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Configuration Management Fundamentals including Margin Management. Presented By: Judy Schulte Duke Power. CM Fundamentals. CM Equilibrium Objective of Configuration Management Margins NEW Using CM to protect Design and Operating Margins CM Process Model Restoring CM Equilibrium

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configuration management fundamentals including margin management

Configuration Management Fundamentalsincluding Margin Management

Presented By:

Judy Schulte

Duke Power

cm fundamentals
CM Fundamentals
  • CM Equilibrium
  • Objective of Configuration Management
  • MarginsNEWUsing CM to protect Design and Operating Margins
  • CM Process ModelRestoring CM Equilibrium
  • Functional Areas
  • Five Functional Areas of CM
what is cm equilibrium
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 Managementis the conformance of the three elements represented by the CM Equilibrium Model
cm equilibrium
CM Equilibrium
  • Design Requirementstechnical 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 equilibrium5
CM Equilibrium
  • Facility Configuration Information
  • 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

FacilityConfigInfo

cm equilibrium6
CM Equilibrium
  • Physical Configuration
  • actual physical location, arrangement and material condition of SSCs
  • What is actually there
  • SSCs installed (design configuration)
  • component position (operating configuration)

Physical Config

cm equilibrium7
CM Equilibrium
  • Work Processes must assure that:
  • Elements conform all the time processes in place to restore CMEquilibrium 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

Physical Config

FacilityConfigInfo

cm equilibrium8
CM Equilibrium
  • Upsets in CM Equilibrium
  • errors in analysis, design inputs
  • errors in licensing documents
  • desired changes, such as power uprating

Design Require-ments

FacilityConfigInfo

cm equilibrium9
CM Equilibrium
  • Upsets in CM Equilibrium
  • drawing / plant discrepancies
  • components in wrong position
  • maintenance errors that affect plant configuration
  • desired changes: modifications, manipulating plant components

Physical Config

FacilityConfigInfo

cm equilibrium10
CM Equilibrium
  • Upsets in CM Equilibrium
  • 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 equilibrium margins
CM EquilibriumMargins

Design Basis

Protect the Design Basis

Design Configuration conforms to Design Basis

Operational Configuration conforms to

Design Configuration

Design Configuration

Operational Configuration

Each boundary has margins to protect these limits

margins
Margins

Failure Point Undetermineddepends on many variables

Documented in engineering calculation

Ultimate Capability

Analytical Margin

unanalyzed region

Analyzed Design Limit

Design Margin

controlled by Engineering

Operating Limit

Operating Margin

controlled by Operations

Range of Normal Operation

Documented on design documents

margins13
Margins

Failure Point Undetermineddepends on many variables

  • 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

Documented in engineering calculation

Ultimate Capability

Analytical Margin

unanalyzed region

Analyzed Design Limit

Design Margin

controlled by Engineering

Operating Limit

Operating Margin

controlled by Operations

Range of Normal Operation

Documented on design documents

margins14
Margins

Other Limits and Setpoints

Failure Point Undetermineddepends on many variables

Documented in engineering calculation

Ultimate Capability

Regulatory Limit

Analytical Margin

unanalyzed region

Analyzed Design Limit

Design Margin

controlled by Engineering

Operating Limit

Tech Spec Limit

Operating Margin

controlled by Operations

Operator Alarm (HI-HI)

Range of Normal Operation

Documented on design documents

Operator Alarm (HI)

margins15
Margins

Elevator Example

Failure Point – undetermineddepends on many variables

Ultimate Capability

Analyzed & tested to 4650 lbs

Analytical Margin

Analyzed Design Limit

Design Margin

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

Operating Limit

Operating Margin

Range of Normal Operation

Rated Load posted in elevator = 3500 lbs

100 – 600 lbs

margins16
Margins

Motor Operated Valve Example

  • Original analysis:
  • Design assumes valve closes in 20 seconds
  • Valve is tested to prove it could close in 16 seconds (with reduced voltage)
  • Normally valve can close in 12 seconds

Analytical Margin

20 sec

Design Margin

16 sec

Operating Margin

12 sec

Normal Operation

Valve Closure Time

margins17
Margins
  • Over time, performance has
  • eroded due to aging :
  • Testing can only prove valve would close in 18 seconds
  • Design Margin is reduced

