ML18100A329
| ML18100A329 | |
| Person / Time | |
|---|---|
| Site: | Salem  |
| Issue date: | 04/26/1993 |
| From: | Miltenberger S Public Service Enterprise Group |
| To: | Russell W NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| References | |
| NLR-N93044, NUDOCS 9305050190 | |
| Download: ML18100A329 (146) | |
Text
Public Service Electric and Gas Company Steven E. Miltenberger Public Service Electric and Gas Company P.O. Box 236, Hancocks Bridge, NJ 08038 609-339-4199 Vice President and Chief Nuclear Officer APR 2 6 1993 NLR-N93044
- u. s. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555 Attention:
Mr. William T. Russell SALEM MATERIEL CONDITION IMPROVEMENT SALEM GENERATING STATIONS UNIT NOS. 1 AND 2 DOCKET NOS. 50-272 AND 50-311 As per your request and in an effort to keep NRC management informed, Public Service Electric and Gas (PSE&G) is providing information on our continued progress on "Salem Generating Station Materiel Condition Improvement" project.
Attached is the summary of the status of various projects underway.
If you have any questions regarding this transmittal or require any additional information, please feel free to contact us.
Attachment (1) 030055 9305050190--930426- ---- ~--\\
PDR ADOCK 05000272 p
PDR Sincerely,
- f.
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~1 Document Control Desk NLR-N93044 2
c Mr. T. T. Martin, Administrator - Region I U. s. Nuclear Regulatory Commission 475 Allendale Road King of Prussia, PA 19406 Mr. J. c. Stone, Licensing Project Manager
- u. s. Nuclear Regulatory Commission One White Flint North 11555 Rockville Pike Rockville, MD 20852 Mr. T. P. Johnson (S09)
USNRC Senior Resident Inspector Mr. K. Tosch, Chief NJ Department of Environmental Protection Division of Environmental Quality Bureau of Nuclear Engineering CN 415 Trenton, NJ 08625 APR 28 1993
0NLR-N93044 SALEM MATERIEL CONDITION IMPROVEMENT SALEM MATERIEL CONDITION IMPROVEMENT INTRODUCTION:
The Nuclear Department Senior Management has established an integrated strategy, Salem Materiel Condition Improvement project to achieve improved operating performance of the Salem plants through significant materiel condition, equipment reliability, procedural and personnel performance improvements.
Salem Materiel Condition Improvement objectives are:
- 1. Achieve a materiel condition that is above the industry average;
- 2. Achieve component and equipment reliability that results in improved plant safety and availability;
- 3. Achieve Regulatory acknowledgement of improved materiel condition and operating performance;
- 4. Accomplish upgrades concurrent with normal outage and non-outage cycles;
- 5. Control project costs through better planning and management oversight;
- 6. Improve project performance through innovative utilization of resources;
- 7. Provide plant personnel with technically accurate and human factored procedures and processes;
- 8. Assure materiel improvements are maintained/sustained;
- 9. Foster appropriate work place values, beliefs, culture, high performance expectations and standards.
Five project/program scope elements were carefully selected to execute and complete those activities necessary to achieve Salem Materiel Condition Improvement objectives.
These are;
- 1. Salem Procedure Upgrade Project
- 2. Corrective/Preventive Maint. Work Order Reduction Program
- 3. Materiel Condition Revitalization Pl::ogram
- 4. Materiel Condition Maintenance Program
- 5. Personnel Performance Improvement Program A brief description of these projects and their status are provided in the following pages.
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.. NLR-N93044 ATTACHMENT 1 SALEM MATERIEL CONDITION IMPROVEMENT PROJECT TITLE:
SALEM PROCEDURE UPGRADE PROJECT (PUP)
PROJECT DESCRIPTION:
Salem Procedure Upgrade Project has been in progress for the last several years with the goal to provide Salem Maintenance, Operations and Chemistry Departments with procedures designed to enhance the plant performance.
The upgrade consists of format, content, level of detail, technical accuracy/adequacy and human factors improvements.
The Project scope consists of the upgrade of 3474 procedures, implementation of computer-based procedure configuration/content controls, and the development of a procedure maintenance process which will allow procedure quality to continue to evolve.
Procedure Upgrade Project utilizes an iterative procedure development and review process specifically designed to provide a high level of assurance that the product will be of consistently strong quality.
This forms the basis for long-term, continuing improvements, which is the true intent of the Project.
PROJECT BENEFITS:
The PUP objective is to provide high quality procedures that would enhance plant performance. A key to achieving the desired quality is developing the acceptance and commitment of the procedure users in each department.
PUP achieves this with dedicated review personnel from the user departments.
As awareness with the Procedure Use and Adherence Policy continues to improve, an increasingly more demanding user community has been observed.
