ENTE PER LE NUOVE TECNOLOGIE, L'ENERGIA E L'AMBIENTE Associazione ENEA-EURATOM sulla Fusione FUSION UNIT TECHNOLOGIES DIVISION COLLECTION AND ANALYSIS OF COMPONENT FAILURE DATA FROM JET SYSTEMS 10th of July 2006 T. Pinna (1) , G. Cambi (2) , F. Gravanti (1) (1) Thermonuclear Fusion Division - Safety & Environment Via E. Fermi 45, I-00044, Frascati (Rome), Italy e-mail: [email protected], [email protected](2) University of Bologna, Physic Department Via Irnerio 46, I-40126 Bologna, Italy, e_mail: [email protected]
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ENTE PER LE NUOVE TECNOLOGIE, L'ENERGIA E L'AMBIENTEAssociazione ENEA-EURATOM sulla Fusione
FUSION UNITTECHNOLOGIES DIVISION
COLLECTION AND ANALYSIS OF COMPONENT FAILURE DATA FROM JET SYSTEMS
(2) University of Bologna, Physic DepartmentVia Irnerio 46, I-40126 Bologna, Italy, e_mail: [email protected]
OBJECTIVE (1)
8th IAEA TM on FPPS - July 2006
To develop a fusion specific component failure database with data coming from operating experiences gained in various fusion laboratories
The activity began in 2001 with the study of data from the JET Vacuum system and Active Gas Handling System (AGHS), plus data from the Tritium Laboratory of Karlsruhe (TLK)
Two years later the Neutral Beam Injectors (NBI) and Power Supply (PS) systems were considered and,
in this last year the Ion Cyclotron Resonant Heating (ICRH) system is under evaluation.
OBJECTIVE (2)
Collect all the information available about single component malfunctions and failures of the systems under investigation, pointing out causes, consequences, maintenance actions
Collect information useful to evaluate probabilistic valuesrelated to component malfunctions and failures
Estimate the main reliability parameters, (such as the failure rate and the corresponding standard errors and confidence intervals), associated to the components
Point out practical information on the operating experienceacquired
8th IAEA TM on FPPS - July 2006
8th IAEA TM on FPPS - July 2006
Neutral Beam Injectors
ASYNC Mode
SYNC Mode
Component malfunctions and failures in NBI boxesAbout 100 failures were identified since the beginning of operations up to March 2004
Faults related to components in NBI Boxes
0 5 10 15 20
Accelerator stackBox scrapers
CalorimeterCentral Support
Cryo plantCryo pump
Deflection MagnetsDuct liner/scrapers
Fast shutterFull energy ion
Ion SourceMagnet liners
NBI diagnosticsNeutraliser
N° of Faults
Trend of failures related to components in NBI boxes
0
20
40
60
80
100
120
1985 1987 1988 1990 1992 1994 1996 1998 2000 2002
8th IAEA TM on FPPS - July 2006
Cooling channels (electrodeposited → drilled)Bellows (single → twin)Cooling line layout to avoid water freeze-upsInability to accurately predict power densities in the duct region under the different magnetic fields
Statistical analysis: Constant Failure Rate Model
TN
=λ
λ= Historical failure rate (/h)N = Observed number of failures over time TT = Timescale derived from period of historical data record
T = Σ(Operating time of single component * N° of components)
Mean time between failures (MTBF)Uncertainty values:
standard error s.e.(λ), lower λL and upper λU limits of the 90% confidence interval
8th IAEA TM on FPPS - July 2006
Statistical analysis: Constant Failure Rate Model
nfPD =
PD= Failure of component on demand (/d)f = Observed number of failures on demandn = number of demands from historical data record
n = Σ(number of demands on single component * N° of components)
