configuration management fundamentals including margin management bill kline firstenergy nuclear...

Configuration Management Fundamentals

including Margin Management

Bill Kline

FirstEnergy Nuclear Operating Company (FENOC)

June 2, 2008

Shell Beach, CA

CM Fundamentals 2008

CM Fundamentals1. CM Equilibrium Objective of Configuration

Management

2. MarginsUsing CM to protect Design and Operating Margins

3. CM Process Model Restoring CM Equilibrium

4. Functional AreasFive Functional Areas of CM


What is CM Equilibrium?In its simplest terms

Configuration Management is what we do to assure ourselves and our regulators that

we are doing everything we said we would do.

The objective of Configuration Management

is the conformance of the three elements represented by the

CM Equilibrium Model


CM Equilibrium

Design Requirements technical requirements, derived from the design process, that are reflected in the final design.

What Needs to be there• Design characteristics and bounding

parameters needed for the design to work• Must be verified or monitored to confirm that

design is valid

DesignRequire-

ments


CM Equilibrium

Facility Configuration Information (FCI)documentation that defines how the plant is designed and how we operate it.

What we say is there• Design Output Documents• Operational Configuration Documents• Other Operating, Maintenance, Training and

Procurement Information

FacilityConfig

Info


CM Equilibrium

Physical Configurationactual physical location, arrangement and material condition of SSCs

What is actually there• SSCs installed (design configuration)• component position (operating configuration)

Physical

Config


CM Equilibrium

Work Processes must assure that: Elements conform all the time

processes in place to restore CM Equilibrium if it is lost

All Changes are Authorizedpeople are trained and qualified

Conformance can be verifieddetermine what configuration is and prove it was done correctly

DesignRequire-

ments

FacilityConfig

Info

Physical

Config


CM Equilibrium Upsets

Upsets Between Design Requirements & Facility Configuration Information

• errors in analysis, design inputs

• errors in licensing documents

• Operating procedure invalidates design calculation (response time)

• desired changes, such as power uprating

Design Require-

ments

FacilityConfig

Info



Upsets Between Physical Configuration & Facility Configuration Information

• drawing / plant discrepancies

• components in wrong position

• maintenance errors that affect plant configuration

• desired changes: modifications, manipulating plant components

FacilityConfig

Info

Physical

Config



Upsets Between Physical Configuration and Design Requirements

• failure of SSC to meet performance criteria as designed

• equipment out of tolerance

• unexpected degradation in performance of SSCs

Design Require-

ments

Physical

Config


CM EquilibriumMargins

Protect the Design Basis Design Configuration conforms to

Design Basis

Operational Configuration conforms to Design Configuration

Design Basis

Each boundary has margins to protect these limits

NSD 106.7Figure 106-3

Operational Configuration

Design Configuration


INPO Margin Model

Analyzed Design Limit

Operating Limit

Normal Operations

Operating Margin

Design Margin

Unanalyzed Margin

Operating MarginRange of Normal

Operation

Equipment /Function FailureLet’s view this cross-section


Margins

Range of Normal Operation

Ultimate Capability

Operating Margin

Design Margin


Operating Limit

Analytical Margin

Documented on design documents

Documented in engineering calculation

Failure Point Undetermineddepends on many variables

controlled by Operations

controlled by Engineering

unanalyzed region


Margins


Ultimate Capability

Operating Margin

Design Margin


Operating Limit

Analytical Margin






unanalyzed region

Notes on Model

• describes one parameter only; different parameters may be interrelated

• direction may be positive or negative

• doesn’t represent all possible limits and setpoints

• gaps not intended to represent relative size of margins – may be zero


Margins


Ultimate Capability

Operating Margin

Design Margin


Operating Limit

Analytical Margin






unanalyzed region

Other Limits and Setpoints

Operator Alarm (HI-HI)

Operator Alarm (HI)

Tech Spec Limit

Regulatory Limit


Operating Margin

Design Margin

Analytical Margin

Margins


Ultimate Capability


Operating Limit

Elevator Example

Rated Load posted in elevator = 3500 lbs

Dept of Labor - design for 25% passenger overload 4375 lbs

Analyzed & tested to 4650 lbs

100 – 600 lbs

Failure Point – undetermined

depends on many variables


Margins

Normal Operation

Operating Margin

Design Margin

Analytical Margin

HVAC Example

OAC Room Temperature

Original analysis:• Room temperature must be kept

under 90° F to protect computers Note: vendor’s Operating Limit = utility’s Ultimate Capability

• Analyzed Design Limit = 84° F, calculated for worst case conditions

• Operating Limit =78° F to give operators time to take action (analysis assumption)

• High Alarm is set at 75° F (warning of abnormal condition)

84° F

78° F

72° F

• 75° F

90° F


MarginsHVAC Example

Over time margin is lost due to one or more of these causes:

• heat loads added to room• lake temperature higher than

analyzed• poor heat exchanger

performance due to fouling


Normal Operation

Operating Margin

Analytical Margin88° F

82° F

74° F

• 78° F

90° F

Design Margin

New Analyzed Design Limit (88°F) reduces Analytical Margin and

• affects Operating Limit (78° F to 82°F)

