ER WORKBENCH
Dennis Adams
First Energy Nuclear Operating Company
Objectives of Presentation
• On Going Communication of ER Process
• Review Status of ER Philosophy
• Review ER Tools
• Integrate Chemistry into Plant Health
• Demonstrate Plant IQ for Chemistry Dept
“Zero Tolerance”
No UNPLANNED FAILURES of CRITICAL COMPONENTS
Resulting in:
Plant trips
Risk-significant Functional Failures
Large sustained MW losses
Offsite Dose Limits Exceeded
BACKGROUND
• In November 2001, INPO issued Rev. 01 – AP-913
“Equipment Reliability Process Description”.
• The purpose of AP-913 was to describe an equipment
reliability process to ensure all utilities maintained high
levels of safe and reliable plant operation in an efficient
manner.
• One of the major changes involved identifying critical
components, and improved guidance for continuing
Equipment Reliability (ER) improvement.
Equipment Reliability
States
Major emphasis is on –
quickly fixing equipment that breaks
that impacts plant operation or safety,
reducing maintenance backlog and
accomplishing planned outage
maintenance activities.
Reactive
Implementation
Strategy
Major emphasis is on –
strategies to address vulnerabilities
to long-term viability, through
contingencies or planned changes.
Preventive
Major emphasis is on –
preventive actions to keep
equipment from breaking.
6
Copyright © 2003 Electric Power Research Institute, Inc. All rights reserved.
Proactive
6 BASIC STEPS SUPPORTING
“EXCELLENT MATERIAL CONDITION”
INPO AP-913
PERFORMANCE
MONITORING
ASSET
CLASSIFICATION
WO
FEEDBACK
CORRECTIVE
ACTION
PM TEMPLATES
AND SPV
MANAGEMENT
LONG RANGE
MANAGEMENT
INPO AP-913 - “If you build the process, success will follow”
Scoping and Identification
of Critical Components
INPO AP-913
(Revision 1)
Equipment Reliability Process Flowchart
Performance Monitoring
Corrective Action
Start Equipment
Reliability Improvement
 Predictive Results
 Equipment Test
Program Results
 Operator Rounds
 System Engineer
Walkdowns
Begin Performance
Monitoring
1
1.1
6.6
6.5
Document AsFound Equipment
Condition
Maintenance
Results
Perform predictive,
periodic PM, test,
or inspection
3.1
3.2
2.1
Unanticipated
Failure that Should be
Prevented?
Establish Performance
Criteria & Monitoring
Parameters
Identify Important
Functions
PM Implementation
Equipment Failure
No
Work Mgmt
Work Mgmt
Perform Corrective
Maintenance
Yes
Work Mgmt
2.2
Monitor/Trend
System/Function
Performance
 EPRI SysMon
Guidelines
 Maintenance
Rule
 PSA/Risk
Significance
 License Renewal,
including passive
SSCs
2.3
Yes
Monitor/Trend
Component
Performance
3.3
6.3
6.2
Update Work
Management
Database
3.4
Is the Failure a
Potential Functional
Failure?
Yes
Determine
Maintenance Rule
Status
Does Model PM Work
Order Exist?
Work Mgmt
2
No
No
2.4
3.5
No
Has Performance
Degraded?
3.6
Determine Cause
& Corrective
Action
Yes
6.4
6.1
Key equipment
Problems Prioritization
by Management
Develop Standard
Postmaintenance Test
(PMT)
Develop Model PM
Work Order
Corr. Action
Work Mgmt
No
Long -Term Planning & Life-Cycle Management
Continuing Equipment Reliability Improvement
4.2
4.1
4.3
4.4
4.5
Yes
Adjust Performance
Measures or Criteria?
No
Change to Task or
Frequency?
Yes
Does PM Basis Exist?
Yes
Is Change Justified?
Yes
5.1
Initiate PM Change
Periodically Assess
System/Component
Health & Vulnerabilities
2
3
No
No
4.6
1.2
Will Component
Failure Defeat or Degrade
Important Function?
Document and Notify
Originator as
Necessary
1.4
Critical
Yes
Document
Classification of Critical
and Noncritical SSCs
Does an Applicable
PM Template Exist?
No
1.3
Noncritical
Can the Component be
Run to Failure?
No
Work Mgmt
No
4.7
5.3
4.8
Change Request
from Anyone
Can Degradation be
Detected?
Yes
Is There
an Aging or
Obsolescence
Concern?
