Institute of Nuclear Power Operations
INPO Engineering – Configuration
Management Activities
Presentation to CMBG
June 20-22, 2011
Bob Gambrill
Department Manager,
Engineering-CM
© 2011 Institute of Nuclear Power Operations
Carl Faller
Assistant Department Manager,
Engineering-CM
Topics
• Consequences of Fukushima
• Industry Performance
(EN & CM Evaluation Results)
• Margin Management
• Engineering Product Quality
• Digital Systems
• Technical Conscience
• Other Emerging Issues
© 2011 Institute of Nuclear Power Operations
Consequences of Fukushima
© 2011 Institute of Nuclear Power Operations
IER Level 1 11-1
Overview
• Issued March 15 (rev March 18)
• Focus is to provide near-term assurance of high state
of readiness to respond to both design basis and
beyond design basis events
• Frequently asked questions—clarified intent of
recommended actions
• Walk down and inspection guidelines
– Industry drafted, endorsed following INPO review and
comment
© 2011 Institute of Nuclear Power Operations
Gap Overview
IER 11-01 Gaps Identified
by Recommendation
4 - Post Seismic Fire /
Flooding Equiq Avail,
30%
1.a - Beyond DBA
Equip Availability,
11%
1.b - Beyond DBA
Procedures, 12%
1.c - Beyond DBA
Staff Qualification,
3% DBA
1.d - Beyond
Plan
Agreement/Contract,
2%
2.a - SBO Material /
Equip Staging, 4%
3.a - Flooding Equip,
29%
© 2011 Institute of Nuclear Power Operations
2.b - SBO Procedures
Executable, 7%
IER 11-1 General Trends / Themes
• SAMG programs / processes have not been updated to
reflect changes to plant configuration
• Required equipment no longer exists
• Procedure execution weaknesses
• Contract elapsed / no longer valid
• Required tools / equipment not staged
• Material not properly maintained
• Design vulnerabilities exist
© 2011 Institute of Nuclear Power Operations
IER 11-2, Spent Fuel Pool Loss of
Cooling and Makeup
• Issued April 26
• Increase sensitivity to SFP
storage event response
1.
Verify shutdown safety provisions
applied to SFP during outage
2.
Apply increased protection for SFP
during operating modes while heat load remains high
3.
Provide time to saturation conditions to control room and emergency
response staff
4.
Abnormal operating procedures address loss of cooling and makeup
5.
Emergency procedures contain precaution for monitoring SFP level
and temperature
© 2011 Institute of Nuclear Power Operations
Fukushima - Next Steps
• Review and consider EAG Working Group
recommendations
• Detailed Fukushima event timeline and causes
• Industry lessons learned working meetings
• New IERs to address other Fukushima lessons learned
• SBO / focus on AC power
© 2011 Institute of Nuclear Power Operations
Industry Performance (CM & EN Evaluation Results)
Categories of AFIs (through end of
Number of AFIs
16
14
12
10
8
6
4
2
0
1st Qtr 2011)
2008
2009
2010
2011
Performance Categories
© 2011 Institute of Nuclear Power Operations
Margin Management
• Ongoing department focus area
• Most stations have performed gap analysis to INPO 09003, Excellence in the Management of Design and
Operating Margins, and addressed identified gaps.
• Examples of Performance Gaps:
… issues that could adversely affect margin not consistently
identified and prioritized as margin issues and integrated with the
priority of other station issues ...
… several margin issues not identified and adequately evaluated
for resolution ...
© 2011 Institute of Nuclear Power Operations
10
Margin Management
Contributors:
…. lack of process / expectation guidance to review SSC
deficiencies for potential impact on operating margin
… insufficient management oversight to ensure margin
issues are identified, tracked, and resolved; insufficient
procedural guidance contributes ...
… site personnel have insufficient understanding of program
requirements / expectations
© 2011 Institute of Nuclear Power Operations
11
Engineering Product Quality
• Focus is on the quality of the modification (produced inhouse or by engineering service provider) when
released by Engineering
• Typically 10 AFIs / year (1/3 vendor, 2/3 in house)
• Examples of Performance Gaps:
… key design inputs not sufficient to assess the affect the
modification will have on plant equipment …
… validation and testing of modifications not adequate to ensure
the modifications performed intended functions ..
