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Obsolescence Impact on Configuration Management

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  1. Obsolescence Impact on Configuration Management Presented By: Rob Santoro PKMJ Technical Services, Inc.

  2. Definition of Obsolescence • Obsolete Equipment - “An item in plant service that is no longer manufactured or are otherwise difficult to procure and qualify.” Source: INPO NX-1037 Revision 1, Obsolescence Program Guideline

  3. Obsolescence in Nuclear • What does that mean to Nuclear Power? • Manufacturers are no longer making components required to maintain Plant • Plants are built with technologies from the 60’s and 70’s • License Renewal: How will obsolescence impact the plant for the next 20 years? • Average of 20% of installed plant equipment is obsolete

  4. Obsolescence Challenges • Existing station workloads make it difficult to allocate resources to support proactive solution development • Daily challenges of operating the plant take precedence over Proactive Obsolescence Management • Obsolescence Is Not Going Away: • Obsolescence is growing by an average of 12,000 models per year

  5. Design Requirements Physical Configuration Documented Configuration How does Obsolescence Affect Configuration? • It Impacts All Pillars of the Configuration Triangle!

  6. How does Obsolescence Affect Configuration? • Documented Configuration: • Do you know what in your plant is obsolete? • Design Requirements • When replacing obsolete components/parts with new ones, will you change the design requirements? • Physical Configuration • The plant may change when replacing an obsolete item with a new item

  7. Tackling Obsolescence • Understand Its Impact • Industry Tools Available: • Proactive Obsolescence Management System (POMS) • RAPID/OIRD • Prioritize Challenges • Industry Tools Available: • Preventive Maintenance Forecaster (PM Forecaster) • Obsolescence Manager (OM) • Solve Challenges • Several Solution Options: • Surplus • Equivalency Evaluations • Design Changes • Reverse Engineer • Industry Tools Available • CMIS

  8. Tackling Obsolescence • Understand Its Impact • The Industry has adopted POMS to identify obsolescence • POMS collects all installed equipment information from each site • Every year, all manufacturers of equipment is contacted to identify obsolescence • All U.S. Utilities are members of POMS

  9. Understanding Obsolescence Impact • POMS Identified: • 19% of Data Collected Un-Usable • Cannot contact a manufacturer called “%^&:” • 15% of Results Incomplete • Model number insufficient to determine obsolescence • 11% of Results Unidentifiable • Manufacturer could not recognize Model Number

  10. Understanding Obsolescence Impact • What does this mean to Configuration Management? • Incorrect/Missing information in Enterprise Management systems could indicate a gap in Configuration Management

  11. Configuration Challenges • Configuration Challenges discovered when trying to understand impact of obsolescence to plant • Master Equipment List’s Incomplete/Inaccurate • Missing Information • Manufacturer • Model Number • Equipment Details • Incomplete • Model Number Incomplete • Series Number listed • Site specific number scheme/code • OEM Not Identified • AE’s listed as OEM • Utility listed as OEM • Bill of Materials Incomplete

  12. Addressing Configuration Data • Data Clean-Up • Review Design Requirements and Physical Configuration to identify what is installed and update Configuration Management Databases • Look at: • Purchase Orders • Work Order History • Drawings • Vendor Manuals • Design Changes • Equivalency Evaluations • Walk-Down: Review Nameplate data • Large Effort • Attack in phases: Critical Components first

  13. Data Clean-Up • Results: • Better data available to identify obsolescence challenges • Provides for better planning • Some Utilities require Configuration Change Management to modify this information

  14. Configuration Changes • Be Cognizant of Obsolescence When Performing Configuration Changes • Do not “design-in” obsolescence • Digital Equipment • Does the OEM have a long term replacement plan? • Does my new design implement an obsolete item? • Consider Adding a Check in your design process to check for obsolescence before completing design changes

  15. Configuration Changes • Post Implementation: Update Data Systems • Does your Configuration Change Process require Enterprise Database Updates before Change is complete? • Have you updated the Master Equipment List? • Have you updated the Bill of Materials? • Avoid future obsolescence challenges by clearly documenting current design changes

  16. Configuration Changes • When Performing activities that impact configuration due to Obsolescence: • Consider a “design once, install many” approach • Replace all affected component locations with the same item (when possible) • Identify and satisfy “worst case” characteristics when replacing obsolete items across multiple systems

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