Identify Condition
Monitoring or
Predictive Task
4.13
1
Initiate
Design Change to
Eliminate Failure
Enter Activities
into Appropriate
Schedule
Develop/Update
System/Component
Long-Term Health
Strategy
Industry OE
 EPRI PM templates
 Vendor
Recommendations
 EPIX
 Aging Studies
 INPO Web Site
(events, JIT OE)
 New Predictive
Technology
5.6
5.2
Yes
5.5
No
Integrate, Prioritize, and
Reconcile SSC Plans
with the Station
Business Plan
No
No
Yes
Yes
Conf Mgmt
3
4.12
4.9
Can Failure or
Consequences be
Controlled?
Is There a Cost- Effective
Periodic or Planned PM to
Prevent Failure?
4.14
Document Basis
for RTF
Apply Configuration
Change or Strategy to
Control Failure
Conf Mgmt
4.10
Yes
No
Yes
Develop New PM
Template to Address
Predominant
Failure Modes
4.11
Select PM Tasks,
Establish Frequency,
and Document Bases
5.4
Initiate Proactive
Strategy for Aging and
Obsolescence
Concerns
Business Plan
NUCLEAR IT SOFTWARE FOR EXCELLENT MATERIAL CONDITION
GATS
P ulls
P us h
S t o re
RBMWare
( o il re s ult s o nly)
P ulls
P us h
S t o re
1
Asset Classification
1.1, 1.2, 1.3, 1.4,
4.12
P ulls
P us h
S t o re
2
Component Template
Building
2.1, 4.3, 4.6, 4.7,
4.10, 4.12
P ulls
P us h
S t o re
3
Comp. Template
Implementation
2.1, 4.1, 4.3, 4.4,
4.5, 4.8, 4.9, 4.11
P ulls
P us h
S t o re
4
Long-Range Asset
Management
4.14, 5.1, 5.2, 5.3,
5.4
P ulls
P us h
S t o re
5
Obsolescence & Parts
Modernization
5.3
P ulls
P us h
S t o re
6
Ranking Index of Orders
(RIO)
3.2, 3.6, 5.4, 5.6, 6.5
P ulls
P us h
S t o re
7
Comp. Health Monitor &
PdM Warehouse
2.1, 2.3, 2.4, 4.2,
4.8, 5.1
P ulls
P us h
S t o re
8
(Sim ilar to Fossil's SPOT)
P ulls
P us h
S t o re
9
System Health Monitor
2.2, 2.4, 3.6, 4.13,
4.14, 5.1, 5.2, 5.3,
P ulls
P us h
S t o re
10
Proactive Maint. (PAM),
CM/EM Review
3.1, 3.3, 3.5, 6.6
P ulls
P us h
S t o re
11
Just in Time (JIT)
PM Review
4.1
P ulls
P us h
S t o re
12
PM Rev. Basis and Long
Range Monitor
4.3, 4.4, 4.11
P ulls
P us h
S t o re
13
Maintenance Rule
Monitoring
1.2, 2.2, 3.1, 3.3,
3.4, 3.5
P ulls
P us h
S t o re
14
Calibration Monitor
(Existing at BV)
6.6
PM Deferrals
P ulls
P us h
S t o re
15
Outage Scope Review and
Validation
5.6
CM/EM WO
Feedback
P ulls
P us h
S t o re
16
PM Template Effectiveness
Review
4.10, 5.1
EPRI - SysMon
2.1, 4.2, 4.7
P ulls
P us h
S t o re
17
Plant Health Long Range
Plan & Budget
3.6, 4.13, 4.14, 5.2,
5.4, 5.5
OE Database Link
P ulls
P us h
S t o re
18
SPV Reduction and
Management
4.12, 4.13, 4.14, 5.1,
5.2
OSI Pi
(Ghent Server)
CREST 3.1, 3.5
( C o ndit io n R e po rt s )
PORTAL
ER-Link
2.1, 2.3, 2.4, 4.2,
4.5, 4.7, 4.8
SOMS
( O pe ra t o r R o unds )
Lubrication
Manual
SAP
Comp. Tracking
Module
(The heart of it
all) Business
FENOC
Key Performance
Indicators (KPI's)
Warehouse
or ODS
Interfaces
1.4, 4.1, 4.3, 4.11,
3.2, 5.6, 6.1, 6.2,
6.3, 6.4, 6.5, 6.6
Supply Chain
Parts &
Capital Spares
PM WO Feedback
6.6
LOTUS
NOTES
SQL
Index
Existing
Transition
Development
Upcoming
P dM
Wa re ho us e
PM Revision
Request 4.5, 4.11
ER WORKBENCH ORACLE DATA TABLES
EMPAC
ENTERPRISE
WAREHOUSE
System Health Report and Data
Compiler
Note: RED num bers
correspond to AP-913
Flow Chart
DASHBOARD
3.6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Forced Loss Rate
Online CM Backlog
Secondary Chemistry
Average Plant Health Report Rating
AFW Unavailability (RHR @ Perry)
HPI Unavailability
EDG Unavailability
Work Management Effectiveness
% Equipment on Pdm Watch List
PM's w/ Multiple Deferrals
Unexpected Equip Related LCO Events
Emergent Equipment Failures (CMU)
# Equip Problems Affecting Capability Factor
MR Functional Failures
Rate of PM Template Implementation
