Sebastián Martorell

Age-dependent reliability model considering effects of maintenance and working conditions

Abstract Nowadays, there is some doubt about building new nuclear power plants (NPPs). Instead, there is a growing interest in analyzing the possibility to extend current NPP operation, where life management programs play an important role. The evolution of the NPP safety depends on the evolution of the reliability of its safety components, which, in turn, is a function of their age along the NPP operational life. In this paper, a new age-dependent reliability model is presented, which includes parameters related to surveillance and maintenance effectiveness and working conditions of the equipment, both environmental and operational. This model may be used to support NPP life management and life extension programs, by improving or optimizing surveillance and maintenance tasks using risk and cost models based on such an age-dependent reliability model. The results of the sensitivity study in the example application show that the selection of the most appropriate maintenance strategy would directly depend on the previous parameters. Then, very important differences are expected to appear under certain circumstances, particularly, in comparison with other models that do not consider maintenance effectiveness and working conditions simultaneously.

Constrained optimization of test intervals using a steady-state genetic algorithm

Abstract There is a growing interest from both the regulatory authorities and the nuclear industry to stimulate the use of Probabilistic Risk Analysis (PRA) for risk-informed applications at Nuclear Power Plants (NPPs). Nowadays, special attention is being paid on analyzing plant-specific changes to Test Intervals (TIs) within the Technical Specifications (TSs) of NPPs and it seems to be a consensus on the need of making these requirements more risk-effective and less costly. Resource versus risk-control effectiveness principles formally enters in optimization problems. This paper presents an approach for using the PRA models in conducting the constrained optimization of TIs based on a steady-state genetic algorithm (SSGA) where the cost or the burden is to be minimized while the risk or performance is constrained to be at a given level, or vice versa. The paper encompasses first with the problem formulation, where the objective function and constraints that apply in the constrained optimization of TIs based on risk and cost models at system level are derived. Next, the foundation of the optimizer is given, which is derived by customizing a SSGA in order to allow optimizing TIs under constraints. Also, a case study is performed using this approach, which shows the benefits of adopting both PRA models and genetic algorithms, in particular for the constrained optimization of TIs, although it is also expected a great benefit of using this approach to solve other engineering optimization problems. However, care must be taken in using genetic algorithms in constrained optimization problems as it is concluded in this paper.

Genetic algorithms in optimizing surveillance and maintenance of components

Abstract Nowadays the great ability of genetic algorithms (GA) to find solutions in complex optimization problems is known, where other methods used to give poor results. This has opened a wide range of application areas using GA and here we present a new approach aimed at the global and constrained optimization of surveillance and maintenance (S&M) of components based on risk and cost criteria. Also, a case study is performed using this approach which shows the benefits of the integration of S&M tasks of components based on optimized intervals. Moreover, this methodology is completely valid in solving other optimization problems with respect to risk and cost beyond the component level.

RAMS+C informed decision-making with application to multi-objective optimization of technical specifications and maintenance using genetic algorithms

Abstract The role of technical specifications and maintenance (TSM) activities at nuclear power plants (NPP) aims to increase reliability, availability and maintainability (RAM) of Safety-Related Equipment, which, in turn, must yield to an improved level of plant safety. However, more resources (e.g. costs, task force, etc.) have to be assigned in above areas to achieve better scores in reliability, availability, maintainability and safety (RAMS). Current situation at NPP shows different programs implemented at the plant that aim to the improvement of particular TSM-related parameters where the decision-making process is based on the assessment of the impact of the change proposed on a subgroup of RAMS+C attributes. This paper briefly reviews the role of TSM and two main groups of improvement programs at NPP, which suggest the convenience of considering the approach proposed in this paper for the Integrated Multi-Criteria Decision-Making on changes to TSM-related parameters based on RAMS+C criteria as a whole, as it can be seem as a decision-making process more consistent with the role and synergic effects of TSM and the objectives and goals of current improvement programs at NPP. The case of application to the Emergency Diesel Generator system demonstrates the viability and significance of the proposed approach for the Multi-objective Optimization of TSM-related parameters using a Genetic Algorithm.

Alternatives and challenges in optimizing industrial safety using genetic algorithms

Safety (S) improvement of industrial installations leans on the optimal allocation of designs that use more reliable equipment and testing and maintenance activities to assure a high level of reliability, availability and maintainability (RAM) for their safety-related systems. However, this also requires assigning a certain amount of resources (C) that are usually limited. Therefore, the decision-maker in this context faces in general a multiple-objective optimization problem (MOP) based on RAMS+C criteria where the parameters of design, testing and maintenance act as decision variables. Solutions to the MOP can be obtained by solving the problem directly, or by transforming it into several single-objective problems. A general framework for such MOP based on RAMS+C criteria is proposed in this paper. Then, problem formulation and fundamentals of two major groups of resolution alternatives are presented. Next, both alternatives are implemented in this paper using genetic algorithms (GAs), named single-objective GA and multi-objective GA, respectively, which are then used in the case of application to solve the problem of testing and maintenance optimization based on unavailability and cost criteria. The results show the capabilities and limitations of both approaches. Based on them, future challenges are identified in this field and guidelines provided for further research.

