eDF - Numex by juanagao


									                              2012 NUMEX MEETING
                              7th – 9th, March 2012 – Barcelona, Spain

The 26th yearly meeting was attended by 9 maintenance managers representing 6
Nuclear Power Plant & Maintenance support Departments from the Czech Republic,
France, Hungary, Sweden, Switzerland and UK.

For detailed 2011 performance statistics of represented plants, please refer to the
members section of the website - Numex.
Temelin NPP Hubert Hasler gave a presentation on his plant’s performance which
is summarised as follows:
    Best production figure to date - 13914 Gwh.
    Unit 1 extended outage because of changeover of fuel suppler.
           decreased power to 55% Nnom on 2 occasions:
        o On the 8.3.2011 at 00:00h lost the RCP2 due to an I and C failure on a
            DPU unit.
        o On the 8.11.2011 at 12:36h lost the RCP1 due to a failure on electro
            protection ALOX M205.
    Unit 2
           Outage - 14.5.2011 extended 2 weeks to solve foreign material
            problem preventing the polar crane lifting the Protection Tubes Block.
           B111 ––unplanned outage (10 days) started with generator oil leak
            followed by flooding of the Unit 2 containment area. (Root causes –
            check valve failure, procedure and line up issues).
Details of work conducted on each unit during outage periods and the projected work
for the 2012 outage periods can be found here
Paks NNP Ferenc Zsoldos gave a presentation on his plant’s performance which is
summarised as follows:
        Production figures (15685 Gwh) exceeded objectives with an overall plant
         loading of 89.65%.
Unit 1
              Control rod supply failures (2)
              Turbine trip due to electric failure
Unit 2
Examination of the turn-to-turn fault in the rotor of the generator
              Failure thermometer on the primary circuit water
              Fault in the automatic control circuit of the pressurizer.
              Main circulation pump fall out due to fault of a thermometer
              High pressure feed water heater trip
Unit 3
              Repair of the thrust bearing segments of the turbine

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                           2012 NUMEX MEETING
                           7th – 9th, March 2012 – Barcelona, Spain

            The turbine oil temperature was too high

Unit 4
            The main transformer protection switch out the generators
            Black out on the main electric grid
            Turbines trip due to black out on the main electric grid
Details of work conducted on each unit during outage periods and the projected work
for the 2012 outage periods can be found here.

With the 2 German NPPs shut down Ulf Johansson gave a presentation on the
plants performance of the remaining 7 operating within Vattenfall. These plant
performances are summarised as follows:
Forsmark 1
Plant availability 79.6%. Problems encountered were:
            Material problems with the Steam Dryer (Fuktavskiljare). The cracks
             could be polished and are approved for operation for 1 year.
             No serious accidents have been reported during the outage
            Reduced power, 50 %, on Saturday 24/9 in order to exchange a
             malfunctioning air hose for a generator-switch. In connection to this, on
             the way up to full power, a periodic valve test was performed.
Forsmark 2
Plant availability 93.9%. Annual outage completed one day ahead of schedule! Start
up went well.
Forsmark 3
Plant availability 85.4%. Problems encountered were:
            Forced shutdown due to fuel failures. 4 leaking assemblies have been
             identified and removed (all GE-fuel). Interestingly, one of the failed
             assemblies was equipped with latest debris-filter technology that
             apparently did not function. The forced shutdown lasted for 7 days
            2 day delay getting back on grid after outage. The delay was mainly
             due to a leakage from SCRAM valves due to poor quality of O-rings.
             Additional delay was due to calibrating problems of new components
             (level gauges) in SCRAM tanks.
Ringhals 1
Plant availability 81.4%. Problems encountered were:
            Faulty transformer in the switchyard was replaced.
            An automatic turbine trip occurred when performing periodic valve test.
             The trip was actuated because of high water level in a moisture
             separator drain tank.

