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1、INPOEquipmentReliabilityProcessDescriptionGENERALDISTRIBUTIONNovember2001ProcessDescriptionAP-913(Revision1)EQUIPMENTRELIABILITYPROCESSDESCRIPTIONNovember2001AP-913(Revision1)INSTITUTEOFNUCLEARPOWEROPERATIONSGENERALDISTRIBUTION:Copyright2001bytheInstrtuteofNuclearPowerOperations.Notforsalenorforcomm

2、ercialuse.AllotherrightsreservedNOTICE:ThisinformationwaspreparedinconnectionwithworksponsoredbytheInstituteofNuclearPowerOperations(INPO).NeitherINPO,INPOmembers,INPOparticipants,noranypersonactingonthebehalfofthem(a)makesanywarrantyorrepresentation,expressedorimplied,withrespecttotheaccuracy,compl

3、eteness,orusefulnessoftheinformationcontainedinthisdocument,orthattheuseofanyinformation,apparatus,method,orprocessdisclosedinthisdocumentmaynotinfringeonprivatelyownedrights,or(b)assumesanyliabilitieswithrespecttotheuseof,orfordamagesresultingfromtheuseofanyinformation,apparatus,method,orprocessdis

4、closedinthisdocument.INPOAP-913(Revision1)INPOAP-913(Revision1)FOREWORDTliisdocumentdescribesailequipmentreliabilityprocessofleredtoassistmemberutilitiestomaintainhighlevelsofsafeandreliableplantoperationinailefficientmaimer.Equipmentreliabilityisoneofailintegratedsetofprocessesfortheoperationandsup

5、portofnucleaiplantsTliisprocessdescriptionreflectstheexperiencegainedfiomequipmentpeiioiiiiaiiceassistancevisitstooperatingplantsandbenchmaikiiigtripstodomesticandiiitemationalutilities.Theequipmentreliabilityprocesswasdesignedwiththediiectparticipationofseveralutilitiesactivelyinvolvedinimprovingan

6、dreengineeringtheirownprocesses.TliisrevisionincludeslessonslearnedfiomiiidustiyexperiencewithsefassessmentsandgapanalysestotheEquipmentReliabilityProcessDescription,AP913Additionalguidancehasbeenaddedformanagingagingandobsolescenceofplantequipment.MajorchangestoAP913,EquipmentReliabilityProcessDesc

7、ription:commonscopingandidentificationofcriticalcomponentsforinputtopeiionnaiicemonitoringplansandPMtechnicalbasesevaluationsimprovedcriteriaforidentificationofcritical,noncritical,.andnm-to-failurecomponentsimprovedguidanceforequipmentrootcausesdetenniiiationimprovedguidanceforcontinuingequipmentre

8、liabilityimprovementimprovedguidanceforagingaiidobsolescenceNucleaiplantoperatorsareencouragedtoprovidecommentsonthecontentaiidfonnatofthisdocumentaiidonanyprocessenhancementsthatwouldimprovethosedescribedhereinTliisinfoniiationwillbeconsideredinafiitiirerevisiontothedocument.Pleasediiectcommentsto:

9、Diiector,PlantSupportDivisionInstituteofNucleaiPowerOperations700GalleriaPaikwaySE,Suite100Atlanta,GA30339-5957770-644-8221Commentscaiibee-mailedtotheAssistancevicepresidentviatheINPOAssistanceWebpage.INPOAP-913(Revision1)INPOAP-913(Revision1)TABLEOFCONTENTSTOC o 1-5 h z HYPERLINK l bookmark6FOREWOR

10、Di HYPERLINK l bookmark10EQUIPMENTRELIABILITYPROCESSOBJECTIVES1 HYPERLINK l bookmark8Definitions1 HYPERLINK l bookmark14EquipmentReliabilityProcessObjectives2 HYPERLINK l bookmark12EquipmentPeiionnaiiceObjectives2 HYPERLINK l bookmark16EQUIPMENTRELIABILITYPROCESSDESCRIPTION5 HYPERLINK l bookmark2EQU

11、IPMENTRELIABILITYPROCESSINSTRUCTIONS9ScopingandIdentificationofCriticalComponents9PerfonnanceMonitoring12ConectiveAction15ContinuingEquipmentReliabilityIinpiovement19Long-TennPlaimingandLifeCycleManagement25PreventiveMaintenanceImplementation28APPENDIXA:INDUSTRYREFERENCESAPPENDIXB:EQUIPMENTRELIABILI

