consumables and to evaluate the remaining life as short for parts with large dimensional variation.

[0066] The consumables soundness evaluation unit 13 evaluates the remaining life using the results of reliability evaluation tests at the time of construction that include a similar usage environment or a usage environment. Here, it is necessary to take into account the degree of deterioration of the consumables used in the environment factors (temperature, radiation dose, characteristics of fluids that come into contact with the consumables (gas, water vapor, water, pH), or use of chemicals that accelerate the corrosion of the consumables (alkali metals, lanthanides, actinides, transition metals, halogens, chalcogen elements)).

[0067] The consumables soundness evaluation unit 13 performs evaluation using the physical property values ​​of consumables that include similar use environments or use environments. Here, the physical property values ​​include chemical and physical values, such as activation energy, hardness, components contained in the consumables, elongation, and wear amount. When the target is an organic material and the deterioration factor is temperature or radiation, the deterioration can be estimated by the activation energy. For example, if the activation energy of organic material A is greater than the activation energy of organic material B (deterioration is slower), but the replacement frequency of organic material A is shorter than the replacement frequency of organic material B, the replacement frequency of organic material A can be extended to the replacement frequency of organic material B. At this time, by using the data included in the configuration management DB, it is possible to cross-examine organic materials A, B, etc. used for each device.

[0068] The consumables soundness evaluation unit 13 performs one or both of the following: evaluating the remaining life from the usage record and evaluating the remaining life taking into account the deterioration of the consumables according to the usage conditions of the consumables.

[0069] <Corrective Measures Department> Fig. 15 is a diagram showing a method for selecting the threshold value of the consumable life of the corrective action unit 15 (see Fig. 1). Fig. 14A and Fig. 14B show the time course of the compression permanent deformation of the sealing member, but the threshold value is important for determining the life of the sealing member. Fig. 15 shows the consumable life threshold data 29.

[0070] FIG. 15 shows two life curves, one for data from the EQ test only (solid line data) and the other for data combining the EQ test and As found data (dashed line data). In general, for high reliability equipment, the threshold for judging the life is set low (strict), while for general equipment, the threshold for judging the life is set high. Setting a high threshold will extend the predicted life, but will increase the risk of leakage, which is not desirable for high reliability equipment. Also, setting a low threshold for all consumables uniformly will lead to earlier replacement of the consumables, which is not desirable from the viewpoint of equipment maintenance. Here, high reliability equipment refers to equipment used in the aviation industry, space industry, energy industry, nuclear industry, etc.

[0071] In this embodiment, the corrective action unit 15 corrects the margin of the life of the consumable based on the importance of the consumable. That is, the corrective action unit 15 is characterized in that it determines the threshold value for determining the life of the consumable according to the importance of the consumable (according to each class).

[0072] Fig. 16 is a diagram showing consumable life threshold data 29A for each class of consumable. Fig. 16 shows the life of each class of consumables as determined by the consumable health evaluation unit 13. The consumable health evaluation unit 13 estimates the life of the consumables according to the threshold selected by the corrective action unit 15. Fig. 16 shows data (dashed line data) that combines the EQ test and As found data, and the consumable health evaluation unit 13 selects a threshold according to the class of the consumables (Class A, Class B, Class C) determined by the consumable importance determination unit 11.

[0073] The consumable health evaluation unit 13 (see Figure 1) can determine that the lifespan of the target consumable is time Ta if it is class A, determine that the lifespan of the target consumable is time Tb if it is class B, and determine that the lifespan of the target consumable is time Tc if it is class C.

[0074] The consumables soundness evaluation unit 13 may determine the usage limit of the consumables based on the importance of the consumables and degradation parameters of the consumables (for example, compression-affected strain).

[0075] The consumable health evaluation unit 13 may determine the replacement period of the consumable based on the importance of the consumable, the usage limit information of the consumable (for example, a threshold value according to the class of the consumable (Class A, Class B, Class C)), and the EQ test result of the consumable.

[0076] <Preventive Maintenance Planning Department> Fig. 17 is a diagram showing the inspection interval extension process S200 of the preventive maintenance planning unit 14 (see Fig. 1). The preventive maintenance planning unit 14 selects the importance of the judgment result of the consumables importance judgment unit 11 (process S201), and judges whether the replacement interval can be extended based on the actual value (process S202). If the replacement interval can be extended (process S202, Yes), the preventive maintenance planning unit 14 proceeds to process S203, and if the replacement interval cannot be extended (process S202, No), the preventive maintenance planning unit 14 proceeds to process S211.