FENOC Equipment Reliability '04 Data
Impact
Factor
Parameter
Beaver Valley U 1
(IF)
Q1
Q2
3
1
1
2
2
2
2
2
2
2
3
3
3
3
1
1.87
83
1.210
3.440
0.004
0.002
0.008
100.0%
3.03%
0
6
1.80
69
1.210
2.918
0.003
0.002
0.010
95.0%
1.86%
0
2
Weighted Score (Max score 128)
Q3
Beaver Valley U 2
Q4
Q1
0.58
0.73
84
57
1.130 1.130
3.020 3.082
0.002 0.002
0.001 0.002
0.005 0.010
82.0% 82.4%
1.63% 3.14%
0
1
4
3
Future SAP Function (CEPM)
Perry
Q4
Q1
Davis-Besse
Q2
Q3
5.30
5.80
60
46
1.006 1.006
3.200 3.200
0.012 0.014
0.032 0.034
0.018 0.020
77.0% 80.0%
0.19% 0.89%
1
6
8
3
Q4
Q1
Q2
GREEN
Q3
Q4
80.02
9.75
120
74
n/a
1.000
3.160 3.210
0.008 0.008
0.003 0.005
0.010 0.010
52.0% 31.0%
5.34% 5.22%
148
74
7
4
< 50
<1.001
3.25 - 4.00
< 0.0034
< 0.0023
< 0.0097
>90%
0 - 3%
0-5
<3
2
1
2
1
2
3
2
4
1
1
1
1
1
4
6
2
85
92
94
91
64
74
58
62
0
<3
100%
130
120
110
100
90
80
Total
4
< 0.92
FENOC '04 Quarterly Totals
MPR EMC-04 Forced Loss.xls
MPR EMC-02 CM Backlog.xls
INPO Plant Information Center
Quarterly Plant Health Report
MPR EMC-06 AuxFeed (RHR).xls
INPO Plant Information Center
INPO Plant Information Center
Quarterly Plant Health Report
PdM Coordinator
MPR MWM-01
MPR OPS-01 (LRF Risk Indicator)
Future SAP Function (CEPM)
Site Monthly Operating Report
Mainteance Rule Coordinator
Q3
0-4
Parameter Sources
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Q2
Points
70
60
50
40
30
20
10
0
1
2
Beaver Valley U 1
Quarter
Beaver Valley U 2
3
Perry
4
Davis-Besse
Reasons for an Equipment
Reliability Program
– Long standing equipment problems
– Eng, Maint, and Ops not aligned in prioritizing and
correcting equipment problems
– Inconsistencies in System Monitoring
– Ineffective Corrective Action Programs
– PM Program weaknesses contribute to equipment
problems
Reliability Program Initiatives
• Capture PM “As-Found” equipment conditions
• Maintain PM bases and monitoring plans as “living
documents”
• Develop long term system and station plans which
include aging and obsolescence issues. (Preventive
Replacement)
• Any chemistry issues associated with each of the
systems will be included in the system health report
Benefits and Features
• Consistent system performance rating calculations across the Fleet
• Centralized Online access of Issue; tracking and status, comments,
decision notes, FVR details, Project options
• Integrated with Long Range Planning
• Automated interfaces with SAP, CREST, Asset Mgmt, Plant IQ
• Pre-defined PM Templates, standard consistent language
• Automated report generation, centralized hard-copy assembly and
distribution and access to current and historical reports
Plant Health Monitor
October 2006
Plant Health Monitor
ER Workbench Module 09
MPR
ER Index
ADMIN MODULE
System Health Algorithm
NOBP-ER-3009
ER CLOCK
System Health Risks
(SPV’s, OE, Chemistry)
System Health
Improvement Plans
Plant IQ
(PdM)
Plant
Health Committee
Quarterly Health Report
Site Long Range
Plan
Site Top Ten
Fleet One-List
h
o
c
Obsolete
Components
Future
Performance
Monitoring
Maint
Rule
a
d
Core
Programs
Core Programs
Algorithms
Site Matrix
• Graphical representation of Site System Health
• Provides management with one concise view of a site’s
System Health
System Inbox
• Personalized
• Quick glance
at your
system’s
performance
compared to
last quarter
• Quick view of
quarterly
report progress for your systems
• Identifies list of new items that are related to Systems
assigned to you
System Health Summary
• System Counts and Calculations updated nightly
• Influenced by your Fleet’s specific criteria
• Displays break down of algorithm counts, individual scores,
overall system score, and historical system scores.