12、TYSELF-ASSESSMENTCHECKLISTAPPENDIXC:STRATEGIESFORSUCCESSFULSELF-ASSESSMENTSORGAPANALYSISTOAP-913APPENDIXD:EXAMPLESOFEQUIPMENTRELIABILITYPERFORMANCEINDICATORSAPPENDIXE:EXAMPLEOFPREVENTIVEMAINTENANCEAS-FOUNDCONDITIONCODESAPPENDIXF:SUGGESTEDAGINGMANAGEMENTPROGRAMATTRIBUTESINPOAP-913(Revision1)INPOAP-91

13、3(Revision1)IVIVTliispageintentionallyleftblank.INPOAP-913(Revision1)INPOAP-913(Revision1) EQUIPMENTRELIABILITYPROCESSOBJECTIVESDefinitionsTlieequipmentreliabilityprocessrepresentstheintegrationandcoordinationofabroadrangeofequipmentreliabilityactivitiesintooneprocessforplantpersonneltoevaluateimpor

14、tantstationequipment,developandimplementlong-tennequipmenthealthplans,monitorequipmentpeiionnaiiceandcondition,andmakecontiiiumgadjustmentstopreventivemaiiitenaiicetasksandfrequenciesbasedonequipmentoperatingexperienceTliisprocessincludesactivitiesnonnallyassociatedwithsuchprogramsasreliabilitycente

15、redmaintenance(RCM),preventivemaintenance(periodic,predictive,andplanned),MaintenanceRule,surveillanceaiidtesting,life-cyclemanagement(LCM)planning,aiidequipmentpeiionnaiiceandconditionmonitoringTlieintentofthisdocumentistoidentify,organize,aiidintegrateequipmentreliabilityactivitiesintoasingleeffic

16、ientandeffectiveprocessNote:Preventivemaintenance(PM)andcorrectivemaintenance(CM)asusedinthisdocumentareconsistentwitlitliefollowingdefinitions,whicharebasedoncommonlyaccepteddefinitionsfiomtliereferencesinAppendixA.Preventivemaintenance(PM)includesactionsthatdetect,preclude,ormitigatedegradationoff

17、imctionalstructures,systems,aiidcomponents(SSC)tosustainorextenditsusefilllifebycontrollingdegradationandfailurestoailacceptablelevel.Tlierearethreetypesofpreventivemaintenance:periodic,predictive,aiidplannedPeriodicmaintenanceisafonnofpreventivemaintenanceconsistingofservicing,partsreplacement,surv

18、eillance,ortestingatpredetenninedintervalsofcalendartime,operatingtime,ornumberofcycles.Predictivemaintenanceisafbnnofpreventivemaintenancepeiionnedcontinuouslyoratiiiteivalsgovemedbyobseivedconditiontomonitor,diagnose,ortrendSSCfimctionalorconditionindicatorsResultsindicatecunentaiidfiiturefimction

19、alabilityorthenatureofandscheduleforplannedmaiiitenaiicePlannedmaintenanceisafonnofpreventivemaintenanceconsistingofrefiirbishmentorreplacementthatisscheduledaiidpeiionnedtoprecludefailureofailSSCCorrectivemaintenanceincludesactionsthatrestore一byrepair,overhaul,orreplacement一thecapabilityofafailedSS

20、Ctofimctionwithinacceptancecriteria.Life-cyclemanagement(LCM)istheintegrationofagingmanagementaiideconomicplanningtooptimizetheoperation,maintenance,andseivicelifeofSSCs;maintainailacceptablelevelofpeiionnaiiceaiidsafety;aiidmaximizeretumofinvestmentovertheseivicelifeoftheplant.EquipmentReliabilityP

21、rocessObjectivesA.Tlieprocessisefficient,iiicoiporateshumanfactorconsiderations,andensureseffectivepeiionnaiiceduringallphasesofplantoperations.BAunifbnnprocessisusedamongallplantsillailorganization.CApplicableinhouseandindustiylessonslearnedareiiicoiporatedintotheprocesstoimproveadequacyandefficien

22、cyDChangestotheprocessaretimely,responsivetouserfeedback,andimplementedatallaffectedplants.EquipmentPerformanceObjectivesA.Equipmentpeiiomisreliablythroughtheoperatingcycle,andstandbysafetyequipmentoperatesproperlyondemand.Equipmentiscapableofsatisfactoiypeiionnaiiceunderalldesignconditions.BCritica

23、lequipmentisidentifiedbasedonimportancetosafetyfimction,safeshutdowncapability,andpowergenerationcapabilityInsightfiomprobabilisticassessmenttechniquesisconsideredillthisdetenuillationCEquipmentandsystempeiionnaiicecriteriaareestablished,peiionnaiiceismonitored,adversetrendsareidentified,andcollecti