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                             2012 NUMEX MEETING
                             7th – 9th, March 2012 – Barcelona, Spain

              Outage extended 12 days because one of the two low pressure
               turbines needed replacing.
              Problems with temperature measurement in the reactor pressure relief
               system (S-314) lead to a manual power reduction to 36%. Analysis
               showed that the indicated high temperature was not the real
Ringhals 2
Plant availability 24.9%. Problems encountered were:
              Planned outage started on April 2. TWICE (RxR of Control Room
               Project)-related problems found which prolonged the outage
               approximately 14 days.
              During Containment Air Test (CAT) a vacuum cleaner caught fire in a
               limited area. The dust/soot resulting from the fire in the containment
               Area continues to be cleaned off. (Expected finish mid March 2012).
Ringhals 3
Plant availability 79.0%. Problems encountered were:
              On 15/2 a main steam isolation valve started to close due to the pilot
               valves unexpectedly opening eventually leading to a reactor scram. All
               safety systems functioned as expected.
              Turbine 32 developed an oil leakage. Back on the grid May 25.
              Ringhals 3 shut down due to foreign material found in the containment
               spray system on Ringhals 4.
Ringhals 4
Plant availability 49.9%. Problems encountered were:
              Long outage started on May 31 to RxR Steam Generator, Pressuriser
               and turbine governor control. Outage length was 168 days compared to
               originally planned 100 days. Test of containment spray system
               revealed a lot of debris within pipework (possibly from original build).
               The Authorities got involved and insisted systems are checked in other
               units as realistic as possible.
Details of work conducted on each unit during outage periods and the projected work
for the 2012 outage periods can be found here.

Beznau NPP
Mike Erdin gave a presentation on his plant’s performance which is summarised as
Unit 1
Capacity Factor 96.5%. Problems encountered were:
        Temperature Limit of Cooling water reached

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                             2012 NUMEX MEETING
                             7th – 9th, March 2012 – Barcelona, Spain

Unit 2
Capacity Factor 91.2%. Problems encountered were:

        Maintenance on Control Valve Condensate Preheater
        Grid provision of Service.
Current projects on the plants are:
        Emergency Power supply system (2)
        New buildings, new Diesel Engines, new Distribution
        Evaluation and Implementation of a new Plant parameter information system
        Replacement of Vessel head in Unit 1 and Unit 2 exchange planned for 2014
         (2 x 100 days shut down)
Further details of work conducted on each unit during outage periods can be found

Dukovany NPP
Jaroslav Jakub gave a presentation on his plant’s performance which is summarised
as follows:
        Production figures were 14369 Gwh, the 2nd highest in the plant’s history, with
         an overall plant loading of 86.04%.
Unit 1
1 x Shut down due to an electrical card problem in the I&C system
Unit 2
2 outages, the second to maintain common cooling systems between Unit 1 & 2.
Shut down due to a defective bearing of the pump motor on the chemical and
volume control system.
Unit 3
Detected a higher level of condensed steam generator secondary water in one of
primary air-conditioning systems and subsequently a wet floor in the steam
generator compartment at Unit 3:
        It was necessary to shut down the unit to identify the cause. Two failures were
             o a leaking valve on SG#4 blow-down pipeline
             o a leaky pipe on the emergency feed water supply line
             o HP Turbine control valve stuffing box repair

Unit 4
        A faulty switch-off of 4DP20 switchboard due to a human failure
        A power reduction to 63% due to a false action of “sudden power increase”
         function – caused by a failure in the switchboard.

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                            2012 NUMEX MEETING
                            7th – 9th, March 2012 – Barcelona, Spain

Further details of work conducted on each unit during outage periods can be found
here along with intended work for 2012.

