Consumables management device and consumables management method

Abstract

This consumable management device (100) is for managing consumables used in apparatuses that constitute system functions in a nuclear power generating plant, and includes: a consumable importance determination unit (11) that determines the importance of consumables; a consumable performance monitoring unit (12) that monitors the performance and reliability of the consumables on the basis of the importance of the consumables; a consumable soundness evaluation unit (13) that predicts the remaining life of each consumable from state information about the consumable and evaluates the soundness on the basis of the assumed remaining life of the consumable; and a preventive maintenance planning unit (14) that plans preventive maintenance on the basis of the evaluation by the consumable soundness evaluation unit.

Description

[Technical Field]

[0001] The present invention relates to a consumables management device and a consumables management method for equipment such as a nuclear power plant. [Background technology]

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

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

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-252311 [Patent Document 2] Japanese Patent Application Publication No. 2019-007852 Summary of the Invention [Problem to be solved by the invention]

[0005] In Patent Document 1, in order to determine a maintenance method for a facility or device, the importance of the facility or device is determined using various importance and risk information related to safety and power supply functions as criteria for determining the importance. However, no technology is disclosed for evaluating the importance or reliability of consumables.

[0006] Generally, for consumables (parts whose performance deteriorates over time and which must be replaced at regular intervals) used in equipment at facilities such as nuclear power plants, the replacement cycle is stated in the instruction manual, 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 managed and maintained appropriately.

[0008] In the past, consumable parts with a limited lifespan were 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 based on experience is set. As a result, there were problems such as failures occurring shortly after replacement, and parts being replaced even though they still had life remaining.

[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 that constitutes a system function in a nuclear power plant, and The nuclear power plant comprises For the system, A storage unit stores a system-function-component correspondence table in which information weighted as the importance of the elemental functions corresponding to the functions required for the system is associated with information weighted as the necessity for each of the plurality of devices that make up the elemental functions, with the function of the system being broken down into a plurality of elemental functions in advance, and a class classification judgment table that classifies the importance of each elemental function and the necessity of the plurality of devices that make up the elemental functions into classes based on a matrix table in which the importance of each elemental function and the necessity of the plurality of devices that make up the elemental functions are arranged in rows and columns;For the system to be conserved, the system function of the system handle Importance of element functions and relevant element function In fulfilling this Necessity of component equipment Gender Determine, The decision was made The aforementioned The importance of the device in the system is classified into classes based on the classification determination table using the importance of the element functions and the necessity of the device, and the classified Equipment Class and device used Consumables Same as class a consumables importance determination unit that determines whether the consumables are important or not, and The consumables importance determination unit determines The consumables class The present invention is characterized by comprising a consumables performance monitoring unit that monitors the performance and reliability of the consumables at a monitoring frequency based on a value obtained by the above calculation, a consumables health evaluation unit that predicts the remaining life of the consumables from the status information of the consumables and corrects the predicted remaining life of the consumables by taking into account the influence of deterioration in accordance with the use conditions of the consumables, and a preventive maintenance planning unit that determines whether the replacement cycle can be extended based on the remaining life corrected by the consumables health evaluation unit and plans preventive maintenance. Other aspects of the present invention will be described in the embodiments described below. [Effects of the Invention]

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

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

[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 are proposed that can appropriately manage consumables used in equipment. First, the terms used in this embodiment, features, etc. will be described.

[0014] In the present invention, the term "elemental functions" is used to describe the system functions of the system to be maintained. In the present invention, the functions of the system are first broken down into "elemental functions," such as pressure resistance, cooling, and flow control. Then, rather than classifying the importance of the functions required of the system alone, weights are assigned based on the importance of the "elemental functions" of the system that correspond to the functions required of the system. Meanwhile, the equipment that makes up the system is weighted from the perspective of its necessity for fulfilling the "elemental functions."

[0015] An example of weighting is shown in Figure 11. Details will be given later, but the elemental functions of the system are broken down into cooling, isolation, flow control, etc., and the importance of each function is weighted as H (High), M (Middle), or L (Low). Meanwhile, the necessity of components for 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 "elemental functions" as a medium.

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

[0017] In Japan, the relative importance of functions required to ensure the safety of light water reactor facilities for power generation is determined from a safety perspective, and the design of structures, systems, and equipment is classified into classes 1, 2, and 3 according to their importance. In conventional maintenance, the importance of maintenance is determined first by the safety importance of the system, and then the importance of the maintenance of the equipment is classified according to the impact that equipment failure would have on the system function.

