ML041100405

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E-mail Regarding Davis-Besse Operational Improvement Plan - Cycle 14, Revision 3
ML041100405
Person / Time
Site: Davis Besse Cleveland Electric icon.png
Issue date: 02/19/2004
From: Becker G
FirstEnergy Nuclear Operating Co
To:
Office of Nuclear Reactor Regulation
References
FOIA/PA-2004-0140
Download: ML041100405 (33)


Text

LChristine Lipa - Davis-Besse Operational Improvement Plan - Cycle 14, Revision 3 Page 1 From:

<gabecker@firstenergycorp.com>

To:

<JAG@nrc.gov>, <CAL@ nrc.gov>, <WHR@nrc.gov>, <CST1 @nrc.gov>

Date:

2119104 3:26PM

Subject:

Davis-Besse Operational Improvement Plan - Cycle 14, Revision 3 Attached, please find an advanced copy of the subject plan. This plan will be submitted to the NRC via docketed correspondence that Is expected to be sent out today.

If you have any questions, please contact Clark Price at (419) 321-8585 Gary Becker (See attached file: Operational Improvement Plan Rev 3.pdf)

(See attached file: Operational Improvement Plan Rev 3.pdf)

CC:

<caprice~firstenergycorp.com>

FirstEnergy Nuclear Operating Company

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 Table of Contents Page

. Introduction.............................................................................................

  • Barriers To Ensure Nuclear Safety..

a Davis-Besse Improvement Initiatives......................................................

  • Improvem ent Initiative Key Actions........................................................
  • Safety Barrier Attributes and Goals........................................................

Individuaal............................................................

Program s...........................................................................................

M anagem ent.....................................................................................

Oversight............................................................................................

2 3

6 7

24 25 28 29 31 I

Page 1 of 31 Revision 3 Page I of 31 Revision 3 hnew

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 Introduction To ensure continued improvements and sustained performance in Nuclear Safety and Plant Operation at the Davis-Besse Nuclear Power Station, the Leadership Team has developed this Improvement Plan to focus on key improvement initiatives and safety barriers essential to safe restart from the Reactor Pressure Vessel Head degradation extended plant outage and into subsequent operating cycles. This plan provides for a managed transition from the organizational and programmatic actions taken to support the Davis-Besse Return to Service Plan and Building Block Plans to that of normal plant operations and refueling outages.

The initiatives discussed in this plan were derived from lessons learned during the extended plant outage which resulted from the significant Reactor Pressure Vessel Head degradation identified at the beginning of the 13"' Refueling Outage. During the extended outage, numerous improvements were made in the areas of Safety Culture, Management, Human Performance, System Health and Programs as described in the Return to Service Plan and the Building Block Plans. However, additional improvements are required to achieve world class performance and to ensure that the safety barriers that failed to detect the significant RPV Head degradation are maintained to prevent a recurrence of an event in the future.

As described in the Return to Service Plan, the numerous root causes associated with the Reactor Pressure Vessel Head degradation could be grouped into the areas of Nuclear Safety Culture; Management/Personnel Development; Standards and Decision-making; Oversight and Assessments; and Programs/Corrective Actions/Procedure Compliance. Actions described in each of the Building Blocks were designed to address numerous significant improvements in each of those areas. This transition plan of Operational Improvements focuses on the four primary safety barriers of Individual, Programs, Management, and Oversight (as described in the following pages) to ensure improvements realized during the extended outage remain in place and are further built upon to improve performance in the future. This plan will ensure that the improvements made to Davis-Besse are "built to last".

This plan will be used by the Davis-Besse Leadership Team on a monthly basis to monitor safety barrier attributes that would provide early detection of declining trends in performance and to focus on major initiatives to achieve operational excellence. This plan is a living document and will be periodically updated and revised to address completed actions and add new initiatives as determined and approved by the Senior Leadership Team.

Page 2 of 31 Revision 3 up

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 Barriers To Ensure Nuclear Safety The safety of nuclear power relies heavily on the "defense in depth" concept. Nuclear power plants are designed with robust systems and redundant back-up safety systems in the unlikely event of a failure. However, systems and equipment must still be operated, maintained and designed by people to ensure reliability and availability if called upon to perform an intended safety function. The first barrier to ensure safety is the Individual. The operator, maintenance technician, engineer and all the other support personnel play an integral role in monitoring plant status and maintaining systems and equipment in top-notch condition. Thus, ensuring that the individuals that support nuclear power plant operation are highly qualified, trained and motivated to do the best job possible is an essential barrier to ensure nuclear safety.

