42
ER WORKBENCH Dennis Adams First Energy Nuclear Operating Company
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
No UNPLANNED FAILURES of CRITICAL COMPONENTSResulting in:
Plant trips
Risk-significant Functional Failures
Large sustained MW losses
Offsite Dose Limits Exceeded
“Zero Tolerance”
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.
6 Copyright © 2003 Electric Power Research Institute, Inc. All rights reserved.
Equipment ReliabilityStates
ImplementationStrategy
Reactive Preventive Proactive
Major emphasis is on –quickly fixing equipment that breaksthat impacts plant operation or safety,reducing maintenance backlog andaccomplishing planned outagemaintenance activities.
Major emphasis is on –preventive actions to keepequipment from breaking.
Major emphasis is on –strategies to address vulnerabilitiesto long-term viability, throughcontingencies or planned changes.
PERFORMANCE MONITORING
ASSET CLASSIFICATION
CORRECTIVE ACTION
WO FEEDBACK
PM TEMPLATES AND SPV
MANAGEMENT
LONG RANGE MANAGEMENT
6 BASIC STEPS SUPPORTING “EXCELLENT MATERIAL CONDITION”
INPO AP-913
Yes
Change Requestfrom Anyone
Equipment Reliability Process Flow chart
Yes
Docum ent and NotifyOriginator as
Necessary
PM ImplementationPerformance M onitoring
Corrective Action
Equipm ent Failure
Yes
Yes
No
Yes
No
2
No
32
Long -Term Planning & Life-Cycle M anagement
Yes
No
Docum ent Basis for RTF
1
1
Start Equipm entReliability Im provem ent
Predictive Results Equipment Test
Program Results Operator Rounds System Engineer
Walkdowns
No
Yes
Yes
Yes
No
Yes
Yes
No
No
YesNo
No
No
No
EPRI SysMonG uidelines
MaintenanceRule
PSA/R iskSignificance
License Renewal,including passiveSSCs
Industry OE
EPRI PM templates Vendor
Recommendations EPIX Aging Studies INPO W eb Site
(events, JIT OE) New Predictive
Technology
IN PO AP-913(R evis ion 1)
Yes
No
Business P lan
M aintenanceResults
Identify Im portantFunctions
1.1
W ill Com ponentFailure Defeat or Degrade
Im portant Function?
1.2
Establish Perform anceCriteria & Monitoring
Param eters
2.1
Monitor/TrendSystem /Function
Perform ance
2.2
Monitor/TrendCom ponent
Perform ance
2.3
Has Perform anceDegraded?
2.4
Yes
Is the Failure aPotential Functional
Failure?
3.3
Perform CorrectiveMaintenance
3.2
W ork Mgmt
Determ ine Cause& Corrective
Action
3.5
Corr. Action
Key equipm entProblem s Prioritization
by Managem ent
3.6
Does PM Basis Exist?
4.3
Is Change Justified?
4.4
Initiate PM Change
4.5
Does an ApplicablePM Tem plate Exist?
4.6
Can Degradation beDetected?
4.7
Identify ConditionMonitoring or
Predictive Task
4.8
Adjust Perform anceMeasures or Criteria?
4.2
Periodically AssessSystem /Com ponent
Health & Vulnerabilities
5.1
Enter Activitiesinto Appropriate
Schedule
5.6
W ork Mgmt
Develop StandardPostm aintenance Test
(PMT)
6.1
Update W orkManagem ent
Database
6.2
W ork Mgmt
Does Model PM W orkOrder Exist?
6.3
Develop Model PMW ork Order
6.4
W ork Mgmt
Begin Perform anceMonitoring
Can the Com ponent beRun to Failure?
1.3
Noncritical
No
Docum ent As-Found Equipm ent
Condition
6.6
W ork Mgmt
Perform predictive,periodic PM, test,
or inspection
6.5
W ork Mgmt
Determ ineMaintenance Rule
Status
3.4
No
Integrate, Prioritize, andReconcile SSC Plans
with the StationBusiness P lan
5.5
Critical
Is There a Cost- E ffectivePeriodic or P lanned PM to
Prevent Failure?