[0077] In process S203, the preventive maintenance planning unit 14 determines whether the extension period can be evaluated as one cycle (1 cyc) or more, and if it can be evaluated as one cycle or more (process S203, Yes), proceeds to process S204, and if it cannot be evaluated as one cycle or more (process S203, No), proceeds to S211.

[0078] In process S204, the preventive maintenance planning unit 14 determines whether or not the technical requirements for extending the inspection period need to be considered. If the requirements do not need to be considered (process S204, Yes), the inspection period is extended (process S205). If the requirements do not need to be considered (process S204, No), the preventive maintenance planning unit 14 considers the technical requirements for extending the inspection period and extends the inspection period (process S206).

[0079] In process S211, the preventive maintenance planning unit 14 determines whether the inspection can be extended by changing the replacement margin in the same way as for general consumables, and if it can be extended (process S211, Yes), it considers the technical requirements if the inspection is extended and extends the inspection period (process S212), and if it cannot be extended (process S211, No), it proceeds to process S213.

[0080] In process S213, the preventive maintenance planning unit 14 determines whether the inspection can be extended by changing to consumables of other equipment, and if it can be extended (process S213, Yes), it considers the technical requirements for changing the consumables and changes to consumables of other equipment (process S214); if it cannot be extended (process S213, No), it continues operation with the current inspection cycle and consumables (process S215).

[0081] The technical requirements in processes S206, S212, and S214 include whether abnormalities in consumables can be detected, whether emergency measures can be taken when an abnormality is detected, whether system functions can be maintained, evaluation of the increased risk in the event of a breakdown in the equipment, consideration of organizational and security aspects, evaluation of the impact on public safety, calculation of the amount of radiation exposure of employees involved in the work, etc.

[0082] For example, the maintenance activity extraction information 22 (see FIG. 1) is information extracted from the pre-review maintenance activity / monitoring item DB 220. The FMEA extraction information 24 (see FIG. 1) is information extracted from the FMEA DB 240. From the FMEA extraction information 24, it can be seen that the deterioration of the packing in the sealing portion is serious.

[0083] One way to detect abnormalities in Class A consumables is to monitor the fluid temperature near the seal. By monitoring during operation, deterioration of the packing due to heat can be detected early.

[0084] As a conservation activity for Class B consumables, there is a material analysis of the seal packing (hardness and compression set analysis). By carrying out this during disassembly and inspection, it is possible to grasp the deterioration of the packing over time and detect any abnormalities in the consumables.

[0085] As part of conservation activities for Class A to C consumables, the degree of deterioration of consumables used in similar environments (temperature, radiation dose, characteristics of fluids in contact with the consumables (gas, water vapor, water, pH), or use of chemicals that accelerate the corrosion of consumables (alkali metals, lanthanides, actinides, transition metals, halogens, chalcogen elements)) can be reflected in the comparison and evaluation, enabling efficient data acquisition and improved evaluation accuracy.

[0086] As a conservation activity for consumables of classes A to C, the environmental information in the configuration management DB 210 (see Figure 1) is used to reflect the degree of deterioration of consumables used in similar environments in comparisons and evaluations. If the lifespan of a class A consumable is longer than the lifespan of consumables used in classes B and C, the lifespan of the class B and C consumables can be extended.

[0087] As another embodiment, as shown in Fig. 18, it is also conceivable that the consumable importance determination unit 11 uses the physical property values ​​of the consumables and the results of reliability evaluation tests at the time of construction to determine the importance of the consumables. In a consumable management method of a consumable management device 100 that manages consumables used in equipment constituting a system function in a nuclear power plant, the consumable management device 100 determines the importance using the importance of the equipment constituting the system function and the physical property values ​​of the consumables, and monitors the performance and reliability of the consumables based on the importance of the consumables and the usage environment. That is, the consumable importance determination unit 11 determines the importance of the consumables by adding the usage environment and the physical property values ​​to the importance of the equipment. This can further improve the reliability evaluation of the consumables.

[0088] In detail, after creating an equipment list for each facility (step S31), the consumable importance determination unit 11 creates a consumable list for each device in the equipment list (step S32), and performs processing of steps S33 to S36 for each consumable in the consumable list to determine the importance of the consumable.