[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 consumables based on the importance (equipment class) of the equipment that constitutes the system function, a consumable performance monitoring unit 12 that monitors the performance and reliability of consumables based on the importance of the consumables, a consumable health evaluation unit 13 that predicts the remaining life of the consumables from the status information of the consumables and evaluates the health of the consumables based on the predicted remaining life of the consumables, a preventive maintenance planning unit 14 that plans preventive maintenance based on the evaluation by the consumable health evaluation unit, a corrective action unit 15 that corrects the life margin of the consumables based on the importance of the consumables, and a life cycle management unit 16 that aggregates the performance history, life history, margin change history, etc. of the consumables 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 consumables from installation to replacement.

[0020] The memory unit 20 stores a correspondence table 21 between systems, functions, and components, 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 consumables monitoring classification table 27, consumables life evaluation data 28, consumables life threshold data 29, etc.

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

[0022] The database device 200 includes a configuration management DB 210, a maintenance activity / monitoring item DB 220, a sensing DB 230, an FMEA DB 240, and a field data DB 250. Note that DB stands for database. FMEA is an abbreviation for Failure Mode and Effect Analysis, and is a systematic analysis method for 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, design documents, and actual data for the power plant. The maintenance activity / monitoring item DB 220 is a database containing information on the maintenance activities and monitoring items of the power plant, that is, the content, frequency, and target deterioration events. The sensing DB 230 is a database that includes the degradation modes and measurement methods (principles, sensor installation locations, etc.) that are covered regarding sensing technologies that can be applied to power plants. FMEA DB240 is a database that contains information on the deterioration modes of equipment that make up 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 on-site, such as the results of maintenance activities (inspection results, test results, etc.), data before inspection and maintenance, and daily monitoring data.

[0024] <Supply Management Process Overview> 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 using FIG.

[0025] The consumables importance determination unit 11 determines the importance of consumables used in equipment that is the target of maintenance at a nuclear power plant based on the importance of that equipment (equipment class). The consumables importance determination unit 11 extracts the relationship between the system, the system's elemental functions, and the equipment that makes up the system, and for the system that is the target of maintenance, classifies (determines) the equipment into three classes (Class A, Class B, Class C) based on the importance of the system function of that system in units of "elemental functions" and the necessity of the component equipment that realizes that "elemental function." Class A is the most important class, Class C is a corrective maintenance class that keeps equipment in operation until maintenance is required, 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 in 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, information on the work performed from the loss of equipment function to recovery and the time required for that work, and information on the impact on plant operation if the function is lost.

[0028] The consumables performance monitoring unit 12 monitors the performance and reliability of consumables based on the importance of the consumables. The monitoring method varies in frequency and content depending on the importance. For example, for Class A, the monitoring frequency is every △ days, and for Class C, the monitoring frequency is every 〇 months. The consumables performance monitoring unit 12 monitors consumables performance by referring to the judgment results of the consumables importance judgment unit 11, the evaluation results of the consumables health evaluation unit 13, the maintenance plan results of the preventive maintenance planning unit 14, and the corrective action results of the corrective action unit 15.

[0029] The consumables health evaluation unit 13 predicts the remaining life of the consumables from the status information 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, for example (see FIG. 15).

[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 a threshold value for the life of the consumable based on the importance of the consumable. The threshold value for 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] FIG. 3 is a diagram showing the relationship between element functions, devices, and consumables. In this embodiment, the functions performed by a system are broken down into "element functions," such as a cooling function, an isolation function, and a flow control function. Each element function is made up of multiple devices that are components of the system. These components use multiple consumables. As described above, importance is not classified based solely on the functions required of the system, but is weighted based on the importance of the "element functions" of the system that correspond to the functions required of the system, and the devices that make up the system are weighted from the perspective of their necessity for performing the "element functions." Importance is classified (determined) from both perspectives.

[0034] Figure 4 is a diagram showing an example of consumables used in equipment. Figure 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 as consumables in the gate valve 70. The gate valve 70 is also called a gate valve, and because the flow path is straight, pressure loss is small. It is used to either allow a forceful flow of fluid when fully open, or to completely stop the fluid when completely closed.

[0035] Consumables used in nuclear power-related facilities include resin products (packings, sealing materials, oil, coating materials, sheets, etc.) and metal products (bearings, etc.).

