Configuration Management Fundamentals including Margin Management

1. Configuration Management Fundamentalsincluding Margin Management Presented By: Judy Schulte Duke Power

2. CM Fundamentals • CM Equilibrium • Objective of Configuration Management • MarginsNEWUsing CM to protect Design and Operating Margins • CM Process ModelRestoring CM Equilibrium • Functional Areas • Five Functional Areas of CM

3. What is CM Equilibrium? • In its simplest terms Configuration Management is what we do to assure ourselves and our regulators that we are doing everything we said we would do • The objective of Configuration Managementis the conformance of the three elements represented by the CM Equilibrium Model

4. CM Equilibrium • Design Requirementstechnical requirements, derived from the design process, that are reflected in the final design • What Needs to be there • design characteristics and bounding parameters needed for the design to work • must be verified or monitored to confirm that design is valid DesignRequire-ments

5. CM Equilibrium • Facility Configuration Information • documentation that defines how the plant is designed and how we operate it • What we say is there • Design Output Documents • Operational Configuration Documents • Other Operating, Maintenance, Training and Procurement Information FacilityConfigInfo

6. CM Equilibrium • Physical Configuration • actual physical location, arrangement and material condition of SSCs • What is actually there • SSCs installed (design configuration) • component position (operating configuration) Physical Config

7. CM Equilibrium • Work Processes must assure that: • Elements conform all the time processes in place to restore CMEquilibrium if it is lost • All Changes are Authorizedpeople are trained and qualified • Conformance can be verifieddetermine what configuration is and prove it was done correctly DesignRequire-ments Physical Config FacilityConfigInfo

8. CM Equilibrium • Upsets in CM Equilibrium • errors in analysis, design inputs • errors in licensing documents • desired changes, such as power uprating Design Require-ments FacilityConfigInfo

9. CM Equilibrium • Upsets in CM Equilibrium • drawing / plant discrepancies • components in wrong position • maintenance errors that affect plant configuration • desired changes: modifications, manipulating plant components Physical Config FacilityConfigInfo

10. CM Equilibrium • Upsets in CM Equilibrium • failure of SSC to meet performance criteria as designed • equipment out of tolerance unexpected • degradation in performance of SSCs Design Require-ments Physical Config

11. CM EquilibriumMargins Design Basis Protect the Design Basis Design Configuration conforms to Design Basis Operational Configuration conforms to Design Configuration Design Configuration Operational Configuration Each boundary has margins to protect these limits

12. Margins Failure Point Undetermineddepends on many variables Documented in engineering calculation Ultimate Capability Analytical Margin unanalyzed region Analyzed Design Limit Design Margin controlled by Engineering Operating Limit Operating Margin controlled by Operations Range of Normal Operation Documented on design documents

13. Margins Failure Point Undetermineddepends on many variables • Notes on Model • describes one parameter only; different parameters may be interrelated • direction may be positive or negative • doesn’t represent all possible limits and setpoints • gaps not intended to represent relative size of margins – may be zero Documented in engineering calculation Ultimate Capability Analytical Margin unanalyzed region Analyzed Design Limit Design Margin controlled by Engineering Operating Limit Operating Margin controlled by Operations Range of Normal Operation Documented on design documents

14. Margins Other Limits and Setpoints Failure Point Undetermineddepends on many variables Documented in engineering calculation Ultimate Capability Regulatory Limit Analytical Margin unanalyzed region Analyzed Design Limit Design Margin controlled by Engineering Operating Limit Tech Spec Limit Operating Margin controlled by Operations Operator Alarm (HI-HI) Range of Normal Operation Documented on design documents Operator Alarm (HI)

15. Margins Elevator Example Failure Point – undetermineddepends on many variables Ultimate Capability Analyzed & tested to 4650 lbs Analytical Margin Analyzed Design Limit Design Margin Dept of Labor -design for 25% passenger overload 4375 lbs Operating Limit Operating Margin Range of Normal Operation Rated Load posted in elevator = 3500 lbs 100 – 600 lbs

16. Margins Motor Operated Valve Example • Original analysis: • Design assumes valve closes in 20 seconds • Valve is tested to prove it could close in 16 seconds (with reduced voltage) • Normally valve can close in 12 seconds Analytical Margin 20 sec Design Margin 16 sec Operating Margin 12 sec Normal Operation Valve Closure Time

17. Margins • Over time, performance has • eroded due to aging : • Testing can only prove valve would close in 18 seconds • Design Margin is reduced Motor Operated Valve Example Analytical Margin • Margin can be regained by • installing larger operator • requires more power(affects voltage analysis) • new operator is heavier(affects seismic analysis) 20 sec Design Margin 18 sec Operating Margin 14 sec Normal Operation Valve Closure Time