4.9
Develop New PMTem plate to Address
Predom inantFailure Modes
4.10
Select PM Tasks,Establish Frequency,and Docum ent Bases
4.11
Initiate ProactiveStrategy for Aging and
ObsolescenceConcerns
5.4
3
Change to Task orFrequency?
4.1
Can Failure orConsequences be
Controlled?
4.12
InitiateDesign Change toEliminate Failure
4.13
Conf Mgmt
Apply ConfigurationChange or Strategy to
Control Failure
4.14
Conf Mgmt
Docum entClassification of Criticaland Noncritical SSCs
1.4
Yes
Continuing Equipment Reliability Improvement
Scoping and Identificationof Critical Components
Develop/UpdateSystem /Com ponentLong-Term Health
Strategy
5.2
Is Therean Aging or
ObsolescenceConcern?
5.3
UnanticipatedFailure that Should be
Prevented?
3.1
INPO AP-913 - “If you build the process, success will follow”
PullsPushStore
PullsPushStore
PullsPush
PdM StoreWarehouse
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPushStore
PullsPush
Index Store
ExistingTransition Pulls
Development Push
Upcoming StoreOE Database Link
6.6
5.6
4.10, 5.1
3.6, 4.13, 4.14, 5.2, 5.4, 5.5
4.12, 4.13, 4.14, 5.1, 5.2
PM Template Effectiveness Review
Calibration Monitor(Existing at BV)
16
2.1, 4.1, 4.3, 4.4, 4.5, 4.8, 4.9, 4.11
4.14, 5.1, 5.2, 5.3, 5.4
5.3
EPRI - SysMon2.1, 4.2, 4.7
1.1, 1.2, 1.3, 1.4, 4.12
1.2, 2.2, 3.1, 3.3, 3.4, 3.5
2.2, 2.4, 3.6, 4.13, 4.14, 5.1, 5.2, 5.3,
3.1, 3.3, 3.5, 6.6
4.1
4.3, 4.4, 4.11
3.2, 3.6, 5.4, 5.6, 6.5
2.1, 2.3, 2.4, 4.2, 4.8, 5.1
3.6
2.1, 4.3, 4.6, 4.7, 4.10, 4.12
6 Ranking Index of Orders (RIO)
LOTUS NOTES
SQL
Supply Chain Parts &
Capital Spares
CM/EM WO Feedback
PM WO Feedback 6.6
PM Revision Request 4.5, 4.11
PM Deferrals
FENOC Key Performance Indicators (KPI's)
DASHBOARD(Similar to Fossil's SPOT)
2
11
9 System Health Monitor
10 Proactive Maint. (PAM), CM/EM Review
Comp. Health Monitor & PdM Warehouse
8
5 Obsolescence & Parts Modernization
OSI Pi (Ghent Server)
SOMS(Operator Rounds)
GATS
14
CREST 3.1, 3.5(Condition Reports)
PORTALER-Link
2.1, 2.3, 2.4, 4.2, 4.5, 4.7, 4.8
13
RBMWare (oil results only)
7
12E
R W
OR
KB
EN
CH
OR
AC
LE
DA
TA
TA
BL
ES
System Health Report and Data Compiler
3 Comp. Template Implementation
4 Long-Range Asset Management
1 Asset Classification
Just in Time (JIT) PM Review
Component Template Building
Comp. Tracking Module
Lubrication Manual SAP
(The heart of it all) Business 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
EMPAC ENTERPRISE WAREHOUSE
Note: RED numbers correspond to AP-913
Flow Chart
17 Plant Health Long Range Plan & Budget
18 SPV Reduction and Management
Maintenance Rule Monitoring
NUCLEAR IT SOFTWARE FOR EXCELLENT MATERIAL CONDITION
PM Rev. Basis and Long Range Monitor
15 Outage Scope Review and Validation
(IF) Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
1. Forced Loss Rate 3 1.87 1.80 0.58 0.73 5.30 5.80 80.02 9.752. Online CM Backlog 1 83 69 84 57 60 46 120 743. Secondary Chemistry 1 1.210 1.210 1.130 1.130 1.006 1.006 n/a 1.0004. Average Plant Health Report Rating 2 3.440 2.918 3.020 3.082 3.200 3.200 3.160 3.2105. AFW Unavailability (RHR @ Perry) 2 0.004 0.003 0.002 0.002 0.012 0.014 0.008 0.0086. HPI Unavailability 2 0.002 0.002 0.001 0.002 0.032 0.034 0.003 0.0057. EDG Unavailability 2 0.008 0.010 0.005 0.010 0.018 0.020 0.010 0.0108. Work Management Effectiveness 2 100.0% 95.0% 82.0% 82.4% 77.0% 80.0% 52.0% 31.0%9. % Equipment on Pdm Watch List 2 3.03% 1.86% 1.63% 3.14% 0.19% 0.89% 5.34% 5.22%10. PM's w/ Multiple Deferrals 2 0 0 0 1 1 6 148 7411. Unexpected Equip Related LCO Events 3 6 2 4 3 8 3 7 412. Emergent Equipment Failures (CMU) 3
