Efficiency Bulletin: 17-03a Value-Based Maintenance

Transcription

1 Jan. 26, 2017 Efficiency Bulletin: 17-03a Value-Based Maintenance Clr Cde: Blue Due: December 2018 Changing the industry s culture f reliability at any cst and mre is better t ne where maintenance is treated as a highly valued and limited resurce is key t advancing safety and reliability in a cst-effective manner. This is the principal efficiency bulletin in a series that mre effectively integrates cst cnsideratins int equipment reliability prcesses. Addressees: Chief nuclear fficers, NEI APCs and INPO APCs Issue: PMP-003, Value-Based Maintenance Summary f Efficiency Opprtunity Desired end-state Statins fully implement value-based maintenance and the assciated culture change t apprpriately ptimize safety and reliability thrugh the mst efficient utilizatin f maintenance. Maintenance strategies will achieve the required levels f reliability fr the least life cycle cst. Cst-benefit analysis will be a rutine element f the preventive maintenance (PM) change prcess. Value prpsitin (visin f excellence) Thrugh the implementatin f value-based maintenance tls, each unit is prjected t begin t see significantly reduced annualized maintenance csts by Dec. 31, The statin maintenance budget required t maintain high levels f equipment reliability is expected t be reduced by at least 25 percent by Dec. 31, The Nuclear Energy Institute is the nuclear energy industry s plicy rganizatin. This bulletin and additinal infrmatin abut nuclear energy are available at nei.rg F Street, NW Washingtn, DC NEI.rg

2 Why is it imprtant? The shift t value-based maintenance cmplements the earlier change t the critical cmpnent definitin (Efficiency Bulletin 16-25) t prvide the prcess and tls that can be effectively and cnsistently implemented in the nuclear industry. The change establishes mre cst-effective maintenance strategies fr thse cmpnents whse failures d nt result in unacceptable cnsequences. Industry benchmark value(s) Equipment reliability index (ERI) cntinues t meet industry standards and imprve. Measure f effectiveness Industry metrics will be established t capture and track cst savings frm this initiative. Maximum benefit is btained when this efficiency pprtunity is implemented in cnjunctin with Efficiency Bulletin 17-03b, Embracing Cultural Shifts fr Value-Based Maintenance. Backgrund This bulletin is principal in a series that integrates cst-effectiveness int equipment reliability prcesses. Efficiency Bulletin 16-25, Critical Cmpnent Reductin, previusly established a zer failure tlerance plicy fr cmpnents whse failures result in unacceptable cnsequences and differentiated them frm cmpnents whse failures d nt result in thse cnsequences. This efficiency bulletin expands this guidance and prvides the fllwing: A definitin fr a new, value-based maintenance strategy: ne that ptimizes safety and reliability while carefully weighing the cst f cmpnent maintenance. This includes identifying pssible adverse csts caused by a resulting increase in failure rates assciated with a change in a maintenance strategy fr a cmpnent. Simply reducing preventive maintenance will likely nt reduce csts if it results in increased crrective maintenance, reduced safety r reliability, r increased regulatry scrutiny. The ttal csts and impact t the statin are required t be cnsidered when establishing cmpnents as nncritical and analyzing value-based maintenance strategies fr nncritical cmpnents. This is shwn in Attachment 1. A value-based apprach fr assessing ttal csts and impact f a maintenance strategy is replacing the current industry discrete listing f attributes fr nncritical cmpnents that drives them t be cnsidered fr PMs. A graded apprach t plan, assess and perfrm maintenance n lwer criticality cmpnents. Relevant Standards Perfrmance Objectives and Criteria (INPO): ER.1, Engineers establish high standards fr equipment perfrmance and prmte intlerance fr failures f critical equipment. ER.2, Engineering and maintenance strategies fcus n cmpnents and systems that are critical t safe, reliable plant peratin. Cmpnents are classified as critical based n the relative imprtance fr maintaining system functin. ER.2, A thrugh prcess is used t review and dcument the technical bases f deferrals, changes, additins and deletins f preventive maintenance tasks. 2