[0036] Returning to FIG. 1, examples of the classification decision table and data configuration of each DB will be described. <Classification decision table> 5 is a diagram showing an example of the class classification determination table 26. The classes (Class A, Class B, Class C) are classified using a matrix of the importance of elemental functions and the necessity of the component devices that realize the elemental functions. The vertical axis represents the importance of the elemental functions, and the horizontal axis represents the necessity of the device for the elemental functions. The importance of elemental 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", or 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", "L", or "-".

[0038] <Examples of data configuration for each DB> Fig. 6 is a diagram showing an example of configuration data in the configuration management DB 210. The configuration management DB 210 is composed of categories and their configuration data. Categories include design requirements, facility configuration information, and physical configuration. For example, design requirements include legal regulations, design criteria documents, and calculation and analysis results.

[0039] For example, it also includes consumable information indicating the contents of consumables to be replaced as part of EQ equipment maintenance. The consumable information includes the consumable name, consumable model number, EQ equipment used, consumable specifications, consumable price, availability period, replacement time, work procedure, last replacement date, recommended lifespan, remaining lifespan, 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 for the consumable in the EQ device. The work procedure is information indicating the procedure for replacing the consumable in the EQ device. It may be a procedure file or a link to a web page showing 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 should be 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, it is not necessary to replace the consumable during this maintenance work.

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

[0044] Figure 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., as well as 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 configuration of the sensing DB 230. The sensing DB 230 has data such as the equipment name, faulty part, deterioration mechanism, cause of deterioration, measurement target, measurement method, sensor installation location, etc. According to Fig. 6, in the case of the XX valve, the faulty part is the seal part, and it can be seen that packing deterioration is expected.

[0046] Figure 9 shows an example of the data configuration of the FMEA DB240. The FMEA DB240 contains data such as equipment name, deterioration mode, effective maintenance activities and monitoring items. The deterioration mode includes the failure location, deterioration mechanism, deterioration impact, deterioration severity, and deterioration frequency. Figure 9 shows that in the case of the XX valve, there is a possibility of leakage occurring due to resin deterioration in 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 includes 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 consumables importance determination unit 11 extracts information from the configuration management DB 210 that organizes the relationships between systems, system functions of the systems, element functions of the systems (system element functions), and equipment that make up the systems, in order to assign priorities when optimizing maintenance activities, and outputs a correspondence table 21 of systems, functions, and components.

[0049] 11 is a diagram showing an example of a system-function-component correspondence table 21. The system-function-component correspondence table 21 is composed of the 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 performed by the system include cooling, isolation, and flow control functions, and the importance of each element function is weighted as H (High), M (Middle), or L (Low). The necessity of a component for that function is weighted as H (High), M (Middle), L (Low), or no contribution (-). According to Figure 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, if 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, if 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 that make up the system are weighted (H, M, L, -) from the perspective of their necessity in fulfilling the element functions.

[0053] The consumables importance determination unit 11 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) that is necessary to maintain the important element function that the system should perform, equipment that is not essential to maintain the function (Class C), or other equipment (Class B).

[0054] FIG. 12A is a diagram showing an example of Class A based on the consumables importance judgment 11. The 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 an equipment necessity of "H" (see the bold frame). Looking at the importance of function x equipment necessity, the cooling function is M x M and the flow control function is L x L, so the judgment is 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 correspondence table 21 of systems, functions, and components is the same as the correspondence table shown in Fig. 11. In the case of the "◇◇ Pump" in Fig. 12B, when looking at the importance of the function x the necessity of the equipment, the cooling function is M x H, the isolation function is H x L, and the flow control function is L x 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 Class C by the consumables importance determination unit 11. The correspondence table 21 of systems, functions and components is the same as the correspondence table shown in Fig. 11. In the case of the "△△ valve" in Fig. 12C, when looking at the importance of the 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 bold frame), and the function is classified (determined) as Class C based on the highest case.

[0057] <Consumables monitoring classification table> Figure 13 is a diagram showing an example of a consumables monitoring classification table 27 used by the consumables performance monitoring unit 12 and the consumables health evaluation unit 13. Figure 13 is a consumables monitoring classification table for sealing members. In Figure 13, EQ test data refers to test data for the environmental performance assurance (EQ) of equipment in nuclear power plants. 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] If the sealing material is static, the confirmation of the amount of wear is classified as whether it can be confirmed from the outside or not. If it can be confirmed from the outside, the life assessment will use 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 assessment will use the initial value data, EQ test data, and as-found data after use.

