EQUIPMENT RELIABILITY AT KOEBERG

1. EQUIPMENT RELIABILITY AT KOEBERG Susan van Wyk Reliability Engineering Manager Koeberg Nuclear Power Station

2. Outline • Setting the Scene: Koeberg Nuclear Power Station • Integration of Equipment Reliability Processes – The INPO AP-913 Equipment Reliability Process • Our Equipment Reliability Journey • Timeline • Integration of Existing Processes • Equipment Reliability Tools • Conclusion

3. 1. Setting the Scene: Koeberg Nuclear Power Station Unit 2 Unit 1 Turbine Hall • Only Nuclear Power Station in Africa • Two Framatome 920 MWe Units • 3-loop Pressurised Water Reactors (PWR) • Unit 1 began operating in 1984 • Unit 2 began operating in 1985 • Provides approx. 6.5% of South Africa’s electricity • Sister plants: Tricastin and Blayais (EDF) Intake Basin

4. 1. Setting the Scene: Koeberg Nuclear Power Station • Primary System: Water as moderator and coolant. Boric Acid and Control Rods for reactivity control. • Secondary System: Steam / Water cycle. Steam drives Turbine-Generator sets. • Ultimate Heat Sink: Cold Sea Water

5. 1. Setting the Scene: Koeberg Nuclear Power Station 3 Steam Generators Containment 3 Steam lines taking steam to the turbine Reactor Vessel 3 Reactor Coolant Pumps Basic PWR Nuclear Island Layout

6. 1. Setting the Scene: Koeberg Nuclear Power Station • Systems, Components & Maintenance • Number of Systems = Approx. 200 systems • Number of Preventative Maintenance (PM) Tasks = Approx. 62 620 (Online and Outage) • Outage 218 Duration Target ≤ 45 days • Outage ALARA Dose Target ≤ 720 mSv • South Africa’s Electricity Demand vs. Generating Capacity • Challenges during winter and unplanned plant outage periods • Equipment Reliability paramount to availability of plants • Strong Demand Side Management programme to reduce wasteful use of electricity

7. What is our common enemy? Unexpected Corrective Maintenance of Critical Equipment

8. 2. Equipment Reliability Guidelines for Nuclear:INPO AP-913 Background • INPO = Institute of Nuclear Plant Operators • INPO developed ER process guidelines • INPO first issued AP-913 “Equipment Reliability Process” in March 2000 • INPO AP-913 provides guidelines to maintain a high level of safe and reliable plant operation in an efficient manner • AP-913 Guides the integration and coordinationof Equipment Reliability activities into one process to: • Evaluate important station equipment • Monitor equipment performance and condition • Make continuing adjustments to the maintenance tasks and frequencies based on equipment operating experience (OE). • Develop and implement long-term equipment health plans

9. 2. Equipment Reliability Guidelines for Nuclear:INPO AP-913 Background To make sure that: • We are working on the right equipment – Critical Component Determination • We are doing the right maintenance – Maintenance Tasks • At the right time – Maintenance Task frequency • While planning ahead – Life of Plant Planning • And Continually Making Improvements by: • Performance and Condition Monitoring • Recording “As-found” conditions and feeding back to PM programme • Using feedback from the Corrective Action Programme • Having a “Living” Maintenance Programme

10. 2. Equipment Reliability Guidelines for Nuclear:INPO AP-913 Top Level Diagram

11. 3. Our Equipment Reliability Journey: Timeline Mid-2007 - Development of “Equipment Reliability” group (3 ppl). Focus on improving PHC (Plant Health Committee) and System Health Reporting Oct 2008 - EPRI AP-913 Gap Analysis – Improvements identified for existing RCM Maintenance Basis EDF / Eskom Contract. EDF fully adopts AP-913, including PM Templates. 2002…. 2006 2007 2008 2009 2010 2011 2002 /3: Organisational Change - Set up for Sys Eng & Comp Eng, SHR,RCM MB, Separate ER Processes Strategy development for further partnerships with EDF and AP-913. Process Integration Maintenance Basis Optimisation Project –identification of failure modes, PM templates 2007 WANO Equipment Reliability Technical Support Mission.

12. 3. Our Equipment Reliability Journey:Integration of Existing Processes • Review of Component Criticality using EDF classifications as input for improved alignment of maintenance strategies • Maintenance Basis Project to review plant maintenance tasks and frequencies based on Industry and plant OE. • Existing processes require further integration: • System Health Reporting • Component Health Reporting • Performance Monitoring and Trending • Component Failure Assessments, Intrusive Task Assessments, Root Cause Analysis, Corrective Actions • Life of Plant Plans (LOPP) • Maintenance Task and Frequency Optimisation based on real plant maintenance feedback

13. 3. Our Equipment Reliability Journey:Equipment Reliability Tools • Individual software systems have grown over time, e.g: • system health database, component health database, Life Cycle Management system, Work management systems, Problem Reporting databases, Corrective Action management, RCM software, Maintenance Basis Database. • Integration of Equipment Reliability software for: • Improved processes • Limiting duplication of data entries • Improved monitoring and trending to become more proactive instead of reactive • Avoiding gaps that may exist between processes • Efficiency • Ease of comparison to Industry peer stations with similar software

14. 4. Conclusion • Our goal is to eliminate unexpected corrective maintenance of critical components • Integration of Equipment Reliability processes for a truly LIVING MAINTENANCE PROGRAMME • Koeberg is continually improving its equipment reliability using the Nuclear Industry guidelines for Equipment Reliability, Industry peer benchmarking, Operating Experience (e.g. EPRI) and partnerships with EDF.

15. Any Questions?