This equates to continually improving and rising quality standards, which are set by the individuals who ultimately benefit from the upgrade.
PROJECT STATUS AS OF APRIL 1993:
The Project is over 95% earned complete with 85% of the procedures approved.
The earned value is based on credit for partially completed, in-process procedures.
All Operations, Mechanical, and Electrical drafts are complete.
The Chemistry scope is complete and closed out.
The targeted end date for the Project is during the 2nd quarter of 1993 (see attached graph).
3,500 (J)
~ 3,000
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~ 2,500 0 a:
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ffi 1,500
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~ 1,000 500 PROCEDURE UPGRADE PROJECT COMPLETION SCHEDULE FOR ALL DISCIPLINES AS OF MARCH 31, 1993 3473 -
- -----------*-**------------*~-------------
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PUPCMP 08-89 12-89 04-90 08-90 12-90 04-91 08-91 12-91 04-92 08-92 12-92 04-93 10-89 02-90 06-90 10-90 02-91 06-91 10-91 02-92 06-92 10-92 02-93 PUP SCHEDULE PUP COMPLETIONS
+------
This Performance Indicator represents procedures completed by PUP, which includes procedures submitted to the manager for approval as well as procedures deleted from the Project scope.
NLR-N93044 ATTACHMENT 1 SALEM MATERIEL CONDITION IMPROVEMENT PROJECT TITLE:
PROJECT DESCRIPTION:
CORRECTIVE AND PREVENTIVE MAINTENANCE WORK ORDER REDUCTION PROGRAM The Nuclear Department established the Corrective and Preventive Maintenance Work Order Reduction Program (CM/PM Program) as part of Salem Revitalization to more aggressively address and improve the quantity of open work orders at Salem Station.
PROJECT APPLICABILITY:
The CM/PM Work Order Reduction Program will achieve its tactical goals by utilizing a combination of the following strategies;
- 1.
Addition of supplemental contractor resources to effect near-term reduction;
- 2.
Adherence to supervisor and craft work standards;
- 3.
Effectively utilize System outages coordinated walkdowns identification of entire work scope
- 4.
Implementation of maintenance work crews on back-shifts;
- 5.
Daily plant management accountability meeting;
- 6.
Reliability Centered Maintenance (RCM) Analysis of overdue PM work orders;
- 7.
Increased productivity as measured by direct work.
PROJECT BENEFITS:
By reducing the CM/PM work load to a desired level, existing Station resources may be reallocated and utilized more effectively and efficiently.
PROJECT STATUS AS OF APRIL 1993 The Corrective Maintenance backlog has been reduQed from 2,252 workorders in 1990 to 1,538 in 1992. The goal is to reduce the backlog to 1,000 by 1993 (see attached graph).
The Preventive Maintenance ratio (PM/CM) has been improved from 29% in 1990 to 56% in 1992.
The.Goal for 1995 is to achieve a 60% PM ratio (see attached graph).
The Overdue Preventive Maintenance backlog has been reduced from 600 in 1991 to 53 to date.
Reliability centered maintenance has evaluated 22 out of 33 systems to date.
Evaluation of all 33 systems will be completed in 1993 (see attached graph).
Approximately 75%
of the recommended Maintenance Task changes have been input in our work planning system.
Corrective Maintenance Backlog Salem Station
- 2,500...............................................................................................................................................................................................................................................................................................
2,000.................
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1990 1991 Actual 800 1992 1993 1995 Goal I !
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Preventive Maintenance Ratio Salem Station 60 50 40
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- > z 40 Reliability Centered Maintenance Salem Station 33 30 0 l__~C:L:.~~~1____£~~~~~.L--...1...L..JL-L-L-JA..-A--4.----~
1991 1992 1993 Actual Goal
NLR-N93044 ATTACHMENT 1 SALEM MATERIEL CONDITION IMPROVEMENT PROJECT TITLE:
SALEM MATERIEL CONDITION REVITALIZATION PROJECT PROJECT DESCRIPTION:
The Salem Materiel Condition Revitalization Project (SMCRP) is primarily responsible for reestablishing the hardware materiel condition of the Salem plants.
It will be achieved by improving equipment, systems and facilities to provide immediate impact and long term value through the elimination of problematic maintenance and operating conditions.
We expect that the reduction of the burden and improvement of materiel condition will enhance plant operating performance.
In addition to accomplishing its mission, the Project intends to:
- 1.
Improve project performance through innovative utilization of resources and processes;
- 2.
Accomplish materiel condition improvements concurrent with normal outage and non-outage cycles;
- 3.
Create an early "perception" change of plant physical materiel condition;
- 4.
Minimize effects on plant staff for project implementation.
PROJECT APPLICABILITY:
Salem Materiel Condition Revitalization Project (SMCRP) is charged with organizing, planning and implementing in a prudent and cost effective manner, the work required to address long standing maintenance issues, which often consume significant station resources.