[0059] If the sealing material is dynamic, the confirmation of the amount of wear is classified according to whether it can be confirmed from the outside. If it can be confirmed from the outside, the life assessment will use 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 assessment will use the initial value data, EQ test data, and as-found data after use.

[0060] <Consumables Health Evaluation Department> 14A is a diagram showing an example of consumable life evaluation data 28 of the consumable health evaluation unit. The consumable 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 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 that indicate life characteristics related to operating time from the dimensions (initial dimensions), shape, or physical properties of the consumables before use, and dimensional changes, shape changes, or physical property deterioration such as compression set at the end of use, and then predicts the remaining life of the consumables from the state of the equipment based on the limit test results.

[0062] The consumables health evaluation unit 13 evaluates the remaining life of the consumables, taking into account the effects of degradation according to the usage conditions of the consumables. Usage conditions that affect degradation include temperature, radiation dose, properties of fluids in contact with the consumables (gas, steam, 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 shows consumable life evaluation data 28 after correction by consumable health evaluation unit 13. Consumable life evaluation data 28B in FIG. 14B shows data that has been corrected to enable an estimate that is more appropriate for the actual equipment (corrected values ​​indicated by dashed lines). Consumable health evaluation unit 13 uses the EQ test results, in-operation data, and as-found data to correct the initial EQ test results for the compression strain of the sealing member over time, thereby making an estimate that is more appropriate for the actual equipment. In this case, consumable health evaluation unit 13 may group the data by environment and evaluate the data across the board for the same materials used in different equipment.

[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 greater and the lifespan of the material will be shorter.

[0065] Furthermore, the consumables soundness evaluation unit 13 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. In this case, it is desirable that the consumables soundness evaluation unit 13 takes into account the dimensional variations of the consumables and evaluates the remaining life to be short for parts with large dimensional variations.

[0066] 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 consumable parts according to the usage conditions of the consumable parts.

[0067] <Corrective Actions Department> Fig. 15 is a diagram showing a method for selecting a threshold value for the life of consumables in the corrective action unit 15. Fig. 14 shows the time course of the compression set of the sealing member, but the threshold value is important for determining the life of the sealing member. Fig. 15 shows consumables life threshold data 29.

[0068] Figure 15 shows two life curves: one for data from the EQ test alone (solid line data) and one for data combining the EQ test and As-found data (dashed line data). Generally, for high-reliability equipment, the threshold for determining life is set low (stricter), while for general equipment, the threshold for determining life is set high. Setting a high threshold extends the predicted life, but increases the risk of leakage, which is undesirable for high-reliability equipment. Furthermore, setting a uniformly low threshold for all consumables would result in earlier replacement times for consumables, which is undesirable from the perspective of equipment maintenance. High-reliability equipment here refers to equipment used in industries such as aviation, space, energy, and nuclear power.

[0069] 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 threshold for determining the life of the consumable is determined according to the importance of the consumable (according to each class).

[0070] Figure 16 is a diagram showing consumable life threshold data 29A for each class of consumables. Figure 16 shows the lifespan for each class of consumables as determined by the consumable health evaluation unit 13. The consumable health evaluation unit 13 estimates the lifespan of the consumables according to the threshold selected by the corrective action unit 15. Figure 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 consumables (Class A, Class B, Class C) determined by the consumable importance determination unit 11.

[0071] The consumable health evaluation unit 13 can determine that the lifespan of the target consumable is time Ta in the case of class A, time Tb in the case of class B, and time Tc in the case of class C.

[0072] The consumables soundness 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 (for example, compression-affected strain).

[0073] 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 results of the consumable.

[0074] <Preventive Maintenance Planning Department> 17 is a diagram showing a regular inspection interval extension process S200 of the preventive maintenance planning unit 14. 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), it proceeds to process S211.

[0075] 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.

[0076] In process S204, the preventive maintenance planning unit 14 determines whether or not the technical requirements for extending the inspection period need not be considered. If the requirements do not need to be considered (process S204, Yes), the preventive maintenance planning unit 14 extends the inspection period (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).