Sizewell B
Olivier Garrigues gave a presentation on Sizewell B’s performance and the highlights
of their WANO Review:
Major Performance issues for 2011 were;
      Forced Outage 44 : Leak on the oil lifting pump on Reactor Coolant Pump
      Refuelling Outage 11 :
          > Pressurizer’s heaters exchange,
          > HP rotor exchange,
          > SF6 equipment exchange on Station Transformer,
          > Reactor Coolant Pump internal exchange,
          > Forced Outage 45 : steam leak on TG1 due to a spool piece on the
            cold reheat line without the right material composition
Highlights of WANO Review are as follows:
   •   Peer Review : 3 AFI in maintenance
          -   Most maintenance workers cannot start maintenance activities as
              scheduled because jobsite conditions, support, parts and tools and
              work packages are not verified before commencing work
          -   The quality of maintenance performed by contractors is sometimes
              unsatisfactory and supervision by the plant does not always identify
              and correct deficiencies.
          -   The unavailability and quality of spare parts is creating delays in
              correcting plant equipment these.
   •   TSM – Maintenance Productivity : 3 AFI in maintenance
          -   Responsibility and ownership of maintenance activities are currently
              too fragmented across the organisation leading to inefficiencies
          -   Some constraints in the process of setting to work and starting to work
              are causing significant delays in getting technicians into the field.
          -   The technical aspects of contract maintenance work are not controlled
              by the maintenance department, causing deviations in productivity and
Further details of performance objectives and maintenance plan for 2012.can be
found here.

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                            2012 NUMEX MEETING
                            7th – 9th, March 2012 – Barcelona, Spain

eDF – Nuclear Fleet Technical Support (UTO)
Michel Savoye gave a presentation on the different aspect of eDF’s Nuclear Fleet
Technical Support Organisation. He gave an overview of the activities undertaken
by UTO, its technical expertise, support and planning for outages, supply chain
management and waste management support. Further details can be found here.

Long Term Operation and Upgrade

Jaroslav Jakub gave a presentation on LTO and Upgrading activities at Dukovany.
He outlined the strategy and implementation program to gain assurance although the
effect of Fukushima may yet have an impact. A key mile stone is the followup IAEA
SALTO visit in September 2012. The presentation can be found here and its
conclusions are:
      Technical-economic study of Dukovany NPP LTO demonstrates a technical
       feasibility and economic profitability of Dukovany NPP LTO with perspective
       for up to 60 years of operation.
      Safety part of “LTO Program” complies with IAEA SALTO recommendations.
      „LTO Implementation Project“ for 2009 to 2015 was approved with major
       targets to renew operational permission and prepare NPP for operation up to
       60 years.
A lively debate followed on the merits of when to invest and how to differentiate
between ageing management and maintenance.

Dukvany’s HP Turbine top – bottom ∆t problems following unit power upgrade.

Pavel Vlcek gave a presentation on Dukvany’s HP Turbine top – bottom ∆t problems
following unit power upgrade. He outlined how the situation following the upgrade
and how it manifested itself during load testing. The difficulties were recognized by
the contractor and a short term solution developed. A new design of PI Governor will
be tested and back fitted. The full details of the presentation can be found here

Theme: Foreign Material Exclusion
Stefan Hafstad started off the discussion on FME with a short presentation on
Foreign Material Management in Vattenfall (see presentation) explaining that the
program was set up to minimise the fuel failures in Forsmark 3 although introduced
in 2001 with a subsequent decrease in FME in 2007-8 it suddenly increased. On
further inquiry by WANO it was discover to be reactive and not proactive. It is not
just confined to fuel failures but to many systems. OSART “AFI” also identified they
did not have an existing FME program. During outages 2010 and 2011 several
severe FME events occurred. As part of the learning process attendance at a FME
workshop in Leibstadt autumn 2011(EPRI, IAEA) and an Industrial Working Group

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                             2012 NUMEX MEETING
                             7th – 9th, March 2012 – Barcelona, Spain

meeting in Florida January 2012 (EPRI, INPO) prove helpful. To continue this
learning process there is a FME workshop in Ringhals last week in April 2012 (EPRI,
So in 2012 the idea is to;
      Have a common approach across all plants which will help with contractors.
      Make sure the FME program is more proactive throughout the technical
      Introduce in a phase manner
      Introduce FME zones (not high risk and low risk zones this year).
      Introduce new roles (FME coordinator, monitors….)
      Introduce training
      Clean-as-you-go policy
      FME indicators
Use NUMEX as the focus for leading a FME working area within Europe. Various
working practices were discussed from the different NPPs, Use of wire brushes,
importance of defined zones, use of FME co-ordinators, tool audits, walkdowns and
housekeeping, who owns the FME personnel – Operations? Changing the culture,
distribution points for FME, using educated personnel as co-ordinators, training,
management support, staged introduction of FME policy and the use of FME
indicators were just some of the areas explored.
Sizewell have a mature FME organisation, culture and processes managed by the
Maintenance Dept. Paks have a similar organisational setup.