[0089] In step S33, the importance of the system function / device that uses the consumable is determined. If it is "LOW", the consumable is determined to be of low importance, and if it is "Middle" or "High", the process proceeds to step S34. In step S34, it is determined whether the consumable is deteriorating quickly based on its physical properties (for example, by determining a threshold value for the degree of deterioration), and if it is not deteriorating quickly (No in S34), the consumable is determined to be of low importance, and if it is deteriorating quickly (Yes in S34), the process proceeds to step S35.

[0090] In step S35, it is determined whether the consumable deteriorates quickly in the usage environment (for example, by determining a threshold value for the degree of deterioration), and if the deterioration is not rapid (No in S35), the consumable is determined to be of medium importance, and if the deterioration is rapid (Yes in S35), the process proceeds to step S36. In step S36, it is determined whether the consumable deteriorates quickly in the reliability evaluation at the time of construction (for example, a threshold value for the deterioration level is determined), and if the deterioration is not rapid (No in S36), the consumable is determined to be of medium importance, and if the deterioration is rapid (Yes in S36), the consumable is determined to be of high importance.

[0091] In step S36, if the deterioration of the consumables is not rapid in the reliability evaluation during construction (No in S36), a judgment may be made according to the degree of deterioration, such as when the deterioration of reliability is small enough to be ignored, and a judgment of importance (low) may be made instead of importance (medium), as shown by the dashed line. The importance of a consumable may also be determined based on the inspection periodicity of consumables used in other devices that have similar operating environments and physical properties. Further, the method of determining the importance of the consumables importance determination unit 11 has been described with reference to FIG. 18 as a method of determining the importance of the consumables by sequentially determining the conditions, but the importance may be determined by adding points to the determination conditions.

[0092] As another embodiment, as shown in FIG. 19, the consumable importance determination unit 11 may use the physical property values ​​of the consumables and the results of a reliability evaluation test at the time of construction to determine the importance of the consumables. In a consumable management method of a consumable management device 100 that manages consumables used in equipment constituting a system function in a nuclear power plant, the consumable management device 100 may determine the importance of the consumables based on the physical property values ​​of the consumables and the usage environment of the consumables, and monitor the performance and reliability of the consumables based on the importance of the consumables and the usage environment. That is, the consumable importance determination unit 11 determines the importance of the consumables by adding the usage environment and physical property values ​​to the importance of the equipment. This makes it possible to improve the reliability evaluation of the consumables even when importance data of the system, equipment, and parts is insufficient.

[0093] In detail, after creating an equipment list for each facility (step S41), the consumable importance determination unit 11 creates a consumable list for each device in the equipment list (step S42), and performs processing of steps S43 to S45 for each consumable in the consumable list to determine the importance of the consumable.

[0094] In step S43, it is determined whether the consumable is deteriorating quickly based on its physical properties (for example, a threshold value for the degree of deterioration is determined), and if it is not deteriorating quickly (No in S43), the consumable is determined to be of low importance, and if it is deteriorating quickly (Yes in S43), the process proceeds to step S44. In step S44, it is determined whether the consumable deteriorates quickly in the usage environment (for example, by determining a threshold value for the degree of deterioration), and if the deterioration is not rapid (No in S44), the consumable is determined to be of medium importance, and if the deterioration is rapid (Yes in S44), the process proceeds to step S45. In step S45, it is determined whether the consumable deteriorates quickly in the reliability evaluation at the time of construction (for example, a threshold value for the deterioration level is determined), and if the deterioration is not rapid (No in S45), the consumable is determined to be of medium importance, and if the deterioration is rapid (Yes in S45), the consumable is determined to be of high importance.

[0095] In step S45, if the deterioration of the consumables is not rapid in the reliability evaluation during construction (No in S45), a judgment may be made according to the degree of deterioration, such as when the deterioration of reliability is negligibly small, and a judgment of importance (low) may be made instead of importance (medium), as shown by the dashed line. The importance of a consumable may also be determined based on the inspection periodicity of consumables used in other devices that have similar operating environments and physical properties. Further, the method of determining the importance of the consumables importance determination unit 11 has been described with reference to FIG. 18 as a method of determining the importance of the consumables by sequentially determining the conditions, but the importance may be determined by adding points to the determination conditions.

