Presenter
Michael BaronGlobal Nuclear Associates
IAEA Technical Meeting on Maintenance Optimization
08-10 September 2014
London, United Kingdom
Church House Conference Center
IAEA-TECDOC-1383 Rev 1Guidance for Optimizing
Nuclear Power Plant Maintenance Programs
Discussion with IAEA Consultancy Members
During Document Revision Preparations
Atoms for Peace
IAEA WNA
International Atomic Energy Agency
Background
In order to increase member states capabilities
in optimizing maintenance programs and
related good practices. The Agency
recommends that TECDOC-1383 Guidelines
for Optimization of NPP Maintenance
Programs, published originally in 2003 should
be reviewed and updated considering new
technologies, methods, techniques, strategies
and identified best practices.
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Background
The updated TECDOC is intended to provide
comprehensive, overview, guidelines and
examples on how the NPP operating utilities
can optimize their maintenance programs.
Sponsors and Contacts
Mr. Jiri Mandula of IAEA
Mr. David Hess of WNA
Team Leader Marty Bridges of EPRI
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Why Optimize?
• Fifty Years of Lessons Learned
– Why not take advantage of what the industry already knows!
• Increased Safety based on enhanced planning
• Reduced Costs because of optimized schedules and future
planning, reduced manpower requirements, Increased use
of innovation, operational experience and lesson learned,
incorporation of long term asset management into the
budget process.
• Use of Modified Condition Based Maintenance
• Expanding On Line Maintenance Programs
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Operational, Outage and Construction
execution, has made incredible strides in the
past decade
Methods to enhance controls, increase
efficiencies will be necessary to maintain
control, schedule and cost.
A stagnant organization will not survive without
continued innovation
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What we Know!
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Inputs to Maintenance Optimization
On Line Maintenance
DCD
Departures
(if any)
TECDOC 1383
Engineering
Standards and
ProcessesLessons Learned
Industry Codes,
Standards, Regulatory
EPRI (URD),
EURD, WANO
IAEA, INPO, WNA
Recent Nuclear
Design
New Technology
Commercial
Specifications
Realistic
Utility
Goals
QA
Utility Operating
Experience
LTAM/Budget
Process
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What We Know!
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What We Know!
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What We Know!
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What We Know!
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What We Know!• Units in the top 10% consistently record capacity factors around
the 90% region with the benchmark at 94% suggesting that there are clear gains to be made by researching industry lessons learned and not repeating errors that the rest of the Global Fleet has experienced.
• Planned outages (around 67% of all outages) are the
single most important area where performance improvements can be
realized. Another one of the biggest causes of energy loss (9%) is an
extension to a planned outage—suggesting that the best outages are
not only short, but also well-planned and executed.
• Outage scope does not have to be cut and therefore risk
does not have to be transferred onto the operating cycle.
• Greater efficiencies can be achieved by lower-performing units in this area.
It is the experience of the group that there is a lot of low-hanging fruit,
(small-scale changes) within the reach of most operators that will result
in meaningful outage gains without requiring regulatory changes.
• Figure 5 demonstrates that a high-performing plant is a safe one;
increasing capacity factor correlates with a reduction in automatic
scrams. Efficient management of daily work activities as well as
effective preventive maintenance plans translates into improved overall
quality of operation and enhanced safety.
International Atomic Energy Agency
What we Know
A Capacity Factor of 94% can be achieved
and sustained!
Top utilities have not only achieved these
efficiency's but have maintained them while
maintaining some of the best safety records
and lowest operating and maintenance costs
per Kw/hour
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TECDOC 1383
Changes in the electricity industry in many countries, such as market liberalization
and privatization processes, including deregulation have given rise to merchant
utilities that have led to a highly competitive market environment. Well managed
nuclear power plants (NPPs), if they have low fuel costs and permanently declining
operation and maintenance costs, are often among the least expensive base load
power plants to operate. In a competitive regime this situation encourages, but also
forces NPP owners to further reduce their operation and maintenance costs, but of
course without compromising safety which is, as always, a paramount
consideration. Since the primary purpose of NPP maintenance is to allow nuclear
operators to use all those functions necessary for safe and reliable power
production by keeping them available, an optimum maintenance program is
essential.
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TECDOC 1383
• There are currently 12 chapters in revision 1 of TECDOC
1383
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Maintenance Process Overview and Definitions
Description, relationships, establishing goals, management commitment
and support, organization, roles and responsibilities,
benefits, monitoring and evaluation, optimization, problem screening and
aging management are discussed in this section.
Maintenance Requirements and Objectives of NPP Maintenance Optimization
Drivers and barriers, key performance indicators, maintenance management
systems, evaluation of plant data, plant process data, roles and responsibilities
and expected results are discussed in this section.
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TECDOC 1383
Scoping and identification of critical components
Boundary definitions, tiered maintenance and review panels are discussed in this
section
Optimization of Maintenance Programs
Evaluation of optimization methods, description of various methods (RCM, Risk
Informed SRCM, deviation analysis, production loss analysis, licensing event
analysis are discussed in this section. Pros &Cons of Various Optimization
Methods. Evaluation of current maintenance programs and selection of targets for
improvement, selection should be focused to areas with great advantage.
Optimization of maintenance programs for selected areas
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TECDOC 1383
Determination of optimization methods, comparison of previous and optimized
maintenance programs.
Performance of Maintenance and Work Management
Work management, work order classification, online maintenance vs. outage
maintenance, definition of the Process for maintenance feedback, 4W’s (Who,
What, Where and When)
Evaluation Performance Monitoring
Monitoring of maintenance key performance indicators, system health reporting,
evaluation of condition monitoring data, plant health reporting.
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TECDOC 1383
Corrective Action Program
Analysis of deviations and corrective actions, tracking of corrective actions,
equipment failure screening, analyse results of maintenance feedback, corrective
maintenance, cause evaluation, corrective actions, prioritization of the equipment
problem.
Continuous Improvement Process
Benchmarking, self-assessment, feedback.
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TECDOC 1383
Long term asset management,
Plant health committee programs, (PHC) develops plant SSC health policy,
capacity and capability. The principal objective of PHC is to improve plant
equipment lifetime reliability, manage risks and facilitate through leadership,
strategic direction and collaboration with stakeholders. Plant lifetime management,
aging management, preventive maintenance (PM), PM Optimization, condition
based maintenance (CBM), predictive maintenance (PdM), component
maintenance optimization (CMO) group, advanced monitoring, advanced
monitoring, long term asset management (LTAM) strategy, Plant Health Committee
Program.
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TECDOC 1383
Benefits
Historical perspective
Bibliography
References
Glossary
Annexes
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TECDOC 1383
Last Comments
Jiri
Marty
David
Team
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Thank you