24、veactionsareimplementedandverifiedforefiectivenessDFailuresandfailurecausesofconcemareidentifiedforcriticalequipment,andmeasuresareestablishedtopreventthem.Tlieneedforiii-depthanalysisofequipmentfailureiscommensuratewiththeequipmentsimportancetoplantsafetyandreliabilityandthelikelilioodofrecuirenceP

25、redictivemaintenancetechnologiesareimplementedtodetectequipmentdegradationwellilladvanceofpotentialfailureandtooptimizeequipmentpeiionnaiice.Equipmentagingismanagedusingpreventivemaiiitenaiicetechniquesandlife-cyclemanagement,includingmitigationofenviionmentalstressors(suchastemperature,radiation,an

26、dmoisture)oroperatingstressors(suchasdutycyclesandvibration).Documentedtechnicalbasesexistforpreventivemaintenanceactivitiesandagingmanagementprograms.Equipmentpeiionnaiicedataandassociatedtrendiiifonnationareunifbnnlycollectedandarereadilyaccessibletosupportthepromptidentificationofproblemsandrootc

27、auses.J.Equipmentunavailabilityassociatedwithpreventivemaintenanceactivitiesisbalancedbytheresultingimprovedequipmentreliabilityandavailabilityfrompreventedfailures.KMinimalin-seivicefailuresofcriticalequipmentoccurbetweenscheduledmaintenanceintervals.INPOAP-913(Revision1)INPOAP-913(Revision1) Tliis

28、pageintentionallyleftblank.EQUIPMENTRELIABILITYPROCESSDESCRIPTIONTlieequipmentreliabilityprocessispresentedonthefollowingpagesillthreesuccessivelevelsofdetail:Atop-leveldiagramisailoveiviewthatrepresentsmajorprocesselementsandtheiirelationships.Tlieprocessflowchaitexpandsonthetop-leveldiagramandincl

29、udesthedetailedactivitiesnecessaiytoachievetheprocessobjectives.Tliewiitteniiistnictionsthatbeginonpage9providespecificcriteriaandconsiderationsforimplementingtheprocessactivities.Tlieshapesinthissectioncoirespondtothoseonthe11x17EquipmentReliabilityProcessFlowchaitINPOAP-913(Revision1)INPOAP-913(Re

30、vision1) # Tliispageintentionallyleftblank.INPOAP-913(Revision1)INPOAP-913(Revision1) #EquipmentReliabilityProcessTopLevelDiagramINPOAP-913(Revision1)INPOAP-913(Revision1) INPOAP-913(Revision1) Tliispageintentionallyleftblank.EQUIPMENTRELIABILITYPROCESSINSTRUCTIONSTheEquipmentReliabilityPiocessmaybe

31、enteredbyanyofthefollowingfivepaths:iStartEquipment.ReliabilityImprovementTliisistlieentiypointforanequipmentreliabilityimprovementeffortsuchasPMoptimizationorlife-cycleplaiming.Pioceedtostep11IBeginPerformaneeMonitoring丿Beginperformancemonitoringbyestablisliingperformancecriteriaandinoiiitoringpara

32、metersinaccordancewithstep2.1.fChangeRequestfromAnyone丿AnyonemayrequestachangetothePMprogramBeginevaluationofthechangerequestinaccordancewithstep4.1.EquipmentFailureWlienanequipmentfailurehasoccuned,evaluationofthecauseandconsequencesshouldbeginwithstep3.1.(IndustryOE)Equipmentreliabilityanalysissho

33、uldbereviewedandupdatedbasedonevaluationofinchistiyoperatingexperiencesuchasnewvendorrecommendations,EPRIPMtemplates,EPIX,oragingstudies.Pioceedtostep4.1.1ScopingandIdentificationofCriticalComponentsIdentifyImportantFunctionsNote:Thescopingandidentificationofcriticalsystems,structures,andcomponents(

34、SSCs)shouldbeanintegratedactivitythatisacommoninputtocontinuingequipmentreliabilityimprovementandestablishingequipmentperformanceciiteiia.DetenninetheSSCfunctionsthatareimportanttomaintainingsafety,reliability,andpowergenerationbypeiforniiiigthefollowingactivities:Definetheintegratedscreeningcriteri

35、atodetemiinethescopeofSSCstobeevaluatedThismayincludesuchcriteriaas:一safety-relatedandessentialnonsafety-related一MaintenanceRulescopingcriteria一licenserenewalscopingcriteria,includiiigpassivefiinctioiis一necessaiyforpowergeneration一enxdromnentalqualification(EQ)一safeshutdown(AppendixR)一stationblackou

