Presented By: John Gierlach, Senior Advisor Ontario Power Generation

1. Vendor Manual Program Implementation Presented By: John Gierlach, Senior Advisor Ontario Power Generation 8th Configuration Management Benchmarking Conference October 29 – 31, 2001 Raleigh, NC

2. Agenda • Background • Vendor Manual Reconstitution Program • Principles • Baseline scope and results • Re-contact scope and results • Analysis of changes • Update of plant documentation • Summary

3. Background • Ontario Power Generation (OPG) nuclear assets • Darlington (4 units) & Pickering (8 units) • Bruce (8 units) leased to Bruce Power in 2001 • History • 1970’s - 1990’s: Construction • 1990’s: Deteriorating performance • 1997: Start of Nuclear Recovery & Configuration Management Restoration Project (CMRP) • Vendor Manual Reconstitution Program for 12 of 20 nuclear units

4. Principles • Use only original approved copies from Records • Minimize paper - electronic image with text • Not done in house - contracted to Data Repro Com • 4,329 Vendor Manuals on intranet, fully text searchable • Satisfy plant personnel • Focused on installation/operation/maintenance (IOM) • Focused on essential systems • Reduce risk of baseline and re-contact effort • Not done in house - contracted to VIS • Included evaluation of changes - minimize OPG workload

5. Baseline Scope and Results • 1,943 Vendor Manuals • 1,448 for essential systems • 495 for non-essential systems • Above Vendor Manuals contained 23,438 Publications • 18,761 for essential systems • 4,677 for non-essential systems • 1,221 vendors • 12% consisted of multiple copies of same publication • Over 50% of the Publications in Vendor Manuals were immediately classified as insignificant - unlikely that evaluation or vendor contact would yield substantive plant operations and maintenance benefit

6. Baseline Results (2) • Largest populations: • Honeywell 232 • Klockner Moeller 222 • Johnson Controls 185 • Solar Turbines 179 • Envirex 152 • ITE 136 • Rotork 128 • Fisher Controls 114

7. Baseline Results (3) • Insignificant Publication types: Catalog (may contain performance specifications) 804 Correspondence (OPG or vendor) 185 Product data sheet, specification 1,492 Drawing (stand alone) 6,644 Seismic, EQ test results 401 Plant cataloging information 1,640 OPG plant procedure 10 Purchase requirements, warranties 111 Sales / price list (no performance specifications) 44 Parts lists ( No IOM or technical information) 1,017 Total 12,348

8. Baseline Results (4) • Significant Publication types: IOM manuals 9,308 Product bulletins 972 SALs, errata, addenda 259 Recommended spare parts 551 Total 11,090

9. Re-contact Scope • Focus on essential systems: 8,705 Publications • Eliminate duplicates: - 1,460 Publications • Staticon, Velan, Crompton Instruments, Honeywell • Eliminate vendors: - 1,001 Publications • Ontario Power Generation, Ontario Hydro Technologies, AECL, General Electric, Westinghouse • Final Re-contact scope: 6,244 Publications • 956 vendor contacts

10. Re-contact Results • 95.8% vendor contact success rate • Uncooperative: Vendors Publications Reason 20 134 Many calls – no response 1 1 Combative 2 12 Other priorities 2 32 Expensive subscription • Unresponsive: Vendors Publications 9 85

11. Re-contact Results (2) • Future contact not necessary: Description Publications Vendor out of business 341 Catalog 24 Out of scope 10 Information not available 33 Not subject to revision 334 Obsolete equipment 1,347 Use original publication 2,648 Total 4,737

12. Re-contact Results (3) • Future contact necessary: Description Publications Current, but may be revised later 503 Out-of-date, new revision sent 703 Not enough info to verify 37 Unresponsive 85 Uncooperative 179 Total 1,507

13. Re-contact Results (4) • Analysis of changes - changes not of concern: • 205 Publications contained administrative or non-technical changes • Trivial, editorial change • Not expected to impact plant configuration or procedures. • Addition of background information • Addition of specifications • General guidance, such as troubleshooting • 33 Publications contained configuration changes: • Change that does not apply to OPG installation

14. Re-contact Results (5) • Analysis of changes - changes of concern: • 28 additional Publications provided: • Publication provides information not previously found in OPG system and cannot be compared to anything • 363 Publications contained technical changes: • Expected to impact plant configuration or procedures • Changes to specifications • Changes in order of task performance • Addition of, or changes to, maintenance • Addition of acceptance criteria

15. Update of Plant Documentation • Routed through Engineering Change Control • No changes - no review • Changes not of concern - minimum review • Changes of concern - full review • PassPort database updated • Vendor Manual image file embedded (Acrobat format) • Review cycle timeframe entered to indicate when future contact is necessary (3 years or 99 years) • Vendor Manual linked to equipment record • Minimize paper copies and distribution

16. Summary • 4,329 Vendor Manuals placed on intranet • 1,943 Vendor Manuals subject to baseline efforts • 18,761 Publications in 1,448 Vendor Manuals for essential systems analyzed in detail: • 67% (12,517 Publications) not significant • 25% (4,737 Publications) significant but do not require future contact • 8% (1,507 Publications) significant and require future contact • 2% (363 Publications) significant and had substantial technical changes