ML20092J244

Duke Power Co 12 H Shift Experience

ML20092J244
Person / Time
Site:	Catawba
Issue date:	06/20/1984
From:	DUKE POWER CO.
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Text

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INTRODUCTION In 1978, the operators at one of Duke Power Cmpany's fossil stations (Belews Creek Steam Station) proposed to the plant management that a different shift rotation schedule be implemented. Management subsequently appointed a comittee-to thoroughly evaluate the feasibility of a revised shift rotation.

'lko years later the committee presented to corporate management the plans for a twelve hour shift based upon programs in existence at other industries in the Southeast. The appropriate approvals were obtained and a four section, twelve hour shift program was implemented on a trail basis in January 1981.

After six months an evaluation was made to detennine if the twelve hour shift program was satisfactory to the station employees as well as enabling the plant to meet the Company's objectives of safe and efficient operation. The employees were very much in favor of the twelve hour shift and the evaluation of employee performance also indicated favorable results. After additional evaluation periods, the four section, twelve hour shift was approved as the normal schedule for operators at Belews Creek Steam Station. Enclosures (1) and (2) are copies of the evaluations done at Belews Creek.

A short time after the twelve hour shift was approved at Belews Creek the nuclear station operators expressed an interest in this program. An additional evaluation

of twelve hour shifts was conducted based upon the needs of the nuclear plants, j and in January of 1983 the program was initiated. A year and a half of operating the nuclear stations with twelve hour shifts has proven that the program is working. -

The Company plans to continue its efforts in this area by allowing other station groups (Maintenance, Chemistry, Health Physics, etc.) to participate in the 1 twelve hour shift program. Catawba Nuclear Station will initially utilize the same twelve hour shift rotation that the Belews Creek Station has tested and prcven to be so successful. In October of this year, it is projected that Catawba will switch to the five section rotation presently in use at the McGuire and Oconce Nuclear Stations.

(1)

Typical Twelve Hour Shift Rotation One of the major reasons for the success of the twelve hour shift program at Duke Power Company is the positive effect it has on employee . morale. To understand why the operators perceive the program as a benefit it is necessary to examine the twelve hour shift and compare it to the eight hour shift rotation.

An example of the twelve hour rotation is presented in Enclosure (3). It is a typical ten week cycle used at the operating nuclear stations. As indicated in the enclosure, the maximun ntuber of consecutive twelve hour shifts worked is four. This occurs only four times in the ten week cycle and only two of these times are on the night shift. On the eight hour shift the operator worked seven days consecutively. The number of consecutive days worked is significant because as disclosed in the two year study prior to initial implementation of this program, employee productivity begins to drastically decrease after six consecutive days of twelve hour shifts. Our experience has shown that working four consecutive twelve hour days is less fatiguing to the operator than .,urking seven consecutive eight hour days. As discussed later in this report the Company's personnel safety record and a decrease in Reportabic Occurances due to personnel errors B

support this fact. It is also consistent with employee comments that they are more rested on the twelve hour shift than they were on the eight hour rotation.

The twelve hour shift schedule enables the operator to be off 173 days per year as opposed to only 92 days when working an eight hour shift. 'Ikelve hour shifts also allow the operator an additional ten weekends off per year. Enclosure (4) compares the eight hour and twelve hbur . shifts in terms of hours worked and time off.

(2)

,' Bnployee Response to Twelve Hour Shift Program As indicated earlier, the increased number of days off per year is the major advantage mentioned by the operators when discussing the twelve hour shift ,,

program. Additional benefits mentioned are the reduction in comuting costs by approximately thirty percent, an increase i. job satisfaction, and less difficulty in maintaining alertness on the night shift.