To guide the individual in performing their required job functions, numerous Programs have been put in place to address the operations, maintenance, design and licensing basis activities performed daily at the station. Programs are implemented by procedures and other written documents to ensure a consistent approach by the individual. Thus, programs are another essential barrier to ensure nuclear safety.

Management also plays a key role in nuclear safety. Management is responsible for providing the proper focus on priorities that ensure the plant is operated and maintained to high standards and expectations. Management is also responsible for creating a work environment that is conducive to a safety conscious work environment and strong safety culture, and to ensure there are adequate staffing levels of qualified and motivated individuals in every department. Management, therefore, is also considered one of the barriers essential to nuclear safety.

To ensure that the individual and management (using established programs and associated procedures) performs their duties to high standards and maintains the proper safety focus, Oversight organizations provide another barrier for nuclear safety. Oversight checks for adverse trends in performance and is independent of other pressures. Independent oversight, when properly used, can identify differences from industry norms for early detection of potential weaknesses developing in the safety barriers.

Together these four barriers work in conjunction to contribute to the safe operation of Davis-Besse.

Page 3 of 31 Revision 3 WmAN am

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 This illustration represents how the four safety barriers failed, allowing the degradation of the RPV Head to go undetected for several years and serves to anchor the lessons learned and corrective actions taken to prevent recurrence.

Programs Oversight C

14 IL IL H

Is H

e4 is Individual Management Page 4 of 31 Revision 3 Page 4 of 31 Revision 3 8tsEi

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 I Barriers Demonstrating FENOC's Strong Safety Focus C

H A

L L

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G E

k FENOC Vision:

'People with a strong safety focus delivering top fleet operating performance' I

r Competent Individual Strong Programs Experienced Independent Management Oversight Page 5 of 31 Revision 3

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 Davis-Besse Inifiatives:

Based on lessons learned from the Reactor Pressure Vessel Head degradation and during the extended plant outage, a series of key initiatives have been developed by the Leadership Team to focus on opportunities for continued improved performance.

These initiatives extend beyond those significant improvements already realized during the extended outage and achieved prior to restart. These initiatives will provide additional improvements to further strengthen each of the four barriers. Details for each initiative are provided in the following pages.

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1. Organizational Effectiveness Improvement X X

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X' X X B. Allen

3. Maintenance Improvement X X X B. Ali eK
4. Tn nv XX B. Allen
5. Work Management Improvement X X X M. Bezilla
7. Continuous Safety Culture Improvement X

X X R. Schrauder

& I dm pro m i X,.

R. Schrauder

9. Corrective Action Program Improvement X

X X X L Myers',,O,

. t.in Ia E-anight it X

X Pag -6of 1 Re is o 3 Page 6 of 31 Revision 3

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 I

Page 7of31 Revision 3

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14

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5. Enhance the Management Observation Program by ensuring personnel providing oversight monitoring are familiar with DBBP-OPS-0001, "Operations Expectations and Standards" 6. Im 'pemenationsitoimprove treig of j"o ph

'ev'lUtion'sutilizing' thMaiametr Obs. r ation-O:

Program to' to frack perrom 6`ance, and feeb ack

7. Provide face-to-face communications training to all site

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supervisors and above 8.' ReXev~uterllavi'Bsse sdeysr

,oass comnpetencyl fo current DosliosI'

9. Conduct Supervisor and Manager Talent Management Talks 10 Cont in 71tu6 withihm4hrnmfen sngsW-_Mebt

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 Page 9 of 31 Revision 3 Fstney

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3. Implement the Operations Improvement Implementation Action Plan, including:
a. StrengthengOprtgCrwiidg assessmerto

-- operators-training 'on procedmure use, and improving.

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b. Strengthening Operating Procedures, including validation of key operating procedures and use of reverse pre-job briefs c.'Stregthening ertn M eeing Operations 0 Unti l onger

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d. Strengthening Independent Oversight of Operations
4. Strengthen Communc ations 4~~.S htho

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5. Benchmark Conduct of Operations
6. Align Performeiance tndin toos toof Oerato Complete I

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 I

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 I

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 I

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 II

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2. Maintenance Backlog Reduction

-a. Complete wakowna Vaier backlogimt; t o e s u r'e p ro p r c t o y 9 or y o n o i a o n r d elim natono of Iaid oTde d at

b. Complete Cycle Plan identifying equipment outages and providing the framework for addressing backlog Order priorities and results of the System Health Report
c. Develop rf6taaltii'o Order backlog,;

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3. Outage Performance
a. Forced Outage 'S dijepn,.