3 MA.1, Maintenance persnnel ensure high-quality preventive maintenance is perfrmed t supprt equipment reliability and that feedback is prvided that accurately reflects equipment perfrmance. OE.1, Internal and industry perating experience is shared and used t prevent events and imprve equipment, wrker and statin perfrmance. EN.1, Engineers engage peratins and maintenance persnnel t fully understand equipment cnditin and perfrmance issues, the peratinal impact f thse issues, and preventive maintenance effectiveness. EN.1, Engineers identify equipment management strategies, including preventive and predictive maintenance, t imprve equipment perfrmance and ensure lng-term reliability. Relevant Regulatry Requirement 10 CFR 50.65, Requirements fr Mnitring the Effectiveness f Maintenance at Nuclear Pwer Plants Regulatry Guide 1.160, Mnitring the Effectiveness f Maintenance at Nuclear Pwer Plants Guidance This efficiency bulletin prvides the change management and recmmends sftware tls t implement a new apprach fr the develpment f cst-effective equipment maintenance strategies t supprt a reductin in the ttal cst f maintenance. Specifically, the fllwing are being implemented: Value-based maintenance prcesses fr nncritical cmpnents will utilize cst data in cnjunctin with perfrmance data when determining the acceptability f equipment perfrmance, as well as mnitr the effectiveness f strategy changes. The prcess changes shuld include, but are nt limited t, the fllwing: Implement PM change prcesses that ensure maintenance strategies are designed t achieve required levels f reliability fr ptimized csts, including labr, materials and assciated administrative csts. Institutinalize cst mnitring and analysis f perfrmance at the cmpnent and system levels. This includes expected levels f wrk rder prductivity. Integrate cst-benefit analysis int statin wrk rder and PM change prcesses. Ensure that the PM change prcesses prvide guidance t supprt develpment f maintenance strategies that maintain the required equipment reliability fr least cst. Dcument cst justificatins int the PM basis dcuments. This includes dcumenting any expected failures based n the maintenance strategy, including anticipated failure rates and failure mechanisms. This dcumentatin will supprt minimizing administrative csts assciated with failure cause analysis. Require expected cst dcumentatin fr any PM changes requesting new PMs r changes requiring additinal resurce r material csts. Statins shuld set a threshld at which a cstbenefit analysis is required t implement a PM change. Ensure that any prcess changes cntinue t prtect the reliability f AP-913 critical cmpnents. An industry maintenance database has been established that will allw fr the evaluatin f the ttal cst f maintenance strategies and identificatin f the mst cst effective maintenance strategies. An industry data visualizatin tl has been btained that prvides the capability t evaluate maintenance cst data at the cmpnent level t determine pprtunities fr industry savings and ability t perfrm statin, fleet r industry cmparisn f maintenance csts t identify best practices. Results will be shared thrughut the industry. 3

4 Tls that allw the develpment f mre cst-effective maintenance strategies are being btained. The tls als determine increases in failure rates that may result frm perfrming less preventive maintenance. Data derived frm these tls will be utilized by industry grups t evaluate imprvement f maintenance strategies that still supprt reliable peratins based n business needs. A list f recmmended tls and appraches will be prvided directly t utilities. At a minimum, the fllwing targeted cmpnent maintenance strategies will be evaluated fr implementatin at each site by Dec. 31, 2018: circuit breakers air-perated valves relays. Nte: Further backgrund infrmatin n value-based maintenance can be fund in the Equipment Reliability Wrking Grup white paper Management f Maintenance Csts, Rev. 0, June (This dcument can be btained frm the INPO member website.) Recmmended Industry Actins Revise applicable fleet/statin prcesses and prcedures t incrprate value-based maintenance apprach. Examples f revised prcess dcuments will be prvided t the industry. Task the industry wrking grups fr circuit breakers, air-perated valves and relays t review the recmmended changes t the industry value-based maintenance strategies fr their equipment and implement site-specific strategies as apprpriate t realize cst savings. Cntinue t develp cmmn value-based maintenance tls. Share best practices fr cmmunicatins methds t facilitate the culture change t value-based maintenance thrughut the utility rganizatin. Crdinate implementatin f value-based maintenance with the ther cmplimentary efficiency bulletins (shwn belw): EB fr High-Cst, Nncritical PM Reductin Utilities identify knwn pprtunities fr High-Cst, Nncritical PMs Reductins. Early implementatin f VBM EB Critical Cmpnent Reductin Implement Classificatin Change EB 17-03a, Value-Based Maintenance (VBM) Utilities Implement Critical Definitin (June 2017) Enabler fr EB 17-03a Implement Value-Based Maintenance/ Targeted PM Changes/Savings Implement EB 17-03a (December 2018) Utilize VBM t reduce ttal maintenance cst Reductin in Ttal Maintenance (2020 > 25 percent reductin in ttal cst f maintenance) December 2020 EB 17-03b, Embracing Cultural Shifts fr Value- Based Maintenance Bradly cmmunicate the reasns and need fr changing the apprach t maintaining equipment 4