… (vendor associated) undetected errors in engineering products
provided by vendors …
© 2011 Institute of Nuclear Power Operations
12
Engineering Product Quality
Contributors
… not being thorough with assumptions (e.g. not recognizing
an assumption was made, not verifying)
… cross cutting weak human performance …
… weak failure modes affects …
… (for vendors) inadequate engineering oversight and
review of vendor supplied products ..
… (for vendors) insufficient specification, missed verification
of design requirements during owner acceptance reviews,
compressed project schedules, lack of intrusive oversight of
vendor activities …
© 2011 Institute of Nuclear Power Operations
13
Product Quality – Industry Aggregate
Engineering
Fundamentals
Knowledge
Worker Process
Challenge
Boards, Design
Review Boards
Technical Risk
Assessment
Tools
Tools &
Techniques
Performance
(Product Quality)
HU Tools
Performance
Indicators
Observations
Training
Monitoring
Performance
(to Improve
Performance)
(Product Quality)
Employee
Development
© 2011 Institute of Nuclear Power Operations
Quality
Review Teams
Post Product
Critique
14
Digital Systems
• Digital system issues continue to result in consequential
events, some resulting in plant scrams (six scrams in
past two years linked with digital).
• Evaluation findings (2009 and 2010)
– 6 AFIs and 3 PDs
– causes / contributors:
• missed design attributes and failure modes
• insufficient review / validation of vendor-supplied firmware
• weaknesses in control of vendor software and testing
• modifications not adequately specified on drawings
• specifications not adequately reviewed and tested
© 2011 Institute of Nuclear Power Operations
Digital Systems
– 3 Strengths
Debbie Williams
• Project Management
• Thoroughness of pre-installation testing
• Process controls & guidance, early procurement of
hardware, and diversified testing methods
• INPO actions
–
–
–
–
Annual digital upgrade working meetings
Improve reporting of industry OE
Involvement with EPRI and ISA working groups
Good Practice: Improving Engineering Quality in Digital System
Projects – Issued October 2010 to identify lessons learned and
recommended practices in key areas
© 2011 Institute of Nuclear Power Operations
Digital Systems
• INPO actions Related to Cyber Security
– EPIX trend codes developed to collect digital issues; includes
codes for cyber .
– Developing training modules for cyber assessment teams and
general awareness (June /July 2011) and technical training
(November 2011).
– Developing a web page on INPO member site to share
information related to cyber security.
– Reviewing INPO documents and evaluation process for
inclusion of cyber security attributes. (1st quarter 2012).
© 2011 Institute of Nuclear Power Operations
Technical Conscience
Frequently Asked Questions
© 2011 Institute of Nuclear Power Operations
18
What are INPO’s expectations for use of
the preliminary document ?
•
Incorporate the principles into ongoing organizational activities used to
reinforce and anchor nuclear safety culture and professionalism of
nuclear personnel.
•
INPO evaluation teams will use the principles documents to help
identify and communicate causes and contributors to weak
performance.
•
Sites are expected to provide feedback to INPO based on experiences
with use of the preliminary documents.
•
We do not expect anyone to create an indicator to monitor TC or OF
performance.
© 2011 Institute of Nuclear Power Operations
What is the relationship between the TC principles
document and other INPO documents ?
• Other principles documents
• Performance Objectives and Criteria
• SOER 10-02, “Engaged, Thinking Organizations”
© 2011 Institute of Nuclear Power Operations
How is the industry using the TC principles document
to enhance performance?
• Performing a gap analysis of performance in comparison to the
principles documents
• Reinforcing the principles during department and station meetings
• Training
– Familiarization/Reinforcement
– Case Studies – reviewing the principles to discuss how they were (or
should have been) applied during plant activities
© 2011 Institute of Nuclear Power Operations
Technical Conscience
INPO Engr-CM perspective:
• Overall, well received
• Helping to frame staff’s thinking and communications
• Based on feedback, do not anticipate any major
changes to the finalized document
• Many sites in the process of training (approach varies)
Basic Power Point
Overview
Increasing Effectiveness
© 2011 Institute of Nuclear Power Operations
Detailed Training w/ DLA &
modules tailored to:
• Sr Leadership (all)
• Engr Leadership
• Individual Contributors
22
Emerging Industry Issues
• Refocus on fundamentals and thinking vs. high reliance
on process
• Time critical operator actions
• Consequences from Fukushima (to unfold over several
years)
© 2011 Institute of Nuclear Power Operations
Next Presentation
23