• affects Operating Margin• affects Alarm Setpoint (75° F to

78°F)


Normal Operation

Operating Margin

Design Margin

Analytical Margin


84° F

78° F

72° F

• 75° F

90° F

Larger air conditioning unit can restore room temperature margin but will

• require more electrical power• increase weight on Aux Bldg roof

MarginsHVAC Example

Voltage Analysis Roof Structural Analysis

Normal Operation

Operating Margin

Design Margin

Analytical Margin

Normal Operation

Operating Margin

Design Margin

Analytical Margin

…resulting in other margin losses


CM Process Model

• high level model

• integrated processes used to return CM Equilibrium

• developed in early 2002 by CMBG task force.

• included in INPO Ap-929, Revision 1 in 2005


CM Process Model

Evaluate Identified Problem or Desired Change• apparent discrepancy (discovered error)• desired change (modification, manipulating plant components)

EvaluateIdentified

Problem orDesiredChange

ChangeFacility

ConfigurationInformation

?

ChangeDesign

Requirements?

ChangePhysical

Configuration?

DoNothing More

CM Equilibrium

Physical Configuration

ChangeAuthorization

Process

DesignRequirements

Change ProcessFacility


Change Process

No No

Yes Yes Yes

No

CM001


CM Process Model

Change Design Requirements?• What are Design Requirements?• Does change affect Design Requirements? Use Design Requirements change process

EvaluateIdentified


ChangeFacility


?

ChangeDesign

Requirements?

ChangePhysical

Configuration?

DoNothing More

CM Equilibrium


ChangeAuthorization

Process

DesignRequirements



Change Process

No No

Yes Yes Yes

No

CM002


CM Process Model

Change Physical Configuration?• Modify components or change position of components? Use mod process to change design Configuration Use operating procedures to change component position

EvaluateIdentified


ChangeFacility


?

ChangeDesign

Requirements?

ChangePhysical

Configuration?

DoNothing More

CM Equilibrium


ChangeAuthorization

Process

DesignRequirements



Change Process

No No

Yes Yes Yes

No

CM003


CM Process Model

Change Facility Configuration Information?• Design Output documents (drawings & specs)• Operational Configuration Documents• Other operating, maintenance, training, etc.

EvaluateIdentified


ChangeFacility


?

ChangeDesign

Requirements?

ChangePhysical

Configuration?

DoNothing More

CM Equilibrium


ChangeAuthorization

Process

DesignRequirements



Change Process

No No

Yes Yes Yes

No

CM004


CM Process Model

Do Nothing More• If cost effective, do nothing more…except• Document your conclusion

EvaluateIdentified


ChangeFacility


?

ChangeDesign

Requirements?

ChangePhysical

Configuration?

DoNothing More

CM Equilibrium


ChangeAuthorization

Process

DesignRequirements



Change Process

No No

Yes Yes Yes

No


Functional Areas of CM#1 Protect the Design Basis

Design Basis Configuration

#2 Modify the PlantEngineering Change Control

#3 Operate the PlantOperational Configuration Control

#4 Maintain the PlantConfiguration of SSCs not in service

#5 Test the PlantPlant Design Validation


Functional Areas of CMProtect the Design Basis

Objective: Understand and maintain design basis consistent with licensing basis design

Major processes• control of licensing and design basis documents (such as 50.59

& UFSAR)• engineering calculations

Causes for upsets in CM Equilibrium• new or revised Design Requirements• inadequate original review


Functional Areas of CMModify the Plant

Objective: Assure that changes to design configuration conform to Design Requirements and are accurately reflected on Facility Configuration Information

Major processes• modification process

Causes for upsets in CM Equilibrium• desired change (modification)• undocumented plant changes


Functional Areas of CMOperate the Plant

Objective: Assure that alignment of in-service equipment is consistent with approved design through use of approved technical procedures.

Major processes• operating procedures • tag out processCauses for upsets in CM Equilibrium• failure to follow operating procedures• human errors due to workarounds, abandoned equipment, temp

mods, etc.


Functional Areas of CMMaintain the Plant

Objective: Assure that SSCs are procured and maintained in accordance with approved design

Major processes• maintenance procedures• procurement procedures

Causes for upsets in CM Equilibrium• failure to follow procedures• inadequate procurement QA


Functional Areas of CMTest the Plant

Objective: Assure the performance of SSCs meets Design Requirements

Major processes• performance testing• plant walkdowns

Causes for upsets in CM Equilibrium• inadequate performance testing programs • inadequate plant aging programs


“It’s what you do now

When you don’t have to do anything

That lets you be

What you want to be

When it’s too late to do anything

about it.”

Warren Owen, former Exec. VP Duke Power

configuration management fundamentals including margin management bill kline firstenergy nuclear...

Documents

design process

design inputserrors

final design

equilibrium upsetsupsets

equilibrium modelpage

mentsfacility config

lostall changes

mentsphysical configpage