Addressing imperfect maintenance modelling uncertainty in unavailability and cost based optimization

Optimization of testing and maintenance activities performed in the different systems of a complex industrial plant is of great interest as the plant availability and economy strongly depend on the maintenance activities planned. Traditionally, two types of models, i.e. deterministic and probabilistic, have been considered to simulate the impact of testing and maintenance activities on equipment unavailability and the cost involved. Both models present uncertainties that are often categorized as either aleatory or epistemic uncertainties. The second group applies when there is limited knowledge on the proper model to represent a problem, and/or the values associated to the model parameters, so the results of the calculation performed with them incorporate uncertainty. This paper addresses the problem of testing and maintenance optimization based on unavailability and cost criteria and considering epistemic uncertainty in the imperfect maintenance modelling. It is framed as a multiple criteria decision making problem where unavailability and cost act as uncertain and conflicting decision criteria. A tolerance interval based approach is used to address uncertainty with regard to effectiveness parameter and imperfect maintenance model embedded within a multiple-objective genetic algorithm. A case of application for a stand-by safety related system of a nuclear power plant is presented. The results obtained in this application show the importance of considering uncertainties in the modelling of imperfect maintenance, as the optimal solutions found are associated with a large uncertainty that influences the final decision making depending on, for example, if the decision maker is risk averse or risk neutral.

Basics of genetic algorithms optimization for RAMS applications

This paper discusses the use of genetic algorithms (GA) within the area of reliability, availability, maintainability and safety (RAMS) optimization. First, the multi-objective optimization problem is formulated in general terms and two alternative approaches to its solution are illustrated. Then, the theory behind the operation of GA is presented. The steps of the algorithm are sketched to some details for both the traditional breeding procedure as well as for more sophisticated breeding procedures. The necessity of affine transforming the fitness function, object of the optimization, is discussed in detail, together with the transformation itself. In addition, how to handle constraints by the penalization approach is illustrated. Finally, specific metrics for measuring the performance of a genetic algorithm are introduced.

Modelling and optimization of proof testing policies for safety instrumented systems

This paper introduces a new development for modelling the time-dependent probability of failure on demand of parallel architectures, and illustrates its application to multi-objective optimization of proof testing policies for safety instrumented systems. The model is based on the mean test cycle, which includes the different evaluation intervals that a module goes periodically through its time in service: test, repair and time between tests. The model is aimed at evaluating explicitly the effects of different test frequencies and strategies (i.e. simultaneous, sequential and staggered). It includes quantification of both detected and undetected failures, and puts special emphasis on the quantification of the contribution of the common cause failure to the system probability of failure on demand as an additional component. Subsequently, the paper presents the multi-objective optimization of proof testing policies with genetic algorithms, using this model for quantification of average probability of failure on demand as one of the objectives. The other two objectives are the system spurious trip rate and lifecycle cost. This permits balancing of the most important aspects of safety system implementation. The approach addresses the requirements of the standard IEC 61508. The overall methodology is illustrated through a practical application case of a protective system against high temperature and pressure of a chemical reactor.

Simultaneous and multi-criteria optimization of TS requirements and maintenance at NPPs

Abstract One of the main concerns of the nuclear industry is to improve the availability of safety-related systems at nuclear power plants (NPPs) to achieve high safety levels. The development of efficient testing and maintenance has been traditionally one of the different ways to guarantee high levels of systems availability, which are implemented at NPP through technical specification and maintenance requirements (TS&M). On the other hand, there is a widely recognized interest in using the probabilistic risk analysis (PRA) for risk-informed applications aimed to emphasize both effective risk control and effective resource expenditures at NPPs. TS&M-related parameters in a plant are associated with controlling risk or with satisfying requirements, and are candidate to be evaluated for their resource effectiveness in risk-informed applications. The resource versus risk-control effectiveness principles formally enter in optimization problems where the cost or the burden for the plant staff is to be minimized while the risk or the availability of the safety equipment is constrained to be at a given level, and vice versa. Optimization of TS&M has been found interesting from the very beginning. However, the resolution of such a kind of optimization problem has been limited to focus on only individual TS&M-related parameters (STI, AOT, PM frequency, etc.) and/or adopting an individual optimization criterion (availability, costs, plant risks, etc.). Nevertheless, a number of reasons exist (e.g. interaction, similar scope, etc.) that justify the growing interest in the last years to focus on the simultaneous and multi-criteria optimization of TS&M. In the simultaneous optimization of TS&M-related parameters based on risk (or unavailability) and cost, like in many other engineering optimization problems, one normally faces multi-modal and non-linear objective functions and a variety of both linear and non-linear constraints. Genetic algorithms (GAs) have proved their capability to solve these kinds of problems, although GAs are essentially unconstrained optimization techniques that require adaptation for the intended constrained optimization, where TS&M-related parameters act as the decision variables. This paper encompasses, in Section 2 , the problem formulation where the objective function is derived and constraints that apply in the simultaneous and multi-criteria optimization of TS&M activities based on risk and cost functions at system level. Fundamentals of a steady-state GA (SSGA) as an optimization method is given in Section 3 , which satisfies the above requirements, paying special attention to its use in constrained optimization problems. A simple case of application is provided in Section 4 , focussing on TS&M-related parameters optimization for a stand-by safety-related system, which demonstrates how the SSGA-based optimization approach works at the system level, providing practical and complete alternatives beyond only mathematical solutions to a particular parameter. Finally, Section 5 presents our conclusions.

The use of maintenance indicators to evaluate the effects of maintenance programs on NPP performance and safety

Abstract Nuclear Power Plants (NPPs) under commercial operation are under continuous demand to meet higher levels of performance and safety by NPP owners, regulatory authorities and the public in general. Maintenance plays an important role in achieving such a goal, therefore, many programs are being conducted in order to improve their effectiveness. A common link between these programs is the necessity to evaluate how maintenance affects NPP performance and safety. This paper presents the foundation of a methodology for a maintenance evaluation program based on maintenance indicators and how it is applied to monitoring the effectiveness of the maintenance at the Cofrentes NPP. The methodology is general and might be applied in other fields of industrial engineering, particularly in those activities which devote many resources to maintain plant equipment, and also in those with less but very critical maintenance.