36、t一fireprotection一anticipatedtransientwithoutscrampresiuizedthennalshock(PWRs)Tliisactivityaddressesallthepotentiallyimportantaiteriaatonetimeinsteadofinseparateeffortsforindividualsetsofrequirements.UsingintegratedscreeningcriteriaalsoensuresconsistencyofapproachForexample,itisimportantthatPMoptimiz

37、ationdoesnotscreenoutailactivityforequipmentthatcouldcauseaMaintenanceRulefiinctionalfailure.Listthesystemdesignfimctions(referencedinthedesignbasis)DetenninetheimportanceofeachfiinctionlistedUsetheprobabilisticsafetyassessment(PSA)modelasoneofthetoolstoperformtliisevaluation.EcjiiipmentPerformancea

38、ndIiifonnationExchange(EPDC)FunctionandDevicerecordsshouldbeofassistance.Ifafiinctionisrequiredfornuclearsafety,reliability,orpowergeneration,thenitisconsideredanimportantfiinctionWillComponent、FailureDefeatorDegradeImportantFunction?CriticalComponentsForeachfiinctionidentifiedinstep1.1,identifyande

39、valuatethestructuresanclcomponentsthatareassociatedwiththeperformanceofthefiinction.Itisimportanttoconsiderbothactiveandpassiveelementsofeachcomponent.Ifafailureofthecomponentoritsstnichiralsupportsdefeatsordegradesanimportantfiinctionorafiinctionthatisredundanttoanimportantfiinction,thenitisacritic

40、alcomponent,andanalysisshouldbecontinuedwithstep4.6.Otherwise,evaluateotherconsiderationsforcontinuousequipmentreliabilityimprovementinstep1.3.Criteria:Ifthecomponenfsfiinctionalfailureresultsinoneormoreofthefollowing,itisconsideredacriticalcomponent:significantpowertransientorderatelossofaredundant

41、safetyfiinctionunplaimedentiyintoateclmicalspecificationLCOhalfscramorpartialtripreactorshutdownachiationofemergencysafeguardsfeaturesfailuretocontrolacriticalsafetyfimctionsuchasreactorwaterlevelandpressure,primaiyandsecondaiycontainment,diywelltemperahireandpressure,orspentfiielpooltemperahireancl

42、leveldegradedcapabilitytoshutdownthereactorandmaintainitinashutdownconditioninabilitytoperformanemergencyoperatingprocedure,ortopreventormitigatetheconsequencesofaccidentsthatcouldresultinpotentialoff-siteexposureinexcessof10CFR100limits;operatorworkaroundoperatorworkaroundforpeifoniiinganyoftheabov

43、efimctionsorprocedures.ntheComponentbexRuntoFailure?NoncriticalComponentshibetweenthecategoriesofcriticalandnin-to-failure,thereareanumberofSSCsforwliichcost-effectivepreventivemaintenancemakessense.IffailureoftheSSCresultsinanyoftheconditionsbelow,thennonciiticalanalysisshouldbecontinuedwithstep4.6

44、.Otherwise,thecomponentcanberuntofailure.Evaluationcriteria:Componentfailurecreatesanunacceptableincreaseinpersonnel,industrial,enviroiunental,orradiologicalsafetyhazard.Tliecomponenthasaliistoiyofunacceptablyliighrepair,replacement,oroperationalcost.Componentfailurerepresentsanoperatorormaintenance

45、burden.Tliecomponentisobsolete,inshortsupply,orveiyexpensivetorepairorreplace.Tliereisalongleadtimeforreplacementparts,wliichpreventsarequiredcomponentfiombeingrepairedinatimelyfasliion.Tliecomponentisnecessaiyforworkoncriticalequipment(forexample,isolationvalve).Componentfailurepromotesfailureofoth

46、ercomponents.Tliereisapotentialfornewrisksfromhazardouschemicalsorenviroimientalconcerns.Failureresultsinapowerhansient,sustainedgenerationloss,orreductioninthenecessaiyredundancyordefensein-depthFailuremayleadtoregulatoiyconsequences.Componentfailurewillhamperorpreventtimelyrepairofaciiticalcompone

47、nt.Itismorecost-effectivetomaintainthecomponent,asopposedtorepairorreplacement1.4DocumentClassificationofCriticalandNoncriticalSSCsDocumenttheclassificationofeachcomponentforconunoninputtoperfonnancemonitoringandcontinuousequipmentperformanceiinproveinentactivities.Thecomponentclassificationsshouldb

