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  • IAEA-TECDOC-1590

    Application of Reliability Centred Maintenance to

    Optimize Operation andMaintenance in

    Nuclear Power Plants

    May 2007

  • IAEA-TECDOC-1590

    Application of Reliability Centred Maintenance to

    Optimize Operation andMaintenance in

    Nuclear Power Plants

    May 2007

  • The originating Section of this publication in the IAEA was:

    Nuclear Power Engineering Section International Atomic Energy Agency

    Wagramer Strasse 5 P.O. Box 100

    A-1400 Vienna, Austria

    APPLICATION OF RELIABILITY CENTRED MAINTENANCE TO OPTIMIZE OPERATION AND MAINTENANCE IN NUCLEAR POWER PLANTS

    IAEA, VIENNA, 2008 IAEA-TECDOC-1590

    ISBN 9789201050083 ISSN 10114289

    IAEA, 2008

    Printed by the IAEA in Austria May 2008

  • FOREWORD

    In order to increase Member States capabilities in utilizing good engineering and management practices the Agency has developed a series of Technical Documents (TECDOCs) to describe best practices and members experience in the application of them.

    This TECDOC describes the concept of Reliability Centred Maintenance (RCM) which is the term used to describe a systematic approach to the evaluation, design and development of cost effective maintenance programmes for plant and equipment. The concept has been in existence for over 25 years originating in the civil aviation sector. This TECDOC supplements previous IAEA publications on the subject and seeks to reflect members experience in the application of the principles involved

    The process focuses on the functionality of the plant and equipment and the critical failure mechanisms that could result in the loss of functionality. When employed effectively the process can result in the elimination of unnecessary maintenance activities and the identification and introduction of measures to address deficiencies in the maintenance programme. Overall the process can result in higher levels of reliability for the plant and equipment at reduced cost and demands on finite maintenance resources.

    The application of the process requires interaction between the operators and the maintenance practitioners which is often lacking in traditional maintenance programmes. The imposition of this discipline produces the added benefit of improved information flows between the key players in plant and equipment management with the result that maintenance activities and operational practices are better informed.

    This publication was produced within IAEA programme on nuclear power plants operating performance and life cycle management.

    The IAEA wishes to express its gratitude to all experts who provided contributions and to all the reviewers listed at the end of this publication. The IAEA officer responsible for this publication is F. Hezoucky of the Division of Nuclear Power.

  • EDITORIAL NOTE

    The use of particular designations of countries or territories does not imply any judgement by the publisher, the IAEA, as to the legal status of such countries or territories, of their authorities and institutions or of the delimitation of their boundaries.

    The mention of names of specific companies or products (whether or not indicated as registered) does not imply any intention to infringe proprietary rights, nor should it be construed as an endorsement or recommendation on the part of the IAEA.

  • CONTENTS

    1. INTRODUCTION ............................................................................................................ 1

    1.1. Background......................................................................................................... 1 1.2. Description.......................................................................................................... 1 1.3. Structure.............................................................................................................. 2

    2. RELIABILITY CENTRED MAINTENANCE................................................................ 2

    2.1. Maintenance and Reliability Centred Maintenance (RCM) ............................... 2 2.2. RCM as a tool for Optimization of Operations and Maintenance activities ...... 3 2.3. The Principles of RCM....................................................................................... 3 2.4. The RCM Process Basic Steps ........................................................................ 3

    2.4.1. Preparation .............................................................................................. 3 2.4.2. Analysis .................................................................................................. 4 2.4.3. Task Selection......................................................................................... 4 2.4.4. Task Comparison .................................................................................... 5 2.4.5. Task Comparison Review....................................................................... 5 2.4.6. Records ................................................................................................... 5

    3. PRACTICAL APPLICATIONS....................................................................................... 5

    3.1. System Selection................................................................................................. 5 3.2. System Boundaries ............................................................................................. 5 3.3. Required Materials and Documentation ............................................................. 6 3.4. Plant Personnel Interviews ................................................................................. 6 3.5. Functional Failure Modes Effects and Criticality Analysis (FMECA) .............. 7

    3.5.1. System Functions.................................................................................... 7 3.5.2. System Functional Failure ...................................................................... 7 3.5.3. Identification of Equipment .................................................................... 7 3.5.4. Identification of Failure Modes .............................................................. 7 3.5.5. Identification of Failure Effects .............................................................. 8 3.5.6. Criticality ................................................................................................ 8 3.5.7. Maintenance criteria for Non-Critical components ................................ 9 3.5.8. Reliability and Performance Data collection and processing ................. 9

    3.6. Use of PSA to support RCM analysis ................................................................ 9 3.6.1. Systems selection.................................................................................. 10 3.6.2. Identification of critical components .................................................... 11 3.6.3. The impact of the maintenance activity changes on Plant Risk ........... 12 3.6.4. The Increased Allowed Outage Time (AOT) ....................................... 13 3.6.5. PSA Capability and Insights ................................................................. 13

    3.7. Task Selection................................................................................................... 13 3.7.1. Task Selection Guidance ...................................................................... 13 3.7.2. Maintenance Templates ........................................................................ 15 3.7.3. Task Selection Hierarchy...................................................................... 15 3.7.4. Task Options ......................................................................................... 16 3.7.5. Non Critical Components ..................................................................... 17 3.7.6. Task Selection Review.......................................................................... 17 3.7.7. Final Phase of Analysis......................................................................... 17 3.7.8. Perform Task Comparison .................................................................... 18

  • 4. DEVELOPMENT AND DEPLOYMENT ..................................................................... 18

    4.1. Management Involvement ................................................................................ 18 4.2. Project Management ......................................................................................... 18 4.3. Analytical and Software Tools ......................................................................... 19 4.4. Databases .......................................................................................................... 19 4.5. Use of Contractors ............................................................................................ 21 4.6. Conditions Monitoring Programme.................................................................. 21 4.7. Skills and Competences.................................................................................... 21

    4.7.1. Project Management Skills ................................................................... 22 4.7.2. Training................................................................................................. 22

    4.8. Performance Indicators..................................................................................... 22 4.9. Integration into O&M Process.......................................................................... 22 4.10. Implementing recommendations ...................................................................... 24 4.11. Living RCM...................................................................................................... 24 4

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