ML033350417
| ML033350417 | |
| Person / Time | |
|---|---|
| Site: | Palisades  |
| Issue date: | 11/25/2003 |
| From: | Consumers Energy |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| Download: ML033350417 (35) | |
Text
Palisades Excellence Plan Update November 25, 2003 1
Principles Picture of Excellence
- Right People / Right Job
- Right Picture
- Right Processes
- Right Management Coaching / Right Worker Involvement 2
3 Right People / Right Job
- Balanced Team Of:
- Internal Candidates
- External Candidates
- INPO Experience
- Fleet Experience
- Succession Plan In Place
- Recent Organizational Changes 4
Site Leadership Senior Vice President Group Operations DE Cooper Site Vice President DJ Malone Site Director PA Harden Site Engineering Regulatory Affairs Plant Manager Training Manager Director Manager RA Remus GA Baustian MH Carlson LA Lahti Maintanence Operations Chemistry/Radiation Outage/Scheduling Manager Manager Protection Manager Manager WG Hettel GC Packard DR Williams ML Richey 5
6 Picture of Excellence 7
Organizational Training Excellence Excellence Predictable Teamwork w Doing What We Say and When We Say w Partnership Between Line And Training It Will Be Done For Success w Training Improves Individual And Plant Teamwork Performance w Dont Walk Past Problems Regardless Of Who Owns It w Communicate What Is Expected PALISADES EXCELLENCE Effective w Training Is Valued By Users And What Is Needed w Know Our Roles Accountable Accountable Safe w Line Organizations Responsible For Content w Holding Ourselves To Highest Standards w Our Own Toughest Critic w Doing What Is Right w Training Champions The SAT Process Model Learning w Training Expectations = Plant Expectations w Improving From The Experience Of Ourselves and Others Predictable w Doing What We Say and When We Say It Will Be Done Equipment Operational w Finding Our Problem Before Others Excellence Excellence Zero Tolerance Safety Reliable w Repetitive Problems Are Unacceptable w Nuclear Safety Is Palisades Highest Priority w Focused On Long-Term Success w What We Touch Is Left Correct Reliable w Doing What Is Right w Preventing Not Reacting w Preventive/Predictive Maintenance Exceeds Corrective Maintenance Configuration Control w Focused On Long-Term Success w Maintain and Understand Design Basis w Preventing Not Reacting w Maintain Plant Configuration Leader Predictable Teamwork w Operating Seamlessly Across w Respected By Employees, Peers, w Doing What Is Right w Meet Schedules With Properly Organizational Lines w Palisades Success = Individual Success Community, Shareholders, Industry Prioritized Work
= Palisades Success Pride w Proud Of Appearance And Performance w Appearance = Performance
NRC PERFORMANCE INDICATOR
SUMMARY
- October 2003 REACTOR SAFETY RADIATION SAFETY SAFEGUARDS Occupational Public Initiating Mitigating Barrier Emergency Physical Radiation Radiation Events Systems Integrity Preparedness Protection Safety Safety Performance Indicators Occupational Emergency AC RETS/ODCM Unplanned Reactor Coolant Exposure Protected Area Power System Drill/Exercise Radiological Scrams Unavailability System Activity Performance Control B Effluent Equipment Effectiveness Scrams with High Pressure Personnel Reactor Coolant ERO Drill Loss of Normal Injection System Screening System Leakage Participation A Heat Removal Unavailability Program Alert and FFD/Personnel Unplanned AFW System Notification Reliability Power Changes Unavailability System A Green December 2005 Program B Green December 2003 RHR System Unavailability Legend Safety System Functional NRC Criteria Failures Pal Criteria Inspection Results Monthly Monthly Monthly Monthly Monthly Monthly Monthly 1 Green 3 Green Year to Date Year to Date Year to Date Year to Date Year to Date Year to Date Year to Date 3 Green 1 Green 3 Green 1 Green 3 Green 9