Design, materiel condition and maintenance workload issues are typical issues the SMCRP addresses.
SMCRP work activities compliments other project work in progress, as well as maintaining close interface with station maintenance in maximizing available resources.
Resources available to SMCRP are experienced, dedicated personnel whose work tasks are identified, scoped and planned with appropriate funds to assure the success and objectives of the Nuclear Department.
PROJECT BENEFITS:
The expected benefits of this project will be seen in improved plant reliability and reduced corrective and preventive maintenance work loads.
Performance will be measured by indicators routinely tracked.
PROJECT STATUS AS OF APRIL 1993 60 projects have been completed to date. Some of the major projects completed are listed on the next page 1993 goal is to complete 79 additional projects tied to step change milestones.
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NLR-N93044 ATTACHMENT 1 SALEM MATERIEL CONDITION IMPROVEMENT PROJECT TITLE:
SALEM MATERIEL CONDITION REVITALIZATION PROJECT Key Materiel Condition upgrades results to date are:
Diesel Generator Reliability Improvements Replace Containment Steam Generator Blow Down Valves Circulating Water Upgrades Pressurizer Insulation Replacement Safeguards Equipment Controller Service Water Piping Replacement Control Air Dryers Lube Oil Storage Facility Condensate Polishing Building Improvements Installation of System to Add Chemicals to Aux Feed System Upgrade Radwaste Panel (Instrumentation and Controls)
Replace Misc. Condensate Strainers Rod Control 24 VDC Power Supply Replacement RMS ESF Monitor Electronics/Unit 2 RMS UPS Replacement Mid Loop Instrumentation Modifications Key upgrades scheduled for 1993 Generator Hydrogen Dryer Dew Point Monitor purge/ vent Diesel Generator HVAC Improvements Circulating Water Mechanical Upgrades Circulating water electrical Upgrades SGFP Independent Control Oil System Platform and Ladder (Partial)
AF-23 and GB-4 valve replacement Small bore pipe replacement Waste Gas System Upgrade Installation of outage Alternate Power Supply Digital Feedwater Control Unit 1 Boric Acid Concentration Reduction Circulating Water Air Removal System Upgrade Station and Control Air Components Condensate Polishing Building Improvements
NLR-N93044 ATTACHMENT 1 SALEM MATERIEL CONDITION IMPROVEMENT PROJECT TITLE:
PERSONNEL PERFORMANCE IMPROVEMENT PROGRAM PROJECT DESCRIPTION:
During the conceptual development of Salem Materiel Condition Improvement it was recognized early on that the materiel condition and procedure improvements at the Salem facility could not be maintained for long-term benefit without personnel performance improvement.
I~ parallel, it was recognized that without the materiel condition and procedure improvements, personnel performance improvement would be impeded.
Therefore, an integrated long-term strategy, Personnel Performance Improvement Program (PPIP), was developed within Salem Materiel Condition Improvement to supplement other Nuclear Department "cultural" change initiatives.
Key elements of the PPIP are directed at effective leadership (vision/values),
communication flow, and a focus on people.
The goals of PPIP are to:
- 1.
Foster appropriate work place values, beliefs, and behaviors at all levels within the Salem Station:
- 2.
Establish means for achieving and sustaining positive behavioral change to support continuous improvement.
PROJECT APPLICABILITY:
PPIP is an ongoing process involving clarifying roles and responsibilities, constant reinforcement, accountability, feedback, and improvement of the work environment accompanied by high performance expectations and standards.
PROJECT BENEFITS:
Expected PPIP benefits are:
- 1.
Overcoming the fundamental causes of inconsistent past performance:
- 2.
The ability to sustain and maintain Salem,Materiel Condition Improvements:
- 3.
To achieve a level of performance consistent with the Nuclear Department VISION; "Among the Best in the U.S. and World Class Status by 1995."
PROJECT STATUS AS OF APRIL 1993:
There are many methods to measure personnel performance improvements. However, some key indicators showing positive trends are; Number of LER'S have been reduced from 84 in 1990 to 40 1992 Number of personnel error LER'S have been reduced from 1990 to 9 in 1992 (see attached graph)
Human Factor type errors show a declining trend in Operation, Mechanical Maintenance and I
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1919 MANAGEMENT UPDATE MEETING SALEM GENERATING STATION PERSONNEL ERRORS LEA'S 21 14 1990 1991 9
1992
NLR-N93044 ATTACHMENT 1 SALEM MATERIEL CONDITION IMPROVEMENT PROJECT TITLE:
MATERIEL CONDITION MAINTENANCE PROGRAM PROJECT DESCRIPTION:
The Materiel Condition Maintenance Program was established in August 1990 to address the degraded materiel condition of Salem Units 1 and 2 equipment and associated support buildings.