[0077] In process S211, the preventive maintenance planning unit 14 determines whether the inspection can be postponed by changing the replacement margin in the same way as for general consumables, and if it can be postponed (process S211, Yes), it considers the technical requirements if the inspection is postponed and extends the inspection period (process S212), and if it cannot be postponed (process S211, No), it proceeds to process S213.

[0078] In process S213, the preventive maintenance planning unit 14 determines whether the inspection can be postponed by changing to consumables of other equipment, and if it can be postponed (process S213, Yes), it considers the technical requirements for changing the consumables and changes to consumables of other equipment (process S214), and if it cannot be postponed (process S213, No), it continues operation with the current inspection cycle and consumables (process S215).

[0079] The technical requirements for 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 functionality can be maintained, an assessment of the increased risk in the event of a failure of the equipment, consideration of organizational and security aspects, an assessment of the impact on public safety, and calculation of the amount of radiation exposure of employees involved in the work.

[0080] For example, the maintenance activity extraction information 22 (see FIG. 1) is information extracted from the pre-review maintenance activity and 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 section is serious.

[0081] One way to detect abnormalities in Class A consumables is to monitor the fluid temperature near the seal. By monitoring during operation, it is possible to detect early deterioration of the packing due to heat.

[0082] Maintenance activities for Class B consumables include material analysis of the seal packing (hardness and compression set analysis). By performing this during disassembly and inspection, it is possible to understand the deterioration of the packing over time and detect any abnormalities in the consumables.

[0083] 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, steam, 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 comparisons and evaluations, enabling efficient data acquisition and improved evaluation accuracy.

[0084] The consumables management device 100 and consumables management method of the present embodiment described above have the following features. (1) A consumables management device 100 for managing consumables used in equipment that constitutes system functions in a nuclear power plant includes a consumables importance determination unit 11 that determines the importance of consumables based on the importance (equipment class) of the equipment that constitutes the system functions, a consumables performance monitoring unit 12 that monitors the performance and reliability of consumables based on the importance of the consumables, a consumables health evaluation unit 13 that predicts the remaining life of the consumables from status information 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 14 that plans preventive maintenance based on the evaluation by the consumables health evaluation unit. This allows for appropriate management of consumables used in equipment in maintenance activities of the nuclear power plant.

[0085] (2) The consumables importance determination unit 11 determines the importance of the equipment for maintenance of the 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 that realizes the element function, and then determines the importance of the consumables used in the equipment based on the importance of the equipment (see Figures 12A, 12B, and 12C).

[0086] (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 loss of equipment functionality to recovery and the time required for that work, and information on the impact on plant operation if functionality is lost.

[0087] (4) The consumables soundness 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).

[0088] (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 results of the consumable (see Figures 15 and 16).

[0089] (6) The consumables management device 100 further includes a corrective action unit 15 that corrects the lifespan margin of the consumables based on the importance of the consumables (see FIG. 15).

[0090] (7) The consumables health evaluation unit 13 may correct the initial EQ test results based on the EQ test results of the consumables, the operating data, and the as-found data, and estimate the remaining life of the consumables (see Figures 14B and 15).

[0091] (8) A consumables management method for a consumables management device 100 that manages consumables used in equipment that constitutes system functions in a nuclear power plant, wherein the consumables management device 100 determines the importance of the consumables based on the importance of the equipment that constitutes the system functions, 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 enables appropriate management of consumables used in equipment in maintenance activities of the nuclear power plant.

[0092] (9) In a consumables management method for a consumables management device 100 that manages consumables used in equipment that constitutes system functions in a nuclear power plant, the consumables management device 100 determines the importance of the consumables based on the importance of the equipment that constitutes the system functions, 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 that has a similar usage environment, and applies this to horizontal maintenance plans. This makes it possible to check the deterioration status of consumables used in different equipment that is installed in a similar environment, thereby improving the reliability evaluation of the consumables.

