High Accuracy Signal Validation Framework for Sensor Calibration Assessment in NPPs
Effective and efficient health management of sensing channels and instrumentation supports reliable and accurate process monitoring capacities in any industry. Current practice in the nuclear industry relies on periodic calibration assessment and correction activities. This time based maintenance technique consists of three steps: i) removal of sensor to a test environment, ii) testing and recalibration, and iii) reinstallation of sensor into its working environment. This procedure is highly labor intensive, adds to the outage cost and timeline, and contributes to worker radiation exposure and ALARA requirements. Furthermore, the human element contributes to error factors in all stages of the procedure. The effectiveness of this calibration procedure after sensors are returned to working environmental variables also raises concerns, and the practicability of this periodic approach is uncertain for future reactor designs with longer operating cycles between refueling outages. Studies indicate that periodic calibration assessment find only 10% of sensing instrumentations with calibration issues during a single outage (18- 24 months), meaning at least 90% of sensors are undergoing unnecessary maintenance actions. This provides an opportunity to maintain the current levels of safety and functional integrity with fewer, more targeted maintenance actions and lower economic burden. Performance-based maintenance planning shows much promise over current periodic maintenance approaches. Specifically, online monitoring (OLM) utilizes the continually collected process data to non-intrusively monitor the calibration status of process instrumentation and detect the onset of de-calibration, thereby minimizing the number of recalibration procedures required. Ultimately, this can lead to termination of time based recalibration at NPPs. OLM utilizes the process measurements made for process monitoring and control to evaluate the calibration status of the sensors and instrumentation making the measurements. OLM can detect and differentiate sensor faults and process anomalies, thus providing a valuable tool to suit the industry's and regulatory body's requirements. Though supported by more than a decade of research, OLM for sensor calibration assessment is yet to be implemented in the US fleet due to regulatory requirements and constraints. As shown in Figure 1, OLM utilizes process data to train statistical models that predict normal, error-free process behavior. Measured process values are compared with error-corrected predictions to ascertain the presence of faults. The reliability of OLM is dependent on the quality of its predictions, measured in part by the uncertainty in these predictions. This research develops a framework to accurately quantify the prediction uncertainty based on Bayesian inference techniques to provide the required confidence levels for OLM systems. The expected outcomes include signal validation by high-accuracy, high-confidence uncertainty quantification for variable sensor types and operating ranges. Furthermore, the framework will facilitate fault detection capacities and so-called virtual sensors, a capability to replace faulty sensor measurements with error-corrected values when a sensor fault is detected. (authors)