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b. Mid-Cycle Outage Preparation

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  • , Compl~ete O Qtr 2004 I mo. prior to Mide-Crvilp Onna C. Car ex c

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d. 14th Refueling Outage Preparation 4th

'Qtr'2004; Qtr 2005

.1 Page 14 of 31 Revision 3

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 bE1R ~

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1. Implement actions to improve Safety Margin:

J. Grabnar

a. Determinethf kS a

t 2004 Systms

and, deeopataitipoe atyhag
b. Electrical System coordination improvements 4th Qtr 2005
c. Masont oa nal' N-ddesign canges tr 2005.
d. Service Water improvements through Cycle 14
2. Perform add tionalIessu vews s

t

3. Implement the Design Calculation Improvement Plan J. Grabnar through Cycle 14
4. Enhance plantnequipnint the 6;

ENOC Jii Equipment Reliability Program I

5. Develop and implement the plan to enhance System B. Boles 4th Qtr 2004 Engineering ownership of plant systems in support of Operations Page 15 of 31 Revision 3 AistEney

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 rV.I TD'I, UE

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- tdi,6soi:oer1 Schedule and conduct additional Program Compliance Reviews including:

a. Qualification of Program Owners
b. Development of Program Manuals
c. Creation of Performance Indicators J. Powers 1-r~-.+-

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blisfi it "e', apVr

Y9_9, I:e Change Requests and develop a plan reduce mailitain the backlogs to-that leel
8. Perform semiannual effectiveness reviews to determine if the problem solving process, NOP-ER-3001 has been properly implemented during the previous period 9.~ Perom-fh meffehtiv prvem
  • actios in -t areas oimodifialionhs,.Syst8 nginering corrective actions and l6lations i

10.Implement electronic accessibility of design basis information and populate with 5 systems J.' Grabn'ar'`"

B. Boles

.-.21'Qtr 2004:

through Cycle 14 C. Hawley 3

Qtr 2004 I

Page 16 of 31 Revision 3 Page 16 of 31 Revision 3 F I S lo

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14

11. Expand the role of the Engineering Assessment Board (EAB) to include the review of Engineering Root Causes and Apparent Causes and Engineering Calculations 6 I~- -__i

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I O pp o, pr; ce'.Ar -a-tyures to"..,*up-

12. Establish' criteria aiid

',:pp restrict the use of.tisk Changes in the plant hiodifcatiorI process.

13. Re-institute the use of Quarterly System Health Reports and Design Basis Assessment Reports
14. Assign a Program Owner or theroblem SaMng poess
15. Develop and begin implementation of the Technical Issues Resolution Process J. Wilcox Complete B. Boles J. Grabnar B. Boles C. Hawley 2n,Qtr 2004'-

Complete 22 nd Qtr 2004 I

J.

.1 Page 17 of 31 Revision 3 MrI1FSrMtIy

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 r

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1. Monitor Safety Culture on a monthly basis M. Bezilla through
2. Assess Safey u using the i
3. Perform a Safety Culture assessment utilizing an independent M. Bezilla 4h Qa outside organization 4.Provide SCW traiin to 1

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cmeted th-SCWE iotio htf theS SieEmployee Oie~hta-tio'n.-

5. Provide refresher training on SCWE and Safety Culture to J. Reddington 1 '& 3rd Davis-Besse Supervisors and above
6.

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Qtr

7. Employee Concems Program group to perform two surveys of L. Griffith 4 th Qtr the Safety Conscious Work Environment
8. Perfoman iveness,,asses eif th t

bt-T-Ri Qn taken in response to the Noeber 2003 SCWEsuersults

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tr 2004 Qtr 2004 2004/05 W

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I Page 18 of 31 Revision 3 Ris~tEner,

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 I

Page 19 of 31 Revision 3

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14

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9. CorrectiVe4btibnPhgratn lh1provemeflt Iniftative



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DSIRED OUTCOME ImprovcI fferfrepess andimpleknehtatoh of the Corrective Actionr6pramgernonstrated thoagh Improved Station nerrormnce Snnnnr R 11 Mg rw---

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1. Implement the Apparent Cause Improvement Plan:
a. Strengthen procedural rejbiroemnts for pofcann pe evaluations, Including analyti cat methsito be' u

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b. Corrective Action Review Board review of Apparent Cause L. Dohrmann Complete Evaluations until standards are consistently met