Picture of Excellence - Site Excellence Summary October 2003 Indicator Picture Path Days Between OSHA Recordable Events External Assessments Meets Validate Internal Assessments Unscheduled EFPDs Less Than 100% Power Doesn't Meet Exceeds Employee Communication Human Performance Related LERs Submittal Quality Refueling Outage Duration 10
Days 0 50 100 150 200 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Picture of Excellence Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Average Days Between OSHA Recordable Events Goal Data Good 11 Forecast
EFPD <100%
0 5 10 15 20 25 30 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Picture of Excellence Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Unscheduled EFPD Less than 100% Power Nov-03 Dec-03 Forecast Data 12 Goal Good
Picture of Excellence - Organizational Excellence Summary October 2003 Commitments Met Attendance at Development Activities Meets Human Performance Event Clock Doesn't Meet Exceeds Root Cause Evaluation Quality Corrective Action Implementation Effectiveness OE Evaluation Effectiveness Site Measures Meeting Performance Milestones 13
Avg Days Between Event Clock Resets 100 90 80 70 60 50 40 30 20 10 0
Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Picture of Excellence Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Forecast Data Good 14 Goal Average Days Between Human Performance Event Clock Resets
Percent 100 95 90 85 80 75 70 65 60 55 50 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Picture of Excellence Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Root Cause Evaluation Quality Index Dec-03 Forecast Data Good Goal 15
Rolling 12 Month Count 20 18 16 14 12 10 8
6 4
2 0
Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Picture of Excellence Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Operating Experience Evaluation Effectiveness Dec-03 Forecast Data Good 16 Goal
Picture of Excellence - Operational Excellence Summary October 2003 Indicator Picture Path Reactivity Management Events Risk Management Effectiveness Meets Components Out of Position Temporary Modifications Doesn't Meet Exceeds Operator Workarounds &
Challenges Radiation Exposure - Non-Refueling Outage Radiation Exposure -
Refueling Outage Effluent Dose Content Lit Annunciators 17
Number 0 2 4 6 8 10 12 14 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Picture of Excellence Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Components Out of Position Sep-03 Oct-03 Nov-03 Dec-03 Good Forecast Data 18 Goal
Number 0 5 10 15 20 25 30 35 40 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Picture of Excellence Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Operator Workarounds and Challenges Nov-03 Dec-03 Goal Data Good 19 Forecast
Total Operator Burden 80 75 70 65 60 55 50 45 40 35 30 25 20 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Picture of Excellence Sep-02 Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Total Operator Burden Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Forecast Good Data 20 Goal
Rem 0 5 10 15 20 25 30 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Picture of Excellence Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Radiation Exposure Non-Refueling Outage Data Forecast Good Goal 21
Picture of Excellence - Equipment Excellence Summary October 2003 Indicator Picture Path Unplanned LCO Entries Preventive Maintenance Meets Meets Performance Maintenance Rework Doesn't Doesn'tMeet Meet Exceeds Exceeds Corrective Maintenance Backlog System Health Assessments Not Meeting Expectations Program Health Assessments Not Meeting Expectations Thermal Efficiency Loss Factor 22
Number 0 2 4 6 8 10 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Picture of Excellence Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Unplanned Tech Spec Action Entries Nov-03 Dec-03 Goal Data Good Forecast 23
Number 0 20 40 60 80 100 120 140 160 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Picture of Excellence Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Corrective Maintenance Backlog Oct-03 Nov-03 Dec-03 Data Good Forecast Goal 24