5 Change Management Cnsideratins Industry Activities Industry cmmunicatins are being develped t facilitate the understanding f the changes t the apprach f develping ptimized maintenance strategies and the needed change in statin culture t take full advantage f value-based maintenance: Site leadership cmmunicates the imprtance f embracing value-based reliability t the statin staff in a high-visibility manner, using presentatins, vide, articles, etc. The acceptability f run-tmaintenance fr select cmpnents is clearly cmmunicated. (Efficiency Bulletin 17-03b, Embracing Cultural Shifts fr Value-Based Maintenance. ) Industry webinar t prvide backgrund fr initiative and prvide an pen frum t ask questins. Webinar infrmatin can be fund at Industry presentatin t be prvided t all nuclear site key stakehlders t cmmunicate the change. Discuss change and change management at Equipment Reliability Wrking Grup (ERWG) and ther rutine industry meetings. As value-based maintenance is implemented thrugh the industry and lessns learned are incrprated, the Equipment Reliability Wrking Grup and INPO will cnsider further refinements t AP-913. Cmpany Actins Site/fleet preventative maintenance prcess wners revise gverning prcesses and prcedures. Obtain access t sftware tls, and develp the change management cnsideratins required t effectively implement value-based maintenance. Integrate cst-benefit analysis int the statin PM change prcesses. Designate persnnel t becme prficient with the value-based maintenance tls. Industry experience has shwn that statins are mre successful when they establish prficiency with the sftware tls prir t mving nt higher cnsequential cmpnents. Crprate and sitewide cmmunicatin and prmtin f the initiative. Reinfrce expectatins fr a healthy technical cnscience, specifically that individuals thrughly challenge analyses and recmmendatins t ensure the full range f ptential cnsequences is clearly defined, understd and cmmunicated as part f the final decisin-making. Using the industry data visualizatin sftware, mnitr cst at the cmpnent and system levels t minimize ttal maintenance csts while maintaining required reliability. Guiderails Full implementatin f this bulletin will result in a reductin in preventive maintenance t imprtant cmpnents. Imprtantly, many f these cmpnents may be safety-related, impact cntrl rm peratins, affect reactivity management indicatrs r cntribute t risk in the statin PRA analyses. Cnsequently, statins shuld ensure that the fllwing guiderails are in place: The cnsequence f failure must be clearly understd during the value-based maintenance evaluatin s that nuclear safety and plant reliability is nt cmprmised while adjusting maintenance strategies. Cnsequences may include mre-expensive and unplanned crrective maintenance as well as intangibles such as staffing the utage cntrl center r lss f regulatry margin. If the cst t recver frm a failure exceeds the cst savings realized thrugh reducing a cmpnent s PM, neither financial perfrmance nr statin reliability will be imprved. Imprtantly, this is true fr nncritical equipment as well as critical cmpnents. The prcess cntrls fr the scpe, frequency and scheduling f preventative maintenance tasks (PM change request and deferral prcesses) must cntinue t require the apprpriate technical authrity t review maintenance strategy changes t identify ptential impacts t the reliability f critical, Maintenance Rule high-risk-significant and risk-significant cmpnents. 5

6 Apprpriate maintenance strategies must be maintained cmmensurate with cmpnent imprtance. Specifically, the statin s administrative cntrls shuld ensure that regulatry and industry cmmitments (NRC, NERC, NEIL, etc.) are apprpriately evaluated prir t any change in maintenance strategy. The impact f change t maintenance strategies n the critical spare parts and lng-range planning prcesses shuld be evaluated during PM changes t ensure the changes d nt result in an inapprpriate business impact. The prjected increase in failure rates as well as the cst f failures shuld be cnsidered when changing maintenance strategies. When changes are made t PM tasks that extend frequency beynd the nrmal service life recmmended by the vendr, a healthy technical cnscience requires that the basis f these changes be retained s this infrmatin is readily retrievable. At a minimum, the set f perfrmance indicatrs (Attachment 2) shuld be mnitred t determine if unintended, adverse cnsequences begin t ccur s that actin can be taken t arrest the adverse trend. Reprt Yur Site s Results Please reprt yur cmpany s implementatin f this imprvement pprtunity, including the date f cmpletin. Send this infrmatin alng with yur cmpany pint f cntact t EfficiencyBulletin@NEI.rg. Industry Cntacts Industry champin fr this issue: Andy Winter, , andrew.winter@exelncrp.cm INPO cntact: Geff Seguin, , seguingc@inp.rg EPRI cntact: Rick Way, , rway@epri.cm NEI cntact: Bruce Mntgmery, , bsm@nei.rg On the web: Industry Apprval: Timthy S. Rausch, CNO Lead David P. Igyart, Institute f Nuclear Pwer Operatins Jseph E. Pllck, Nuclear Energy Institute 6

7 Attachment 1 Value-Based Maintenance 7

8 Attachment 2 Perfrmance Indicatrs Full implementatin f this bulletin will result in a reductin in preventive maintenance t imprtant cmpnents. Many f these cmpnents may be safety-related, impact cntrl rm peratins, affect reactivity management indicatrs r cntribute t risk in the statin PRA analyses. The fllwing indicatrs shuld be mnitred, as a minimum, t determine if unintended adverse cnsequences begin t ccur s that crrective actin can be taken t arrest the adverse trend. Cnsequence Functinal failure f a high-safetysignificant r risk-significant system/functin Unplanned engineered safety features system actuatin Unplanned shutdwn LCO actins statement less than r equal t 72 hurs Indicatrs Maintenance Rule functinal failures Regulatry versight prcess Licensee event reprts Shrt-term unplanned LCO entries Online Reliability Lss Factr Unit Capability Factr Equipment Reliability Index (ERI) Unplanned pwer reductins f 20 percent r less Online Reliability Lss Factr Unit Capability Factr Unplanned Pwer Reductins per 7000 Hurs Critical (NRC Indicatr) Cnsequential Failure Events (ERI subindicatr) Reactivity Management Perfrmance Indices Maintenance cst metric ERWG/PMWG will develp industry cst metric (within the cst visualizatin tl) t be maintained at INPO 8