WANO SOER – Shutdown Safety Protected Equipment Handling – Temelin
Hubert Haslar gave a presentation on WANO’s SOER – Shutdown Safety Protected
Equipment Handling (see presentation). What is the definition of “Protected
equipment” and the requirements for when they should be enforced and how to
control this area or equipments where just some of the areas touched upon. How to
develop a procedure to implement this programme and in particular systems that
operate to support a key shutdown safety function, including support systems were
discussed together with how to communicate protected equipment lists and status,
including expected changes in protected equipment, to station personnel and
supplemental workers. Sizewell mentioned they have a policy for both in operation
and outage which uses barriers to identify protected equipment. Operations daily
send an email to state where protected barrier areas are in force.

Work hour regulations at Beznau NPP
Mike Erdin gave a presentation (see presentation)on the working hours for hired
people, contractors and employees KKB and the impact on scheduled outages. In
particular contractor’s working practices and the effect on an outage and the need for
KKB personnel to supplement contractor work force to complete an outage. In
France the contractor is responsible and the Nuclear Regulator (Inspector of Works)
checks compliance with the working time directive. So to ensure an outage in KKB
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                           2012 NUMEX MEETING
                           7th – 9th, March 2012 – Barcelona, Spain

remains of the same duration more resources are required but this does not always
work due to the limited working area. In the Czech Republic it is the contractor’s
responsibility to ensure compliance to the regulations. Paks have a limit on overtime
of 300 hours.

Equipment Reliability and Performance
Pavel Vlcek gave a presentation (see presentation) on Health Reports to trend
equipment reliability on all important systems. Dukovany have created a process of
data collection for a number of systems and produced a system card which covers
parameter weight, occurrence weight, parameter evaluation, area evaluation to
produce a “total system health indicator” using 4 different colours. The discussions
centred around:
        • Plant systems, how to define the system boundaries the pilot focused on
          EFWS and MCirc Pumps.
        • System-health monitoring environment
        • Data sources – should it be an automatic or manual system
        • System-health evaluation criteria what should be the weight
        • System-health evaluation feedback and who uses the data
Vattenfall’s processes are somewhat behind Dukovany. EDF – UTO have followed a
similar path to Dukovany, Sizewell have a mature health monitoring system. This is
within the Maintenance Department. The system health engineering department
follows an AP913 process using system and component engineers. They produce a
monthly report where it is discussed at Plant Health Committee with the Plant
Manager to review the actions required for any system indicating red. Questions
were raised about when you should bring back a system to “green” (obscelence,
long term investment and LTO issues). EDF – UTO also raised the point about what
maintenance state a NPP is in when introducing such a system. Edf use a modified

How to associate technicians with Key Performance Indicators
Olivier Garrigues wanted to know how members engage technicians in the NPP
KPI’s. They (Sizewell B) have rationalised the number and relevance of their KPI’s.
The business plan has fleet, operational and business objectives that, following a
number of inputs from external organisations and reviews has been modified to
produce a Maintenance Excellence Plan (see presentation). There are 8 relevant
KPIs but the challenge is to gain ownership of these with the workforce. KPI
information is displayed in the workshop on TV screens along with other information.
There are monthly meetings to discuss monthly targets. KPIs are compared to other
fleet plants. The emphasis has moved away from productivity to plant safety and
conduct of maintenance. Some non monetary reward is given if personnel achieve
targets. Once targets are set they remain in force for the year. Contractors are not
included in the system yet. Paks have a similar system although they have not been
able to delegate KPIs to the technicians (they are managed by Section Heads) they