'. identify AppareitCaiise, atbirs9 M

ow>a fT*nple o ss a~te

d. Develop Training Program and Expectations and provide J. Reddington Initial Complete /

training to the Apparent Cause Evaluators Additional ISt Qtr (Initial Evaluator Classes and Additional Classes in 2004) 2004

e. QUalify, the- _r aInd sr 2004 SystematiA o

to

'Trinng

f. On an interim basis, rotate team of apparent cause L. Dohrmann Complete evaluators to Support Services cear Review O l

e of oiirgh ycie 14l eecte6d Ap par6en Cau6se, dvtationS~i Page 20 of 31 Revision 3 FkSIEWj

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14

.i Q~9Oi~etive Actor Irb r mpdv ienld ItV e' con"

2. Establish the appropriate level of workload for Condition L. Dohrmann 2nd Qtr 2004 l

Report Evaluations and Corrective Actions and develop a plan to reduce the backlogs to those levels

3. Performs a focused ap piatele ofw l

adfition L. Dohrann 2 Qtr 2004 the v Corrective-Ato A

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inds pees :

-o a"
4. Reestablish the Corrective Action Program trending L. Dohrmann Complete process s
5. Prvide Apparen t aunse L. Dohia t Q 0 04 Page 21 of 31 Revision 3 L

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 I

Page 22 of 31 Revision 3 AisE y

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 pn4or t

y e s

7. Perform Quality Oversight of Engineering using the Continuous Assessment Process
8. Conduct assessmentbbctivitiet of the Correctve Atio Program to evaluate effebtiveness o forrective actiohs-taken: toImpre i

-Mpementation "an improveten Ievaluation I

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.*gi S. Loehlein S -Loehlein through Cycle 14 througi C byc 14 Pae2 f31Rvso Page 23 of 31 Revision 3 FlIstEm, M.MW

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 Safety Barrier Attributes and Goals Safety Barrier attributes and goals have been identified within this plan to provide a focus on key parameters to assess and ensure that safety barriers are being maintained. These attributes, which are grouped by each of the four barriers, will be monitored monthly by the Davis-Besse Leadership Team.

Performance indicators contain the criteria for monitoring each attribute. Some attributes will be monitored by periodic assessments such as surveys or self-assessments to determine if the goal for that attribute is being met. Monitoring sources for the performance indicators referenced in the Barrier Attributes are identified in the table below:

Key OIP MPR SHAR Performance Indicator Monitoring Sources Operational Improvement Plan Performance Indicator Report FENOC Monthly Performance Report SCWE Health Assessment Report Page 24 of 31 Revision 3 AristEw,~

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 d~u4i~

AfrkWfeA 1-01 Human Performance

> 40 days on average Reddington SPO-03 MPR Success Days (Event Free Clock) 1-02 OSHA Recordable

<4 OSHA Recordable Injuries per year Farrell SPO-02 MPR Injuries (Industrial Safety Performance) 1-03 Radiation Protection c 2 events In any 4 consecutive quarters Farrell NRC MPR Events Performance Indicator 1-04 Individual Error Rate

< 0.36 Individual errors per 10,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> worked Reddington SPO-04 MPR based on a 12 week rolling average I-5 Employee willingness to

> 90% of individuals are willing to raise Loehlein NQA OIP raise concerns concerns to their supervisors or the Employee Interviews Concerns Program 1-06 Operator Work Arounds Level I and 2 Work Arounds goal in accordance Ostrowski EMC-10 MPR with FENOC Monthly Performance Indicator 1-07 Control Room Control Room Deficiencies goal In accordance Ostrowski EMC-09 MPR Deficiencies with FENOC Monthly Performance Indicator 1-08 Condition Report

> 90% of Condition Reports are self-identified Dohrmann P-05 OIP Self-Identified Rate I

Page 25 of 31 Revision 3 F:, E p.,

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14

Ifidlv"'Id `A&Sa' Itilb-i6g:

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N Pfeei"eS~c 1-09 Risk Performance

> 75 Risk Assessment Indicator Mugge SPO-01 MPR Indicator (indicator of Cross-The Risk Assessment Indicator assesses each functional teamwork) unit's risk of achieving safe and reliable operation. This indicator accomplishes this by measuring elements related to the probability and consequence of station events. Examples of elements making up this Indicator Include Probabilistic Safety Assessment, Aggregate System Health, Schedule Adherence, Activities Resulting In Reduced Trip-Logic, Schedule Stability, Scrams, Derates, Unplanned entry into Tech Specs, Entry into Abnormal Procedures 1-10 Condition Report