The~j$bsatisfactionaswellasimprovedemployeemoraleisattributedtothe oveIvhelming majority of shift personnel who prefer the twelve hour shift rotation. Initially, approximately eighty percent of the employees had indicated an interest in going on a twelve hour shift rotation. Today, ninety-seven per cent of the operators favor continuation of the program. Station groups other than Operations are interested in the twelve hour shift program. At Oconee Nuclear Station, for example, ninety percent of the maintenance personnel who work a twelve hour shift volunteered for the program. The benefits of groups other than operations being on a twelve hour shift are numerous. Improved response time to equipment problems can eliminate plant shutdowns and has contributed to higher capacity factors. A positive team spirit has developed among Operations, Health Physics, and Maintenance since they all rotate on the comon twelve hour shift schedule. The Materials group is more effective because materials can be pre-staged on the night shifts for use by the oncoming day shift workers.

Job satisfaction is also enhanced by the twelve hour shift program because the same shift now completes many evolutions which used to be turned over when working eight hour days. The operators can now see the end result of their efforts more frequently, providing the shift workers with a significant feeling of accomplishment.

(3)

d Capany Benefits of 'Ikelve Hour Shift Productivity An imediate benefit to the Company of having only two shifts per day versus three is that there is obviously one less shift turnover per twenty-four hour period. This enables the manhours nomally involved in the third turn-over process for each watch station to be applied to more productive tasks.

Improved productivity also results from enabling a single shift to complete nmerous evolutions instead of turning them over to the following shift.

Reducing the n m ber of turnovers also decreases the probability for error in failing to turn over infomation correctly.

Employee Attrition / Absenteeism The evaluation period to-date has not been sufficient to fully assess the effect the twelve hour shift program has on employee attrition.- Resignations and requests for transfer have remained fairly constant and have not been attributable to avoiding the twelve hour shift. Absenteeism can be reduced by high morale and job satisfaction, just as the attrition rate can. A review of absenteeism data over the last four years shows that percentages have continued to remain quite low indicating no adverse effect fra the twelve ~

hour shifts. This data is tabulated in Enclosure (5) for the operating nuclear stations.

(4)

A Personnel Safety An improvement in the personnel safety record of the nuclear stations cannot be directly attributed to implementing the twelve hour shifts. Management's continued emphasis on personnel safety as well as the individual employee's contributions are only a few of the reasons Duke Power Company maintains an 6xEe11sht safetf ~ record. It has' been detemined that the minor medical injuries that did occur t_he last year and a half are not related to the implementation of

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the twelve hour shift. There has been no indication from the safety statistics that the twelve hour shift program results in increased employee fatigue and a resultant increase in personnel injuries. It is noteworthy that Oconee Nuclear Station received the Edison Electric Institute award for two million manhours worked without a lost work day case through February of this year.

Catawba Nuclear. Station and.McGuire Nuclear Station have each recently received awards for one million manhours worked without a lost work day case.

Personnel Error Since implementation of the twelve hour shift program, Duke Power Company's

. nuclear stations have shown a decrease in the nunber of reportable occurrences caused by personnel error. Enclosures (6) and (7) graphically display this information for Oconee and McGuire Nuclear Stations. The infomation on these enclosures is represented in tems of reactor years. Because Oconee Nuclear Station is a three unit plant, the number of reportable station occurrences is divided by three before being plotted. This affords a better comparison between stations which vary in the nunber of operating units. Similiarly, the data for McGuire Nuclear Station has been adjusted to account for the licensing and initial criticality o.f its second unit in'1982.

(5)

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Personnel Error (continued)

Because the above method of tracking reportable occurrences includes errors '

caused by non-shift employees in groups other than Operations, a more detailed review was conducted. Enclosure (8) lists the number of reportable occurrences caused by personnel error for Operations shift personnel only. This data has not been stated in tems of reactor years, but indicates the total number of occurrences per har per station. Obviously, Duke's improved performance in this area cannot be solely attributed to implementing the twelve hour shift program, hhat can be deduced, however, is that we have not decreased the quality of our operations. There is no evidence to suggest that working a twelve hour shift results in an increase in operator fatigue and a corresponding increase in personnel error.

