Obsolescence Impact on
Configuration Management
Presented By:
Rob Santoro
PKMJ Technical Services, Inc.
1
Definition of Obsolescence
• Obsolete Equipment - “An item in plant
service that is no longer manufactured or
are otherwise difficult to procure and
qualify.”
Source: INPO NX-1037 Revision 1, Obsolescence Program Guideline
2
Obsolescence in Nuclear
• What does that mean to Nuclear Power?
– Manufacturers are no longer making components
required to maintain Plant
– Plants are built with technologies from the 60’s and 70’s
• License Renewal: How will obsolescence impact
the plant for the next 20 years?
• Average of 20% of installed plant equipment is
obsolete
3
Obsolescence Challenges
• Existing station workloads make it difficult to
allocate resources to support proactive solution
development
– Daily challenges of operating the plant take precedence
over Proactive Obsolescence Management
• Obsolescence Is Not Going Away:
– Obsolescence is growing by an average of 12,000
models per year
4
How does Obsolescence Affect
Configuration?
Design
Requirements
Physical
Configuration
Documented
Configuration
• It Impacts All Pillars of the Configuration Triangle!
5
How does Obsolescence Affect
Configuration?
• Documented Configuration:
– Do you know what in your plant is obsolete?
• Design Requirements
– When replacing obsolete components/parts with new
ones, will you change the design requirements?
• Physical Configuration
– The plant may change when replacing an obsolete item
with a new item
6
Tackling Obsolescence
• Understand Its Impact
– Industry Tools Available:
• Proactive Obsolescence Management System (POMS)
• RAPID/OIRD
• Prioritize Challenges
– Industry Tools Available:
• Preventive Maintenance Forecaster (PM Forecaster)
• Obsolescence Manager (OM)
• Solve Challenges
– Several Solution Options:
•
•
•
•
Surplus
Equivalency Evaluations
Design Changes
Reverse Engineer
– Industry Tools Available
• CMIS
7
Tackling Obsolescence
• Understand Its Impact
– The Industry has adopted POMS to identify
obsolescence
• POMS collects all installed equipment information from
each site
• Every year, all manufacturers of equipment is contacted to
identify obsolescence
– All U.S. Utilities are members of POMS
8
Understanding Obsolescence Impact
• POMS Identified:
– 19% of Data Collected Un-Usable
• Cannot contact a manufacturer called “%^&:”
– 15% of Results Incomplete
• Model number insufficient to determine obsolescence
– 11% of Results Unidentifiable
• Manufacturer could not recognize Model Number
9
Understanding Obsolescence Impact
• What does this mean to Configuration
Management?
• Incorrect/Missing information in Enterprise
Management systems could indicate a gap in
Configuration Management
10
Configuration Challenges
• Configuration Challenges discovered when trying
to understand impact of obsolescence to plant
– Master Equipment List’s Incomplete/Inaccurate
• Missing Information
– Manufacturer
– Model Number
– Equipment Details
• Incomplete
– Model Number Incomplete
– Series Number listed
– Site specific number scheme/code
• OEM Not Identified
– AE’s listed as OEM
– Utility listed as OEM
• Bill of Materials Incomplete
11
Addressing Configuration Data
• Data Clean-Up
– Review Design Requirements and Physical
Configuration to identify what is installed and update
Configuration Management Databases
– Look at:
•
•
•
•
•
•
Purchase Orders
Work Order History
Drawings
Vendor Manuals
Design Changes
Equivalency Evaluations
– Walk-Down: Review Nameplate data
– Large Effort
• Attack in phases: Critical Components first
12
Data Clean-Up
• Results:
– Better data available to identify obsolescence challenges
– Provides for better planning
– Some Utilities require Configuration Change
Management to modify this information
13
Configuration Changes
• Be Cognizant of Obsolescence When Performing
Configuration Changes
– Do not “design-in” obsolescence
• Digital Equipment
– Does the OEM have a long term replacement plan?
• Does my new design implement an obsolete item?
– Consider Adding a Check in your design process to
check for obsolescence before completing design
changes
14
Configuration Changes
• Post Implementation: Update Data Systems
– Does your Configuration Change Process require
Enterprise Database Updates before Change is
complete?
• Have you updated the Master Equipment List?
• Have you updated the Bill of Materials?
– Avoid future obsolescence challenges by clearly
documenting current design changes
15
Configuration Changes
• When Performing activities that impact
configuration due to Obsolescence:
– Consider a “design once, install many” approach
• Replace all affected component locations with the
same item (when possible)
– Identify and satisfy “worst case” characteristics when
replacing obsolete items across multiple systems
16
Questions
Next Presentation
17