18. Margins Motor Operated Valve Example • Margin regained on valve closure time • Margin lost on Voltage Analysisand Piping Stress Analysis Analytical Margin Analytical Margin Analytical Margin 20 sec Design Margin Design Margin Design Margin 16 sec Operating Margin Operating Margin Operating Margin 12 sec Normal Operation Normal Operation Normal Operation Valve Closure Time Voltage Analysis Piping Stress Analysis

19. CM Process Model • High level model • Integrated processes used to return CMequilibrium • Developed in early 2002 by CMBG task force

20. CM Process Model • Influenced content of industry guidancedocuments: • NEI Standard Nuclear Performance Model • INPO Operation Excellence Outcomes enablers • Used by CMBG to develop CMPerformance Indicators

21. CM Process Model ChangeDesignRequirements? ChangePhysicalConfiguration? ChangeFacilityConfigurationInformation? EvaluateIdentifiedProblem orDesiredChange • Evaluate Identified Problem or Desired Change • apparent discrepancy (discovered error) • desired change (modification, manipulating plant components) DoNothing More No No No CM Equilibrium Yes Yes Yes CM001 DesignRequirementsChange Process Physical ConfigurationChangeAuthorizationProcess Facility ConfigurationInformationChange Process

22. CM Process Model ChangeDesignRequirements? ChangePhysicalConfiguration? ChangeFacilityConfigurationInformation? EvaluateIdentifiedProblem orDesiredChange • Change Design Requirements? • What are Design Requirements? • Does change affect Design Requirements? • Use Design Requirements change process DoNothing More No No No CM Equilibrium Yes Yes Yes DesignRequirementsChange Process Physical ConfigurationChangeAuthorizationProcess Facility ConfigurationInformationChange Process CM002

23. CM Process Model ChangeDesignRequirements? ChangePhysicalConfiguration? ChangeFacilityConfigurationInformation? EvaluateIdentifiedProblem orDesiredChange • Change Physical Configuration? • Modify components or change position of components? • Use mod process to change design Configuration • Use operating procedures to change component position DoNothing More No No No CM Equilibrium Yes Yes Yes DesignRequirementsChange Process Physical ConfigurationChangeAuthorizationProcess Facility ConfigurationInformationChange Process CM003

24. CM Process Model ChangeDesignRequirements? ChangePhysicalConfiguration? ChangeFacilityConfigurationInformation? EvaluateIdentifiedProblem orDesiredChange • Change Facility Configuration Information? • Design Output documents (drawings & specs) • Operational Configuration Documents • Other operating, maintenance, training, etc. DoNothing More No No No CM Equilibrium Yes Yes Yes DesignRequirementsChange Process Physical ConfigurationChangeAuthorizationProcess Facility ConfigurationInformationChange Process CM004

25. CM Process Model ChangeDesignRequirements? ChangePhysicalConfiguration? ChangeFacilityConfigurationInformation? EvaluateIdentifiedProblem orDesiredChange • Do Nothing More • If cost effective, do nothing more…except • Document your conclusion DoNothing More No No No CM Equilibrium Yes Yes Yes DesignRequirementsChange Process Physical ConfigurationChangeAuthorizationProcess Facility ConfigurationInformationChange Process

26. Functional Areas of CM • #1 Protect the Design Basis • Design Basis Configuration • #2 Modify the Plant • Engineering Change Control • #3 Operate the Plant • Operational Configuration Control • #4 Maintain the Plant • Configuration of SSCs not in service • #5 Test the Plant • Plant Design Validation

27. Functional Areas of CM • Protect the Design Basis • Objective: Understand and maintain • design basis consistent with licensing • basis design • Major processes • control of licensing and design basis documents (such as 50.59 & UFSAR) • engineering calculations • Causes for upsets in CM Equilibrium • new or revised Design Requirements • inadequate original review

28. Functional Areas of CM • Modify the Plant • Objective: Assure that changes to design • configuration conform to Design • Requirements and are accurately reflected • on Facility Configuration Information • Major processes • modification process • Causes for upsets in CM Equilibrium • desired change (modification) • undocumented plant changes

29. Functional Areas of CM • Operate the Plant • Objective: Assure that alignment of in service equipment is consistent with approved design through use of approved technical procedures. • Major processes • operating procedures • tag out process • Causes for upsets in CM Equilibrium • failure to follow operating procedures • human errors due to workarounds,abandoned equipment, temp mods, etc.

30. Functional Areas of CM • Maintain the Plant • Objective: Assure that SSCs are procured and maintained in accordance with approved design • Major processes • maintenance procedures • procurement procedures • Causes for upsets in CM Equilibrium • failure to follow procedures • inadequate procurement QA

31. Functional Areas of CM • Test the Plant • Objective: Assure the performance of SSCs meets Design Requirements • Major processes • performance testing • plant walkdowns • Causes for upsets in CM Equilibrium • inadequate performance testing programs • inadequate plant aging programs