Motor Operated Valve Example

Analytical Margin

  • Margin can be regained by
  • installing larger operator
  • requires more power(affects voltage analysis)
  • new operator is heavier(affects seismic analysis)

20 sec

Design Margin

18 sec

Operating Margin

14 sec

Normal Operation

Valve Closure Time

margins18
Margins

Motor Operated Valve Example

  • Margin regained on valve closure time
  • Margin lost on Voltage Analysisand Piping Stress Analysis

Analytical Margin

Analytical Margin

Analytical Margin

20 sec

Design Margin

Design Margin

Design Margin

16 sec

Operating Margin

Operating Margin

Operating Margin

12 sec

Normal Operation

Normal Operation

Normal Operation

Valve Closure Time

Voltage Analysis

Piping Stress Analysis

cm process model
CM Process Model
  • High level model
  • Integrated processes used to return CMequilibrium
  • Developed in early 2002 by CMBG task force
cm process model20
CM Process Model
  • Influenced content of industry guidancedocuments:
    • NEI Standard Nuclear Performance Model
    • INPO Operation Excellence Outcomes enablers
  • Used by CMBG to develop CMPerformance Indicators
slide21

CM Process Model

ChangeDesignRequirements?

ChangePhysicalConfiguration?

ChangeFacilityConfigurationInformation?

EvaluateIdentifiedProblem orDesiredChange

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

DoNothing More

No

No

No

CM Equilibrium

Yes

Yes

Yes

CM001

DesignRequirementsChange Process

Physical ConfigurationChangeAuthorizationProcess

Facility

ConfigurationInformationChange Process

cm process model22
CM Process Model

ChangeDesignRequirements?

ChangePhysicalConfiguration?

ChangeFacilityConfigurationInformation?

EvaluateIdentifiedProblem orDesiredChange

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

DoNothing More

No

No

No

CM Equilibrium

Yes

Yes

Yes

DesignRequirementsChange Process

Physical ConfigurationChangeAuthorizationProcess

Facility

ConfigurationInformationChange Process

CM002

cm process model23
CM Process Model

ChangeDesignRequirements?

ChangePhysicalConfiguration?

ChangeFacilityConfigurationInformation?

EvaluateIdentifiedProblem orDesiredChange

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

DoNothing More

No

No

No

CM Equilibrium

Yes

Yes

Yes

DesignRequirementsChange Process

Physical ConfigurationChangeAuthorizationProcess

Facility

ConfigurationInformationChange Process

CM003

cm process model24
CM Process Model

ChangeDesignRequirements?

ChangePhysicalConfiguration?

ChangeFacilityConfigurationInformation?

EvaluateIdentifiedProblem orDesiredChange

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

DoNothing More

No

No

No

CM Equilibrium

Yes

Yes

Yes

DesignRequirementsChange Process

Physical ConfigurationChangeAuthorizationProcess

Facility

ConfigurationInformationChange Process

CM004

cm process model25
CM Process Model

ChangeDesignRequirements?

ChangePhysicalConfiguration?

ChangeFacilityConfigurationInformation?

EvaluateIdentifiedProblem orDesiredChange

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

DoNothing More

No

No

No

CM Equilibrium

Yes

Yes

Yes

DesignRequirementsChange Process

Physical ConfigurationChangeAuthorizationProcess

Facility

ConfigurationInformationChange Process

functional areas of cm
Functional Areas of CM
  • #1 Protect the Design Basis
  • Design Basis Configuration
  • #2 Modify the Plant
  • Engineering Change Control
  • #3 Operate the Plant
  • Operational Configuration Control
  • #4 Maintain the Plant
  • Configuration of SSCs not in service
  • #5 Test the Plant
  • Plant Design Validation
functional areas of cm27
Functional Areas of CM
  • Protect 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 cm28
Functional Areas of CM
  • Modify 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 cm29
Functional Areas of CM
  • Operate 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 process
  • Causes for upsets in CM Equilibrium
  • failure to follow operating procedures
  • human errors due to workarounds,abandoned equipment, temp mods, etc.
functional areas of cm30
Functional Areas of CM
  • Maintain 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 cm31
Functional Areas of CM
  • Test 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