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                            7th – 9th, March 2012 – Barcelona, Spain

also have a bonus system after outages. In Vattenfall there is a general annual
survey. Beznau were concerned that too many KPIs would put personnel under a lot
of pressure and questioned whether performance was linked to salary (it is not).
EDF- UTO and Vattenfall felt it was important to ensure that the technicians “owned”
the system and to monitor rework as it was a good way to implicate the technician
and appeal to their pride. Dukovany have 2 systems, one for the company and one
for contractors. KPIs are reported monthly

Maintenance reorganization as a member of a concern
Ference Zsoldos gave a presentation (see presentation)on Paks’ outsourcing
program. He outlined the business drivers behind the decision e.g. the requirement
to build 2 new units, how to finance the building of the new units and trying to
increase earnings (EBITDA). Utilisation of existing sister company skills
(maintenance and grid supplies) which now must be used in an outsourcing
program. Project is now running Areas of concern are how to evaluation the effect on
of nuclear safety, production safety, economical issues. What the effect on the
licensee responsibility is not known, which is taking up their time at the moment.
Streamlined the maintenance organisation and ensuring they are focussed on safety
is one of the main issues with the contractor. When the groups were outsourced
cost rose by 25%. The statement from the recent WANO peer review said that the
contractor industry safety is 6 times worse than in Paks so the focus is on training
contractors but this will be a slow process (years). Motivation of the young
generation is also an area of concern especially the ownership of systems. What
areas should be kept within the company and what to outsource remains an
unanswered question, should Paks outsource maintenance on reactor, SG and I&C
areas or should they be left within the company. Dukovany had a similar strategy 20
years ago they questioned how do you ensure 2 company competition. SZB raised
the point about „intelligent customer” where the regulator wants to know how you, as
the licencee, ensure the contractor is doing what you want. EDF conducted a n
assessment based on the criteria of Safety, special knowledge and whether it was
easy to obtain in the market. EDF-UTO followed a similar route of outsourcing but
discovered that they had almost lost their inhouse skills so have recruited and
trained specialist teams.

Post Fukushima experiences and lessons learnt
A summary of the impact Fukushima has had on the maintenance departments of
those NPPs is summarised below, many proposals are in the discussions stages
following completion of the various stress tests:

Beznau – New fuel pool cooling, emergency equipment dumps in the mountains(old
army facility). Addition of new EDGs; Re-siting fire fighting trucks into tents.

Dukovany – List of findings indicate robustness of buildings, habitability of main
control room; plan to build new cooling towers( this is also a LTO issue), fuel pool

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                            2012 NUMEX MEETING
                            7th – 9th, March 2012 – Barcelona, Spain

new cooling system, closer co-operation between VVER plants in the event of an
emergency (Czech Republic, Hungary, Slovakia).

EDF UTO - Establish corporate high level emergency team able to deal with more
than 1 plant. Improve response of delivering equipment (live test conducted in
February with use of helicopters); increase the safety margin in some plants to
flooding is required; establishment of a quick response (48hrs) specialist team, from
UTO, to be deployed in the event of an emergency.

EDF Energy -; build new emergency centre capable of resisting flooding with a
ground floor containing 40 ISO containers and 1st floor being the emergency centre 1
km away from site; Passive H2 re-combiners and containment filters (U5); upgrade
battery charging EDGs. Upgrade clean air train; add 1 person to each shift in
operation department; for AGR units there will be a central equipment store.

Vattenfall – install steam driven feed pumps; dedicated EDGs for battery charging;
replace EDG sea water coolers for an alternative. Develop common approach to
Ringhals, Forsmark and Oskarshamn. Investigate the use of gas turbines situated
within the local area (though they are not safety justified).

Temelin – Remove personnel out of containment area; overcome EDG cross
connection problem; establish emergency equipment dump.