[0096] The consumables management device 100 and the consumables management method according to the present embodiment described above have the following features. (1) A consumables management device 100 for managing consumables used in equipment constituting a system function in a nuclear power plant includes a consumables importance determination unit 11 for determining the importance of the consumables based on the importance of the equipment constituting the system function, a consumables performance monitoring unit 12 for monitoring the performance or reliability of the consumables by changing the monitoring frequency or monitoring content based on the importance of the consumables, a consumables health evaluation unit 13 for predicting the remaining life of the consumables from status information related to the performance or reliability of the consumables and evaluating the health of the consumables based on the predicted remaining life of the consumables, and a preventive maintenance planning unit 14 for planning preventive maintenance based on the evaluation by the consumables health evaluation unit. This makes it possible to appropriately manage consumables used in equipment in maintenance activities of the nuclear power plant.

[0097] (2) The consumable importance determination unit 11 determines the importance of the equipment for the maintenance of a system to be maintained based on the importance of the system functions of the system at the element function level and the necessity of the component equipment to realize the element function, and determines the importance of the consumables used in the equipment based on the importance of the equipment (see Figures 12A, 12B, and 12C).

[0098] (3) The consumable importance determination unit 11 may determine the importance of consumables by utilizing the importance of the consumables, information on the radiation dose of workers, information on the work performed from the time the equipment loses function to its recovery and information on the time required for this, and information on the impact on plant operation in the event of a loss of function.

[0099] (4) The consumables health evaluation unit 13 may determine the usage limit of the consumables based on the importance of the consumables and the deterioration parameters of the consumables (see FIG. 15).

[0100] (5) The consumable health evaluation unit 13 may determine the replacement period of the consumable based on the importance of the consumable, the usage limit information of the consumable (for example, a threshold value according to the class of the consumable (Class A, Class B, Class C)), and the EQ test result of the consumable (see Figures 15 and 16).

[0101] (6) The consumables management device 100 further includes a corrective action unit 15 that corrects the life margin of the consumables based on the importance of the consumables (see FIG. 15).

[0102] (7) The consumables health evaluation unit 13 may correct the initial EQ test result based on the EQ test result of the consumables, the operation data, and the As found data, and estimate the remaining life of the consumables (see FIG. 14B and FIG. 15).

[0103] (8) A consumables management method of a consumables management device 100 that manages consumables used in equipment constituting a system function in a nuclear power plant, the consumables management device 100 determines the importance of the consumables based on the importance of the equipment constituting the system function, monitors the performance and reliability of the consumables based on the importance of the consumables, predicts the remaining life of the consumables from status information of the consumables, evaluates the soundness based on the predicted remaining life of the consumables, and plans preventive maintenance based on the evaluation of the soundness. This makes it possible to appropriately manage consumables used in equipment in maintenance activities of the nuclear power plant.

[0104] (9) A consumables management method of a consumables management device 100 that manages consumables used in equipment constituting a system function in a nuclear power plant, the consumables management device 100 determines the importance of the consumables based on the importance of the equipment constituting the system function, monitors the performance and reliability of the consumables based on the importance of the consumables and the usage environment, compares and evaluates the reliability of consumables used in other equipment with similar usage environments, and applies the results to a maintenance plan. This makes it possible to check the deterioration status of consumables used in different equipment installed in similar environments, thereby improving the reliability evaluation of the consumables.

[0105] (10) A consumables management method of a consumables management device 100 that manages consumables used in equipment constituting a system function in a nuclear power plant, the consumables management device 100 determines the importance of the consumables based on the importance of the equipment constituting the system function and the results of inspection cycles of consumables used in other equipment with similar usage environments and physical property values, monitors the performance and reliability of the consumables based on the importance and usage environment of the consumables, compares and evaluates the reliability of consumables used in other equipment with similar usage environments, and applies horizontal deployment to maintenance plans. This makes it possible to check the deterioration status of consumables used in different equipment installed in similar environments, thereby improving the reliability evaluation of the consumables.

[0106] The present invention is not limited to the above-mentioned embodiment, and various modifications are included. For example, the above-mentioned embodiment has been described in detail to easily explain the present invention, and is not necessarily limited to those having all the configurations described. It is also possible to replace a part of the configuration of a certain embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of a certain embodiment. It is also possible to add, delete, or replace a part of the configuration of each embodiment with another configuration. In addition, each of the above-mentioned configurations, functions, processing units, processing means, etc. may be realized by hardware, for example, by designing them as integrated circuits. In addition, each of the above-mentioned configurations, functions, etc. may be realized by software by a processor interpreting and executing a program that realizes each function. Information such as a program, table, file, etc. that realizes each function can be placed in a memory, a recording device such as a hard disk or SSD (Solid State Drive), or a recording medium such as an IC card, SD card, or DVD. [Explanation of symbols]