[0093] The present invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and are not necessarily limited to those including all of the described configurations. Furthermore, part of the configuration of one embodiment can be replaced with the configuration of another embodiment, or the configuration of another embodiment can be added to the configuration of one embodiment. Furthermore, part of the configuration of each embodiment can be added, deleted, or replaced with other configurations. Furthermore, the above-described configurations, functions, processing units, processing means, etc. may be implemented in hardware, in part or in whole, by designing, for example, an integrated circuit. Furthermore, the above-described configurations, functions, etc. may be implemented in software, by a processor interpreting and executing a program that realizes each function. Information such as programs, tables, and files that realize each function can be stored in 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]

[0094] 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 (consumable) 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 Periodic 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, With respect to the systems constituting the nuclear power plant to be maintained, the functions of the systems are decomposed into multiple element functions in advance, a storage unit that stores a system-function-component correspondence table that is configured by associating information in which the elemental functions are weighted as importance corresponding to the functions required for the system with information in which the necessity of each of the plurality of devices that constitute the elemental functions is weighted, and that stores a class classification determination table that classifies the importance of each of the elemental functions and the necessity of the plurality of devices that constitute the elemental functions into classes using a matrix table in which the importance of each of the elemental functions and the necessity of the plurality of devices that constitute the elemental functions form rows and columns; a consumables importance determination unit that determines, for a system to be maintained based on the system / function / component correspondence table, the importance of each element function corresponding to the system function of the system and the necessity of constituent equipment for fulfilling the element function, and classifies the importance of the equipment in the system into classes based on the class classification determination table using the determined importance of the element function and the necessity of the equipment, and determines that the classified class of the equipment is equivalent to the class of the consumables used in the equipment; a consumable performance monitoring unit that monitors the performance and reliability of the consumable at a monitoring frequency based on the class of the consumable determined by the consumable importance determination unit; a consumables health evaluation unit that predicts a remaining life of the consumables from the state information of the consumables and corrects the predicted remaining life of the consumables by taking into account the influence of deterioration according to the use conditions of the consumables; a preventive maintenance planning unit that determines whether the replacement cycle can be extended based on the remaining life corrected by the consumables health evaluation unit and plans preventive maintenance.

2. The consumables importance determination unit classifies the consumables into classes as follows: when the importance and necessity of maintenance is high, it is class A; when the importance and necessity of maintenance is low compared to class A, it is class C; and when it is other than class A and class C, it is class B.

2. The consumables management device according to claim 1.

3. The consumable health evaluation unit determines a usage limit time of the consumable based on time-elapsed data of the value of the deterioration parameter of the consumable and a usage limit threshold of the deterioration parameter of the consumable according to the class of the consumable.

3. The consumables management device according to claim 2.

4. The consumables health evaluation unit determines a replacement cycle for the consumables based on time-elapsed data of EQ test results of the deterioration parameters of the consumables and a threshold value of a usage limit of the deterioration parameters of the consumables according to the class of the consumables.

3. The consumables management device according to claim 2.

5. The consumables management device further comprises: a corrective action unit that sets a threshold value for a usage limit of a deterioration parameter of the consumable based on the class of the consumable; 5. The consumables management device according to claim 3 or 4.

6. The consumables soundness evaluation unit corrects the initial EQ test result data of the consumables based on the operation data and the as-found data, and estimates the remaining life of the consumables based on the corrected data so that the remaining life can be estimated more appropriately for the actual machine.

2. The consumables management device according to claim 1.

7. A consumables management method for a consumables management device that manages consumables used in equipment that constitutes a system function in a nuclear power plant, comprising: With respect to the systems constituting the nuclear power plant to be maintained, the functions of the systems are decomposed into multiple element functions in advance, storing a system-function-component correspondence table in which information on the elemental functions weighted as importance corresponding to the functions required for the system is associated with information on the weighted necessity of each of the plurality of devices constituting the elemental functions, and storing a class classification determination table in which the importance of each of the elemental functions and the necessity of the plurality of devices constituting the elemental functions are classified into classes according to the importance of the devices for maintenance using a matrix table in which the importance of each of the elemental functions and the necessity of the plurality of devices constituting the elemental functions are arranged in rows and columns; The processing unit of the consumables management device For a system to be maintained based on the system / function / component correspondence table, the importance of each element function corresponding to the system function of the system and the necessity of the component equipment for fulfilling the element function are determined, and the importance of the equipment in the system is classified into classes based on the class classification determination table using the determined importance of the element function and the necessity of the equipment, and the class of the classified equipment is determined to be equivalent to the class of the consumables used in the equipment, monitoring the performance and reliability of the consumable with a monitoring frequency based on the class of the consumable; predicting a remaining life of the consumables from the status information of the consumables; correcting the predicted remaining life of the consumables by taking into account the influence of deterioration according to the conditions under which the consumables are used; Based on the corrected remaining life, it is determined whether the replacement cycle can be extended and preventive maintenance is planned. A consumables management method comprising:

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