The primary scope of the Materiel Condition Maintenance Program is focused on the "physical" appearance of equipment and associated support buildings.
The Program is comprised of the following separate and interdependent entities;
- 1.
Housekeeping
- 2.
Labeling
- 3.
Painting
- 4.
Insulation
- 5.
Minor Work Orders and Minor Maintenance PROJECT APPLICABILITY:
The Materiel Condition Maintenance Program will achieve its tactical and strategic goals utilizing a combination of strategies:
- 1.
Establish and implement a station rating system using the five entities previously described to prioritize corrective actions in those areas (i.e., housekeeping, labeling, painting, insulation, and minor maintenance);
- 2.
Perform re-ratings of areas that have had their materiel condition levels raised to support sustaining these levels and effect accountability;
- 3.
Establishing a Materiel Condition Maintenance Program that will be integrated into an expanded site Maintenance organization.
- PROJECT STATUS AS OF APRIL 1993:
Elevating the "physical" appearance of materiel at Salem, will help support the "culture" change associated with achieving the Nuclear Department's VISION/VALUES. Physical appearance improvements have been significant, and have had a positive impact on personnel behavior. The plant rating system has been established and its implementation completed. Seventy-nine projects that address painting, insulation, labeling and housekeeping have been completed to date (see attached* pictures).
11 & 12 Safety Injection Pump Room Before Rating 1.36 Red - Extremely Poor After Rating 3.75 Green - Good
OPS~G Research & Testing Laboratory 8 1--tq i.-:"' -r Prt No.
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PrinL Number 4 0766 PSE&G R&T LAB 12 9 2
SALEM GENERATING STATION MATERIEL CONDITION MAINTENANCE BEFORE & AFTER PICTURES 22 COMPONENT COOLING HEAT EXCHANGER ROOM UNIT 1 CONTAINMENT SPRAY PUMP AREA UNIT 1 TURBINE BUILDING CRANE UNIT 2 TURBINE BUILDING CRANE 23 EAST MOISTURE SEPARATOR REHEATER 11 COMPONENT COOLING HEAT EXCHANGER ROOM 21 & 22 AUXILIARY FEED PUMP AREA 12 SAFETY INJECTION PUMP ROOM
22 Component Cooling Heat Exchanger Room Before Rating 1.50 Red - Extremely Poor After Rating 4.83 Blue - Excellent
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Print Number 8 0868 PSE&G R&T LAB 1-18-93
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Print Number 6 0868 PSE&G R&T LAB 1 93
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21 & 22 Auxiliary Feed Pump Area Before Rating 1.59 Orange - Poor After Rating 4.34 Green - Good
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11 Component Cooling Heat Exchanger Room Before Rating 1. 09 Red - Extremely Poor After Rating 4.34 Green - Good
Unit 1 Containment Spray Pump Area Before Rating 1.45 Red - Extremely Poor After Rating 3. 7 5 Green - Good
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11 & 12 Safety Injection Pump Room Before Rating 1.36 Red - Extremely Poor After Rating 3.75 Green - Good
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SALEM GENERATING STATION MATERIEL CONDITION MAINTENANCE BEFORE & AFTER PICTURES 22 COMPONENT COOLING HEAT EXCHANGER ROOM UNIT 1 CONTAINMENT SPRAY PUMP AREA UNIT 1 TURBINE BUILDING CRANE UNIT 2 TURBINE BUILDING CRANE 23 EAST MOISTURE SEPARATOR REHEATER 11 COMPONENT COOLING HEAT EXCHANGER ROOM 21 & 22 AUXILIARY FEED PUMP AREA 12 SAFETY INJECTION PUMP ROOM
22 Component Cooling Heat Exchanger Room Before Rating 1.50 Red - Extremely Poor After Rating 4.83 Blue - Excellent
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Print Number 50 0828 PSE&G R&T LAB 12-17-92
Print Number 12 0868 PSE&G R&T LAB 1-18-93
Print Number 8 0868 PSE&G R&T LAB 1 93
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Print Number 6 0868 PSE&G R&T LAB 1-18-93
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Print Number 16 0666 PSE&G R&T LAB 10-22-92
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21 & 22 Auxiliary Feed Pump Area Before Rating 1.59 Orange - Poor After Rating 4. 34 Green - Good
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11 Component Cooling Heat Exchanger Room Before Rating 1. 09 Red - Extremely Poor After Rating 4.34 Green - Good
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Unit 1 Containment Spray Pump Area Before Rating 1.45 Red - Extremely Poor After Rating 3. 7 5 Green - Good
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Print Number 15 0780 PSE&G R&T LAB 12 92
Print Number 12 0780 PSE&G R&T LAB 12-7-92
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Print Number 9 0748 PSE&G R&T LAB 11 92
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