Rating Criteria Metrics
• Graphical representation of the influences to your System
Health
• Graphical view of current system health versus previous
system health
Order Aging Report
• Provides System Engineers the ability to maintain and control their
Corrective Maintenance backlogs
• Displays listings of the oldest open corrective maintenance work,
corrective maintenance orders greater than 12 months old, and all
corrective maintenance orders closed within the quarter
Building System Report
• Two Methods to build System Report:
1) Report Builder:
-Step by Step report
building
-Simple to use
2) Main Report Section:
-Advanced Report options
-Verify and Submit reports
-View other System reports and/or Executive Summaries.
Report Builder (1/3)
Report Builder (2/3)
Report Builder (3/3)
Plant Health Report: System Issues
Improvement Plan
• Provides System Engineers the ability to effectively manage
their System to identify what work needs to be completed
during the next quarter to improve their System Health
• Unfinished items automatically copy from quarter to quarter
so that work is not missed
Executive Summary
• Preview the Site Breakdown of System Health before
publishing report
Organizational Effectiveness
View System
breakdown
• Lets site management know how well Systems are being managed
• Easily view for the site, what percentage of System Health related work
was completed.
Solving Obsolescence Issues
•
Integrated with:
– System Inbox
– System
Health rating
– Long Range
Planning
• Determine the relative importance of your Obsolete stock
• Roll Obsolete stock up to the component and system level
• Items Rated to give relative importance
Solving Obsolescence Issues
•
•
Displays rating data for the
Obsolete issue
Determine the impact of the
obsolete stock part
Solving Obsolescence Issues
•
View System related
obsolescence issues at the
component & stock level on the
System Inbox
View
additional
obsolescence
details
Create System Issue
and future Long
Range Plan project
based off
obsolescence item
Plant Health Committee Issues
• Draft System Issues to submit to the Plant Health Committee
• Integrate Fleet Value Ranking and Prescreening Form
• Integrates System related issues such as Obsolescence directly to the
Plant Health Committee
Draft New Issue:
NOBP-ER-1004 Fleet Value Rating (FVR) Methodology
FVR Form:
•
•
Provides a qualitative analysis to objectively provide each
issue with a relative rating
Administratively controlled to enable users to change and
required
Plant Health Committee
•
•
•
•
•
•
Integrates System
Related data
directly to the Plant
Health Committee
Create new
meetings and
agendas. Stay on
top of all current
open issues
Track meeting
minutes and issue
decisions all in one
place
Seamlessly transition issues to the Technical Oversight Sub-Committee (TOS), Project
Review Committee (PRC), or Executive Project Review Committee (EPRC)
Don’t lose anything: view meeting history and decisions made to issues gone past.
Same workflow and input screens for PRC, EPRC, and TOS
Long Range Planning
• Integrates System Issues and the Plant Health Committee
directly with the Long Range Plan
• Build and maintain budget information for approved projects
• Define and track the One List and the Site Top 10 List
Long Range Planning
• Define project level details
• Link System Issues to projects
• Integrates with Fleet Data Warehouse
Long Range Planning
Monthly Cash flow
• Track the monthly cash flow per year per project
• Automatically calculates variance
• Graphically displays when projects are over budget
Long Range Planning
Capitol One-List
• Build your site’s Capitol One List
• Preview and print report
Long Range Planning
Financial Forecast
• Forecast future spending per project per investment type
• Proactively determine funding for projects for future years
Long Range Planning
Plant Maintenance Plan
• Keep track of the cost of the Plant Maintenance work being performed
• Forecasts spending per component per system for the next 10 years
ER Clock
• Track the success of the Equipment Reliability program at your Fleet
• View all ER Clock resets and potential impacts
• Analyze reset criteria to determine the weaknesses in your ER Program
Equipment Reliability Event Free
Days.
(1)
(2)
(3)
(4)
(5)
A declaration of any ERO Emergency Classification.
An unplanned reactor trip (manual or automatic).
A Level 1, 2 or 3 Reactivity Event (i.e., control rod mis-positioning).
An entry into an Emergency Operating Procedure (EOP).
An entry into an Abnormal Operating Procedure (AOP) with significant
impact on plant operation.
(6) An unplanned entry into a shutdown Technical Specification Action/LCO,
License Requirements Manual.
(7) An unplanned increase by a factor of 10 in core damage frequency
category.
(8) An unplanned increase in On-line risk by one or more color levels.
(9) An unplanned increase by one or more color levels in Shutdown Risk
category.
(10) A failed Critical Component with an actual loss of system design function.
(11) A Force Loss rate event of 2% or greater for more than 12 hours.
(12) A Repeat Maintenance Rule Functional Failure.