[0107] 10 Processing section 11 Consumables importance determination section 12 Consumables performance monitoring department 13 Consumables Health Evaluation Department 14 Preventive Maintenance Planning Department 15 Corrective Action Division 16 Life Cycle Management Department 20 Memory section 21 System / Function / Component Correspondence Table 22 Conservation activity extraction information 23 Field Data Extraction Information 24 FMEA Extraction Information 25 Sensing Extraction Information 26 Classification decision table 27 Consumables Monitoring Classification Table 28, 28A, 28B Consumables Life Evaluation Data 29,29A Consumables Life Threshold Data 30 Input section 40 Output section 50 Communications Department 70 Gate valve 71 Handle 72 Valve stem 73 Upper Base 74 Lower Base 75 Valve seat 76,77 O-ring (consumables) 100 Consumables management device 200 Database device 210 Configuration management DB 220 Maintenance activities / monitoring item DB 230 Sensing DB 240 FMEA DB 250 Field Data DB 300 Consumables Management System S200 Inspection interval extension process

Claims

1. A consumables management device for managing consumables used in equipment constituting a system function in a nuclear power plant, comprising: a consumable importance determination unit that determines the importance of the consumable based on the importance of a device that configures the system function; a consumable performance monitoring unit that monitors performance or reliability of the consumable by changing a monitoring frequency or a monitoring content based on the importance of the consumable; a consumable health evaluation unit that predicts a remaining life of the consumable from status information related to performance or reliability of the consumable and evaluates health of the consumable based on the predicted remaining life of the consumable; a preventive maintenance planning unit that plans preventive maintenance based on the evaluation by the consumables health evaluation unit.

2. The consumables importance determination unit determines the importance of the system to be maintained for the equipment based on the importance of each element function of the system function and the necessity of the component equipment to realize the element function, and determines the importance of the consumables used in the equipment based on the importance of the equipment.

2. The consumables management device according to claim 1.

3. The consumables importance determination unit determines the importance of the consumables by adding a usage environment and a physical property value to the importance of the device.

3. The consumables management device according to claim 2.

4. The consumables importance determination unit determines the importance of the consumables by adding the results of inspection cycles of consumables used in other devices having similar usage environments and physical property values ​​to the importance of the device.

3. The consumables management device according to claim 2.

5. The consumable importance determination unit determines the importance of the consumables by utilizing the importance of the consumables, information on radiation exposure dose of workers, information on work from the loss of function of the equipment to recovery and information on the time required for the work, information on the effect on plant operation in the event of loss of function, and environmental information during operation / stoppage.

3. The consumables management device according to claim 2.

6. The consumable health evaluation unit determines a usage limit of the consumable based on the importance of the consumable and a deterioration parameter of the consumable.

6. The consumables management device according to claim 5.

7. The consumables health evaluation unit determines a replacement period of the consumables based on the importance of the consumables, information on the use limit of the consumables, an EQ test result of the consumables, and a reliability evaluation test result at the time of construction.

6. The consumables management device according to claim 5.

8. The consumables management device further comprises:

3. The consumables management device according to claim 2, further comprising a corrective action unit that corrects a margin of the life of the consumables based on the importance of the consumables.

9. The consumables health evaluation unit corrects an initial EQ test result based on the EQ test result, operation data, and As found data of the consumables, and estimates the remaining life of the consumables.

2. The consumables management device according to claim 1.

10. A consumables management method for a consumables management device that manages consumables used in equipment that configures a system function in a nuclear power plant, comprising: The consumables management device determines the importance of the consumables based on the importance of devices that configure the system function, changes the monitoring frequency or monitoring content based on the importance of the consumables to monitor the performance or reliability of the consumables, predicts the remaining life of the consumables from status information related to the performance or reliability of the consumables, evaluates the soundness of the consumables based on the predicted remaining life, and plans preventive maintenance based on the evaluation of the soundness. A consumables management method comprising:

11. A consumables management method for a consumables management device that manages consumables used in equipment that configures a system function in a nuclear power plant, comprising: The consumables management device determines the importance of the consumables based on the importance of the equipment constituting the system function and the results of inspection cycles of consumables used in other equipment with similar usage environments and physical property values, monitors the performance and reliability of the consumables based on the importance and usage environment of the consumables, compares and evaluates the reliability of consumables used in other equipment with similar usage environments, and applies horizontal deployment to maintenance plans. A consumables management method comprising:

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