Fast Track Modifications Keith ReinsmithPPL Susquehanna Tuesday June 3, 2008
Fast Track Modifications • Plant changes are the biggest exposure to the health of a station’s CM program • Plants have strong processes and controls around ‘normal’ modifications • Often are challenged to accelerate this process to get a modification developed and implemented quickly (a fast track modification) • Higher risk of errors, near misses, and CM issues exist from this type of modification.
Fast Track Modifications • A plant change that is scoped, designed, planned, installed and tested all in a very short time frame. • Typically in response to an emergent degraded plant condition or to address a new regulatory requirement or discovered non-compliance. • Poses challenges to human performance and Configuration Management
Human Performance Challenges • Engineer Fatigue • Lack of attention-to-detail • Working to assumptions that were not or could not be validated • Inadequate peer reviews • Imprecise or incomplete communications among project team members • Inadequate vendor oversight • Inadequate post-mod training (operators, maintenance personnel)
CM Challenges • Insufficient inputs to design (wrong solution) • Incomplete designs • Latent errors introduced • Overlooked impacted FCI sources • Concurrent design/ installation • Insufficient planning of installation • Installation problems requiring design rework • Inadequate post-installation testing
Logistics Challenges • Material availability/ expediting • Lack of qualified workers (engrs/ craft) • System availability
How to Mitigate Risks • Requires a disciplined approach; can’t let schedule drive process • Need to recognize and address potential error traps • Develop special actions to mitigate identified risks. • Breakout Session: Looking for industry best practices to improve performance in Fast Track modifications