Picture of Excellence Elective Maintenance Backlog Industry Comparison 3000 2500 2000 No. Work Orders 1500 Elective 571 1000 500 0
Palisades (1) 1 3 2 1 2 1 1 1 1 2 2 2 2 2 2 1 1 1 2 2 2 1 2 2 2 3 2 3 2 2 1 2 4 25 Sites (No. of Units)
Picture of Excellence Systems Not Meeting Performance Expectations Good 25 Red system 20 Red Forecast Yellow system Number 15 Yellow forecast 10 Red Goal 5 Yellow Goal 0
Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 26
27 Right Processes
- Focus on Key Processes:
- Corrective Action Process
- Work Management Process
- Training 28
Right Processes
- Corrective Action Process Improvements
- Line Management Ownership
- Identification of Performance Trends
- Root Cause Quality
- Corrective Action Process Challenges
- Use of Operating Experience 29
Right Processes
- Work Management Process Improvements
- Focus Groups Implemented to Reduce Operator Burdens
- Implemented Formal Derate/Outage Response Plan
- Work Management Process Challenge
- Schedule Stability
- Effective Planning 30
Right Processes
- Training Improvements
- Line Management Ownership
- Consistency of Processes and Expectations
- Supervisory/Leadership Training Program
- Training Challenges
- Reducing Human Performance Errors
- Lowering Site Radiation Exposure 31
32 Right Management Coaching / Right Worker Involvement
- Focus on Behaviors:
- Develop Supervisor/Manager Coaching Skills
- Clarify Expectations, Roles and Responsibilities
- Establish Worker Coaching as a Priority 33
No more than 2 OSHA Recordable Events Spent fuel load campaign complete for INPO Index of 96 full core offload capability 10/05 Cost per MWh of <$13.98 License Renewal Application Submitted to NRC 9/05 Capacity factor of >98%
100% Success on Initial License Examinations 5/05 Bargaining Union employee contract 5/05 INPO Index of 96 Cost per MWh of <$17.39 No more than 3 OSHA Recordable Events Capacity factor of >90%
New Radwaste Processing Unit Installed 12/04 Approval to Purchase New Reactor Head 12/04 Event free (30 day) REFOUT All scheduled equipment reliability & operator issues completed 10/04 2400 volt Breakers Replacement 12/04 Spent fuel load campaign complete 8/04 Security Orders Implemented 10/04 INPO Plant Rating of "1" 6/04 EP NRC Graded Exercise With No Findings 8/04 The Lights Are On for NRC Biennial Ops Training Requal Inspection With no 2005 &
Findings 4/04 WANO Plant Evaluation 5/04 beyond!
Plant Instrument Air Compressors Replaced WANO Simulator Evaluation 4/04 01/04 NMC Mission Technical Training Accreditation Renewed 2/04 Achieve excellence in safe, reliable and cost-effective Power Uprate of 1.4% 01/04 operation, while sustaining &
Ac cre ditatio n As s es s me nt o f growing the business.
Te chnic al Pro grams QC Program under NOS 1/04 All S e lf As s e s s me nt Is s ue s
>91% Capac ity Factor, <1.0% Achieve excellence in safe, Plan Ide ntifie d Forc e d Outage predictable, reliable generation of
<2 Human Pe rformance electrical energy Lic e ns e Eve nt Re po rts As s e t Owne r Appro val to proc ee d with Lic e ns e Re ne wal Worke r Equipment Event R
Employe e S urve ys Training No Mo re than 3 OS HA Prac tic e s
>70% Pos itive Re co rdable Eve nts Operational S upe rvis or Davis -Be s s e S OER 02-04 S Eve nt fre e (25 day) REFOUT All Ove rs ig ht Organizational R S c he dule d Equipme nt Reliability and Ope rator Is s ue s Comple te d Ve rific ation &
R Validation Ne w DFS S to rage Pad Proc edures &
Built Work Ins truct.
Job Planning Monitor Performance and Pre ps Management Coaching Peer Coaching Recognize Qualifie d Worke rs Performance Indicators success, accept Benchmarking failure, learn and Internal/external assessments try again!
Corrective action program 34
Summary
- Excellence Plan Originally Developed in 2000
- Performance Continues to Improve
- Excellence Plan will Continue to Drive Palisades Excellence 35