Mean number of demands between failures (MDBF)Uncertainty values:
standard error s.e.(PD), lower (PDL) and upper (PDU) limits of the 90% confidence interval
8th IAEA TM on FPPS - July 2006
NBI: Number of pulses/operating days
SYNC & ASYNC Pulses in the period January 1994 - March 2004
Schematic of Poloidal Field power supply sub-system
NBI PS
Component malfunctions and failures in PS system
2150 failures/malfunctions for the Power Supply system sinceJanuary 1997 up to May 2003 have been collected in the JET Logging System
About 1935 records are related to Coil PS and NBI. They havebeen classified:
Main Component/ System
Type of failure /malfunction
Component/ Subsystem in fault conditions
Failure Mode
Causes
Efforts to classify PS events => ~ 1000 h x 2 PPY8th IAEA TM on FPPS - July 2006
Classification of failures/malfunctions on PS system
8th IAEA TM on FPPS - July 2006
Classification of failures/malfunctions on PS system
8th IAEA TM on FPPS - July 2006
Failures/malfunctions on PS system
8th IAEA TM on FPPS - July 2006
Code Description N° of failures/malfunctionsGrid 400kV 400kV Distribution System 25Grid 36kV 36kV Distribution System 33PFGC Poloidal Flywheel Generator Converter 54TFGC Toroidal Flywheel Generator Converter 50PF-P1 Poloidal Field - P1 Coil 12PF-OH Poloidal Field - Ohmic Heating system 195PDFA1/4 Poloidal Diverter Field Amplifier 1/2/3/4 50PVFA Poloidal Vertical Field Amplifier 90PVFB Poloidal Vertical Field Booster 19FRFA Fast Radial Field Amplifier 82DFAS Disruption Feedback Amplifier System 16TF-Coil Toroidal Field - Coils 5TF-SU Toroidal Field - Static Units 87DMSS-PF Direct Magnet Safety System - Poloidal Field 6DMSS-TF Direct Magnet Safety System - Toroidal Field 7RPC Reactive Power Compensation 70CODAS Control Data Acquisition System (general) 13CPS Coil Protection System 140MDS CODAS - Machine Diagnostic System 29NBI Power Supply of Neutral Beam Injectors (general) 20NBI4 Power Supply of Neutral Beam Injectors in Octant 4 415NBI8 Power Supply of Neutral Beam Injectors in Octant 8 417NBI-TB Power Supply of Neutral Beam Injectors - Test Bed 43AncW Ancillary - Water cooling system (general for all PS systems) 2AncA Ancillary - compressed Air (general for all PS systems) 3AncP Ancillary - Power Supply Low Voltage (general for all PS systems) 4NoId Not Identified 2None Not Significant 40
8th IAEA TM on FPPS - July 2006
Failures/malfunctions on Coil PSFailures/malfunctions in Coil Power Supply systems
0 50 100 150 200
Ancillary systems
Control systems
DFAS
DMSS
FGCs
FRFA
Grid 400kV / 36kV
PDFA
PF-OH
PVFA&PVFB
RPC
TF-SU
N° of Faults
Main component or large Unit interested by the faults
0 50 100 150 200
Air cool. system
Compressed air systemAncillary Power Supply
Water cool.systemBusbar
CapacitorCircuit breaker -ac -36kV
Circuit breaker -Disconnector -36 kV
CODASProtec.& Contr.Sys.
Coil -CPSConverter
CrowbarElectrical filter
FGCsGrid 400kV / 36kV
InductorRPC Unit (general)
Resistor
Switch -Earth switchSwitch -Switchgear
Switch -Vacuum switch -36kVTransformer
Not significant
N° of Faults
8th IAEA TM on FPPS - July 2006
Failures/malfunctions on Coil PSFailures/malfunctions in Coil Power Supply systems
0 50 100 150 200
Ancillary systems
Control systems
DFAS
DMSS
FGCs
FRFA
Grid 400kV / 36kV
PDFA
PF-OH
PVFA&PVFB
RPC
TF-SU
N° of Faults
Main component or large Unit interested by the faults
0 50 100 150 200
Air cool. system
Compressed air systemAncillary Power Supply
Water cool.systemBusbar
CapacitorCircuit breaker -ac -36kV
Circuit breaker -Disconnector -36 kV
CODASProtec.& Contr.Sys.