48、ereadilyaccessibletosystemandcomponentengineers.Somestationsalsoaimotatemaintenanceworkrequestswithtliisiiifonnationsocraftpersoimelareiiifonnecloftheimportanceofthecomponentstheyareworkingon.RuntoFailureRun-to-FailuieComponentsAnm-to-failurecomponentisoneforwliichtherisksandconsequencesoffailureare

49、acceptablewithoutanypredictiveorrepetitivemaintenancebeingperfonneclandthereisnotasimple,cost-effectivemethodtoextendtheusefilllifeofthecomponentTliecomponentshouldbenmuntilcollectivemaintenanceisrequired.2.PeifomianceMonitoring2.1|Note:Theresultsofthecontinuingequipmentreliabilityimprovementanalysi

50、sinSection4areadesiredinputtohelpestablishthetechnicalbasesformonitoredpaiaineters.Establishperfonnancecriteriaandmonitoringparametersforimportantsystemfunctionsandciiticalcomponents.Considerthefollowingfordevelopmentofperformancecriteria:Useperfonnancecriteriathatarebasedonavailability,reliability,

51、orconctition.Lookforleadingindicatorsthatpreclictperfonnance,inadditiontoindicatorsbasedonequipmentfailures.Understandthedamagemechanisms,effects,andleadingincticatorsofdamageforcriticalcomponents.Recognizethatcomponentactiveperfonnancemaynotbeagoodindicatorofcomponentmaterialcondition(forexample,he

52、atexchangerhibecrackingcanoccurbeforealossofthermalperfonnanceisdetectable)Recognizethatcomponentsinitiallyfailatveiylocalizedlevels.RelianceonaFendandreplace59agingmanagementstrategyrequirestheuseofveiylocalizedandspecifictrendingindicators.Relatemonitoredparametersandacceptablelevelsofperfonnancet

53、omeasurableindicationsofcomponentdegradationidentifiedinsteps4.6and4.8.Employconditionmonitoringtechniqueswhenperfonnancemonitoringcamiotberelatedtocomponentdegradation.EstablishPerformanceCriteria8MonitoringParametersIncludespecificalertvaluesforcondition-monitoringdatainthecomponentperfonnancecrit

54、eria.Establishspecificperfonnancecriteriaforrisk-significantsystems/trainsandthosenomisksignificantsystems/trainsthatareinstandbymodeinaccordancewiththestationMaintenanceRuleprogiamTrendcriticalparametersofprogiamsusedtoretardage-relatecldamage(forexample,aiticalelementsofthewatercheniistiyprogram;t

55、emperatureassumedinenviroiunentalcjiialificationofequipment;voltagepotentialdifferenceforcatlioticprotection)Validateperfonnancecriteriaforrisk-significantsystemsagainstthereliabilityassumptionscontainedinthePSA/IPEmodel.PerfonnancecriteriaareestablishedusingMaintenanceRuleguidance,inclustiyexperien

56、ce,operatingdata,sinveillancedata,PSAassumptions,andstationequipmentoperatingexperience./Monitor/TrendSystem/Function/Performanee丿Capturetherelevantdatafiomequipmenthistoiyforcompletedworkactivities,completedpostmaintenancetestactivities,predictivemaintenance,equipmentconditiondatafiomcompletedPMand

57、sinveillanceactivities,programtestresults,systemengineeringwalkdowns,trendsfiomprocesscomputerdata,operatorrounds,andanyothersourcesofperfonnancedata.Comparetheactualperfonnancetocriteria.Atregularintervals,systemexpertswilltrendtheplantdatausedtodetemiinesystem/tiainperformanceagainsttheestablished

58、performancecriteria./Monitor/TrendComporient)、Performanee丿Perfonncross-systemcomponentfailureandproblemtrenciingusingmaintenanceliistoiy,conditionreportcfata(tliisistypicallyalowtluesholdcorrectiveactionprocessfonnthatidentifiesequipmentproblems),andindustiyoperatingexperiencesuchasEPIX.Establishcom

59、ponentexpertiseandownershiptoresolveemergentequipmentproblemsandbetteridentifymaintenancecontributorsThisallowssystemengineerstoperfonnlongertermequipmentreliabilityimprovementactivities.Suggestedcomponentexpertiseincludesmotors,pumps,valves(manual,check,relief,etc.),motor-operatedvalves,air-operate

60、dvalves,breakers,I&C(powersupplies,recorders,controllers,transmitters),andheatexchangers,withafocusbeyondregulatoiyprogramcomplianceforbothshort-termandlongtermhealthConsiderations:Ensurethatcomponentandsystemengineersunderstandbothactiveandpassivecomponentdamagemechanisms,effects,andindicators.Usee

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