Paks – Speed up installation of passive H2 re-combiners; modification to cooling
tower (extreme wind issues); install high range temperature measuring
instrumentation for severe accident conditions; test ability to cross connection of
EDGs; establish alternative cooling in the event of building collapse on cooling

Current Problems in EDG related problems in Ringhals and Forsmark -–
Mapping report
Ulf Johansson gave a presentation (see presentation)on EDG Issues within
Vattenfall. –In recent years there have been a rising number of questions regarding
spare parts, load margins and availability for the emergency diesel generators
(EDG). Vattenfall Safety Board recommends to summarizes the various current and
recently occurring EDG related problems at Vattenfall NPPs and SKB facilities,
including design, maintenance, manufacturing/supplier related etc. The purpose of
the Mapping report is to survey the status of EDG for FKA, RAB, OKG and SKB
regarding historical problems, the current situation and the planned and approved
actions. Some of the finding to date are:
          •   All units perform preventative maintenance based on the supplier's
              recommendations, and applicable requirements and standards

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                            2012 NUMEX MEETING
                            7th – 9th, March 2012 – Barcelona, Spain

          •   The maintenance is divided into:
                 •   Annual inspection / service which is performed at 1-2 year
                 •   Maintenance which is performed at 4-6 year intervals
                 •   Overhaul which is performed with 10-16 year intervals
          •   RCM analysis shows that the majority of maintenance is carried out
              correctly. However several critical components (primarily service
              systems) shows a lack of preventive maintenance
          •   Some operating units have not performed the recommended
              (10-16 years) overhaul on the diesel engine.
   •   It is clear that the failure rate trend on emergency power diesels are rising
   •   The diesel engine represent a large number of faults and most of the
       problems are age related
   •   Most problems are small. However this is not acceptable for NPP EDGs
Diesel engines manufactured by SACM stand out with most problems, NOHAB and
MTU least.
Start-up regimes, replacement policy, defect reporting and root cause analysis, type
of fuel used, manufacturer design limitations in relation to running, size of the nuclear
diesel business, overhaul periodicity, long term replacement balanced against LTO
of NPP were discussed between members.
The details of the actions and the situation to date can be found here

NUMEX future activities for the next 18 months
Meetings and Experience Exchange

The salient points of this session are summarised below:

      Managers would rather have a single point of contact for questions etc.
      Information on meetings can be sent to all on contact list i.e. those who may
       have previously attended a meeting/workshop.
      NUMEX to advise Managers if anyone from their NPP books a place on a
      NUMEX to promulgate an attendee list to all Managers either by e-mail or on
       a specific place on the members section of the website.

Meetings/workshops including 3 year programme

      It was explained that the purpose of the rolling programme and asking
       managers to prioritise the subjects they wish to discuss is so that meetings
       and workshops are based on what the managers want rather than what we
       think they want.

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                            2012 NUMEX MEETING
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      From information given at the meeting we now have a rolling programme
       which will be used going forward for meeting/workshop topics.

Which broadly are as follows:
             When               Topic
             April 2012         Condition Based Maintenance
             April 2012         Reliability Centred Maintenance
             October 2012       FME – Procedures and processes
             October 2012       FME – Best Practice
             March 2013         Contractor Qualification
             March 2013         Long Term Service Agreements
             April 2013         Electrical – Generators Maintenance Routines
             April 2013         Electrical - Motors, aging management and suppliers

      Now that we have a rolling programme of topics. Managers can plan in
       advance and forward us their presentations/comments in advance along with
       any other topics i.e. current problems they wish to discuss.
      It was requested that the above mentioned presentations are sent a month
       before the meeting/workshop which will allow NUMEX time to promulgate
       them to all attending and give delegates the opportunity to gather the relevant
       information in preparation.
      2013 is a NUMEX Trophy year – information on the NUMEX trophy will be
       sent to all members in due course so that they can start to plan for this.
      The general consensus was that next year’s MMM should be held near an
       NPP so that a site visit could be arranged, it was noted however that there
       would not be time for this and the trophy, CG will look into agenda timings etc.
      It would be a good idea to have someone from a different industry to speak at
       the MMM.
      Plant status presentations for previous year should be kept short and focus on
       what is of interest highlights, lowlights, problems, successes rather than
       statistics and when plants had their outages.

Going forward

      It was agreed by all that to continue to grow NUMEX must focus on gaining
       new members and that all maintenance managers should help with this by
       forwarding contact details of contacts at other plants or assist with

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