Coil -CPSConverter
CrowbarElectrical filter
FGCsGrid 400kV / 36kV
InductorRPC Unit (general)
Resistor
Switch -Earth switchSwitch -Switchgear
Switch -Vacuum switch -36kVTransformer
Not significant
N° of Faults
Low level compon. or ancill. subsyst. in fault conditions without I&C
0 10 20 30 40 50 60
Ancillary Air cool. System - FanAncillary Compressed air system
Failures & malfunctions in NBIs versus Operating days
y = 0.9708x - 233.28
0100200300400500600700800900
1000
0 200 400 600 800 1000 1200
N° of operating days since January 1997
N° o
f fau
lts
Main component or large Unit interested by the faults
0 50 100 150 200
NBI PS Module (generic)
Compressed air
SF6 supply
Water cool.system (generic)
Protec.& Contr.Sys.
Transmission Line
Auxiliary PS (FIL,ARC,SB)
Grid 1Protection Unit
Grid 2 PS
Grid 3 PS
Circuit breaker -ac -36kV
HV - Rectifier PS
Magnetic Field Compensation PS
Magnet PS
Not identified
Not significant
N° of Faults
Failures/malfunctions on NBI PS
8th IAEA TM on FPPS - July 2006
Failures/malfunctions in PS systems during pulses
1E-3 1E-2 1E-1 1E+0
Ancillaries (general for PS plant)
CPS
DMSS
FRFA
Grid 400kV / 36kV
MDS
PDFA
PVFA1/4
PVFA5/6
PVFB
RPC
PF-OH
FGCs (both)
PFGC
T FGC
T F-SU
NBIs (both)
NBI4
NBI8
Fail . Rate (1/h ) for C omp. O N
PS: Statistical evaluationsGlobal data
Coil and NBI PS troubles with regard to operating days
1E-2 1E-1
Coil PS Systems - Generic trouble
Coil PS Systems - Alarm/Erratic Alarm/Failto preset
Coil PS Systems - Fail to operate/Spuriousoperation
NBI PS Systems - Generic trouble
NBI PS Systems - Alarm/Erratic Alarm/Failto preset
NBI PS Systems - Fail to operate/Spuriousoperation
Fail. Rate (1/h)
PS: Statistical evaluations
On average more than one trouble (1.2 trouble/day) occurred every day of operations (16 h/day) for the Coil PS and one trouble/day for the NBI PS.
55 % of the Coil PS troubles were due to “Alarm” or “Erratic Alarm” indicating a failure or a malfunction of the systems or “Failure to preset” the systems to operate. The other 45 % of the troubles were due to “Failure to operate” or “Spurious operation” of the system components.
72 % of the NBI PS troubles were due to “Alarm” or “Erratic Alarm” indicating a failure or a malfunction on the systems or “Failure to preset” the systems to operate. The other 28 % of the troubles were due to “Failure to operate” or “Spurious operation” of the systems.
8th IAEA TM on FPPS - July 2006
PS: Statistical evaluations
8th IAEA TM on FPPS - July 2006
Samples of data evaluated for the PS componentsWith regard to full
AGHS: about 130 failures on a set of 6259 components, operating for about 156 767 000 hours, have been pointed out since 1995 up to January 2002
Vacuum system: about 600 failures on a whole set of 4012 components, operating for about 249 450 000 hours, have been pointed out since March 1983 up to January 2002
TLK: 52 failures on a set of 584 components, operating for about 10 746 732 hours, have been pointed out up to October 2002
8th IAEA TM on FPPS - July 2006
Overview on the data collection activity (2)
From AGHS
Failure Rate of Indicator types for "Erratic/No output" faults (1/h)
ICRH: 4741 events of failures/malfunctions have been identified and classified for the operating period March 1996 – November 2005. Daily pulses have been counted for a total of 897 days with ICRHplasma pulses. Report to be reviewed by JET Operators.
This activity is set in the frame of Task 5 of the IEA Agreement
Data collected in the “Fusion Component Failure Rate Database”.
8th IAEA TM on FPPS - July 2006
8th IAEA TM on FPPS - July 2006
Overview on the data collection activity (1)
ACKNOWLEDGMENT
The authors have to thank members of the JET Groups:
Neutral Beam Injectors,
Power Supply,
Active Gas Handling System,
Vacumm System,
Ion Cyclotron Resonance Heating,
Close Support Unit and,
TLK Group for the supplying of data used in this study