> 95% of SRO review required Condition Ostrowski CA-0l OIP SRO Review Reports were reviewed for operability within 24 (SRO reviews for hours Operability are performed In a timely

_ manner) 1-11 Employee willingness to

< 5% of individuals are not willing to use the Griffith SCWE/NQA OIP use the Corrective Corrective Action Program Surveys Action Program 1-12 Worker confidence In

> 90% of workers believe they can raise nuclear Griffith SCWEINQA OIP raising safety concerns safety or quality concerns without fear of Surveys retaliation I

Page 26 of 31 Revision 3 RrlstEwpg

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 B

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____e 1-13 Training Programs meet

> 2.5 Training Program Performance Indicator Reddington P-02 OIP Industry standards and effectively improve station performance as measured by NOBP-TR-1501 1-14 Licensed Operator

> 95% pass rate In the Licensed Operator Reddington To be OIP Requalification Training Requalification Training Program I

_I developed I

Page 27 of 31 Revision 3 Page 27 of 31 Revision 3

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 I

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Page 28 of 31 Revision 3 Page 28 of 31 Revision 3 AFist~mjQwll

Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14

~ 1/2 ManerAttribues M-01 The Quality of

< 0.5 score based on a 12 week rolling average Grabnar EN-03 OIP Engineering Products (as measured by the Engineering Assessment Board)

M-02 Satisfaction of

> 75% of employees that use the Employee Griffith SCWE 3-4 SHAR employees using the Concerns Program report being satisfied with Employee Concerns the process Program (ECP)

M-03 NRC Allegation Ratio

<2 times the Industry average of NRC Griffith SCWE 1-2 SHAR allegations M-04 Effectiveness of Safety

< 15% SCWERT Non-Concurrence Ratio Schrauder SCWE 4-5 SHAR Conscious Work AND Environment Review

<2 times the Industry average of NRC SCWE 1-3 SHAR Team (SCWERT) in rtaiiaton allegations avoiding discrimination claims M-05 Management Field

> 80% of the management field observations Fehr Semiannual OIP Observations are self performed are self-critical Assessments critical M-06 Effectiveness of Managers and supervisors are generally Loehlein NQA Field OIP Management and effective with a few exceptions Assessments Supervisors M-07 Talent Management and Goal in accordance with FENOC Monthly D. Haskins PDE-01 MPR Personnel Development Performance Indicator M-08 Leadership Development Goal in accordance with FENOC Monthly D. Haskins PDE-02 MPR Performance Indicator Page 29 of 31 Revision 3 rm-EI I y

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Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14 em Monitorin M-09 Reactivity Management 1 Level 2 Reactivity Management Event per Ostrowski Operations OIP year Reactivity AND Management 0 Level 1 Reactivity Management Events per Pi year.__

M-10 Fuel Reliability Zero fuel defects Kelley SPO-07 MPR M-11 I Maintenance Order Online:

Mugge Backlog

< 50 Corrective Maintenance Orders KPI-WM-02 OIP AND

< 450 Elective Maintenance Orders KPI-WM-02 OIP Outage (prior to the startup from 14RFO):

c 250 Corrective/Elective Maintenance Orders MA-01 OIP M-12 Number of Temporary c 5 during the Operating Cycle Boles Plant OIP Modifications A

Engineering 0 related to equipment and design deficiencies Pi after restart from major outages Page 30 of 31 Revision 3 AmtE~~jg

a-S Davis-Besse Nuclear Power Station Operational Improvement Plan Cycle 14

'DAt rrryEiS.Ate 0-01 Field Activity

> 45 Observations completed per unit per month Loehleln DB-01 OIP Assessments 0-02 Responsiveness to QA

< 45 days for SCAQ Condition Report Loehlein DB-02 OIP Identified Issues Investigations AND

< 60 days for CAQ Condition Report Investigations 0-03 Condition Report NQA

> 90% of Condition Report Investigations Loehlein DB-03 OIP Review reviewed by NQA are accepted or rejected within 15 days after the Investigation was complete 0.04 Corrective Action NQA

> 90% of Corrective Actions verified or rejected Loehlein DB-04 OIP Verification by NQA within 30 days 0-05 Timeliness of NQA

< 25 working days from the date of the exit Loehlein DB-05 OIP Audit Report Issuance conference 0-06 Use of Industry Peer 100% utilization of the scheduled INPO Assist Bezilla To be OIP Support Visits for 2004 developed I

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Page 31 of 31 Revision 3 Rrst~neWW