13. # Equip Problems Affecting Capability Factor 3 2 2 2 2 1 1 1 614. MR Functional Failures 3 1 1 3 4 1 1 4 215. Rate of PM Template Implementation 1
85 92 94 91 64 74 58 62
Parameter Sources
1. MPR EMC-04 Forced Loss.xls
2. MPR EMC-02 CM Backlog.xls
3. INPO Plant Information Center
4. Quarterly Plant Health Report
5. MPR EMC-06 AuxFeed (RHR).xls
6. INPO Plant Information Center
7. INPO Plant Information Center
8. Quarterly Plant Health Report
9. PdM Coordinator
10. MPR MWM-01
11. MPR OPS-01 (LRF Risk Indicator)
12. Future SAP Function (CEPM)
13. Site Monthly Operating Report
14. Mainteance Rule Coordinator
15. Future SAP Function (CEPM)
Weighted Score (Max score 128)
< 0.92
0 - 3%
Points
GREEN
4
Beaver Valley U 1 Beaver Valley U 2 PerryParameter
Imp
ac
t F
ac
tor
FENOC Equipment Reliability '04 Data
Davis-Besse
< 0.0023
< 0.0097
<1.001
>90%
< 50
3.25 - 4.00
< 0.0034
0 - 5
< 3
0 - 4
0
< 3
100%
FENOC '04 Quarterly Totals
0
10
20
30
40
50
60
70
80
90
100
110
120
130
1 2 3 4Quarter
To
tal
Beaver Valley U 1 Beaver Valley U 2 Perry 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
Quarterly Health Report
ad
hoc
System HealthImprovement Plans
CorePrograms
PlantHealth Committee
System Health AlgorithmNOBP-ER-3009
Core ProgramsAlgorithms
Plant Health MonitorER Workbench Module 09
System Health Risks(SPV’s, OE, Chemistry)
Fleet One-List
ER CLOCK
Obsolete Components
MPRER Index
ADMIN MODULE
Site Top Ten
Site Long RangePlan
PerformanceMonitoring
Maint Rule
Future
Plant IQ(PdM)
Site Matrix
• Graphical representation of Site System Health• Provides management with one concise view of a site’s
System Health
• Personalized• Quick glance
at your system’s performance compared to last quarter
• Quick view of quarterly
System Inbox
report progress for your systems• Identifies list of new items that are related to Systems
assigned to you
• 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.
System Health Summary
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
• Lets site management know how well Systems are being managed• Easily view for the site, what percentage of System Health related work was completed.
View System breakdown
Solving Obsolescence Issues
• Determine the relative importance of your Obsolete stock• Roll Obsolete stock up to the component and system level• Items Rated to give relative importance
• Integrated with:
– System Inbox
– System Health rating
– Long Range Planning
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
Create System Issue and future Long
Range Plan project based off
obsolescence item
View additional
obsolescence details
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
• 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
• 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
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 PlanningMonthly Cash flow
• Track the monthly cash flow per year per project• Automatically calculates variance • Graphically displays when projects are over budget
Long Range PlanningCapitol One-List
• Build your site’s Capitol One List• Preview and print report
Long Range PlanningFinancial Forecast
• Forecast future spending per project per investment type
• Proactively determine funding for projects for future years
Long Range PlanningPlant 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) A declaration of any ERO Emergency Classification.(2) An unplanned reactor trip (manual or automatic).(3) A Level 1, 2 or 3 Reactivity Event (i.e., control rod mis-positioning).(4) An entry into an Emergency Operating Procedure (EOP).(5) 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.
