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ER WORKBENCH

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”.

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ER WORKBENCH

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  1. ER WORKBENCH Dennis Adams First Energy Nuclear Operating Company

  2. 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

  3. “Zero Tolerance” • No UNPLANNED FAILURES of CRITICAL COMPONENTS Resulting in: • Plant trips • Risk-significant Functional Failures • Large sustained MW losses • Offsite Dose Limits Exceeded

  4. 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.

  5. 6 BASIC STEPS SUPPORTING “EXCELLENT MATERIAL CONDITION” INPO AP-913 PERFORMANCE MONITORING WO FEEDBACK ASSET CLASSIFICATION CORRECTIVE ACTION PM TEMPLATES AND SPV MANAGEMENT LONG RANGE MANAGEMENT

  6. INPO AP-913 - “If you build the process, success will follow”

  7. 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

  8. 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

  9. 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

  10. Plant Health Monitor October 2006

  11. Plant Health Monitor ER Workbench Module 09 MPR ER Index ADMIN MODULE System Health Algorithm NOBP-ER-3009 ER CLOCK Quarterly Health Report System Health Risks (SPV’s, OE, Chemistry) Plant Health Committee Site Long Range Plan a d h o c System Health Improvement Plans Site Top Ten Fleet One-List Plant IQ (PdM) Obsolete Components Future Performance Monitoring Maint Rule Core Programs Core Programs Algorithms

  12. Site Matrix • Graphical representation of Site System Health • Provides management with one concise view of a site’s System Health

  13. 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

  14. 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.

  15. Rating Criteria Metrics • Graphical representation of the influences to your System Health • Graphical view of current system health versus previous system health

  16. 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

  17. 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.

  18. Report Builder (1/3)

  19. Report Builder (2/3)

  20. Report Builder (3/3)

  21. Plant Health Report: System Issues

  22. 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

  23. Executive Summary • Preview the Site Breakdown of System Health before publishing report

  24. 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.

  25. 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

  26. Solving Obsolescence Issues • Displays rating data for the Obsolete issue • Determine the impact of the obsolete stock part

  27. 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

  28. 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

  29. 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

  30. 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

  31. 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

  32. Long Range Planning • Define project level details • Link System Issues to projects • Integrates with Fleet Data Warehouse

  33. 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

  34. Long Range Planning Capitol One-List • Build your site’s Capitol One List • Preview and print report

  35. Long Range Planning Financial Forecast • Forecast future spending per project per investment type • Proactively determine funding for projects for future years

  36. 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

  37. 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

  38. 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.

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