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I (6)

r Stenary This report provides a quantitative assessment of specific Duke Power Company' achievements in the area of nuclear power plant operation. No single activity

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can be identified as the basis for Duke Power's success in the nuclear industry. !

-The Company's -programs to ensure personnel safety, employee job satisfaction, and a high level of proficiency are continually being reviewed and modified as necessary as we approach our goals of excellence. As can be seen from enclosures (9) and (10), Duke's overall nuclear capacity factor and unit avail-ability have steadily increased, and are above the industry average. Enclosures (11) and (12) show the decreasing trends in forced outages and forced load reductions since 1983. The twelve hour shift program has undoubtedly had an ,

effect on employee morale, personnel errors, absenteeism, productivity, and ultimately power generation. The twelve hour shift program is contributing to the success of the nuclear stations.

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I (7)

Enclosure (1)

Page 1 of 4 4 DUKE POWER COMPANY P. o. sox ss7 BELEWS CREEK STEAM STATION TELEPHONE: AREA 919 WALNUT COVE. N. C. 27052 October 11, 1983 Julian D'Amico, General Manager -

. Fossil Stations

' Fossil Production Duke Power Company Charlotte, NC

Subject:

Twelve Hour Operations Shift

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Belews Creek Steam Station File: BC-108.65  :

Dear Sir:

Attached are the current statistics of most pertinence to the twelve-hour shift schedule. All other factors or opinions are unchanged from those mentioned in the first six month review (attachment #2) with the exception that there have been no fur-ther problems obtaining people for off-schedule overtime.

I hope this suffices for your present need of information re-lated to this item. If not please let me know.

Sincerely yours,  ;

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ohn E. Ellington Superintendent of Operations JEE/jbe Attachments 2

Enclosure (1)

Page 2 of 4 12 Hour Shift Schedule Fossil Production Belews Creek Steam Station .

Program Evaluation

1) Sickness Allowance Base Data Twelve Hour History 1980 1981 -

234 days (1876 hours0.0217 days <br />0.521 hours <br />0.0031 weeks <br />7.13818e-4 months <br />) 179 days (2153 hours0.0249 days <br />0.598 hours <br />0.00356 weeks <br />8.192165e-4 months <br />)

, 23.5% less (14.8% more) 1982 110 days (1316 hours0.0152 days <br />0.366 hours <br />0.00218 weeks <br />5.00738e-4 months <br />)

(53.0% less) (29.9% less) 1983 (Jan-June) 73 days (882 hours0.0102 days <br />0.245 hours <br />0.00146 weeks <br />3.35601e-4 months <br />)

2) Sickness Allowance for Appointments' 1980 1981 1982 1983 (Jan-June) 82 hours9.490741e-4 days <br />0.0228 hours <br />1.35582e-4 weeks <br />3.1201e-5 months <br /> 102 hours0.00118 days <br />0.0283 hours <br />1.686508e-4 weeks <br />3.8811e-5 months <br /> 120 hours0.00139 days <br />0.0333 hours <br />1.984127e-4 weeks <br />4.566e-5 months <br /> 46 hours5.324074e-4 days <br />0.0128 hours <br />7.60582e-5 weeks <br />1.7503e-5 months <br /> (24.4% more) (46.3% more)

3) Overtime off-schedule 1980 1981 1982 1983 (Jan-June) 7405 hours0.0857 days <br />2.057 hours <br />0.0122 weeks <br />0.00282 months <br /> 2953 3106 1455 (60% less) (58% less)

4) Medical only injuries 1980 1981 1982 1983 (Jan-June) 3 2 4 0

5) Disabling Injuries -

1980 1981 1982 1983 (Jan-June) 1 0 1 0

6) Resignations 1980 1981 1982 1983~(Jan-June) 1- 1 0 0

7) Requests for Transfer 1980 1981 1982 1983 (Jan-June) 1 0 2* 1

• Same person twice.

Enclosure (1)

Page 3 of 4 e

12 Hour Shift Schedule Steam Production Department Belews Creek Steam Station Program Evaluation A 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> shift schedule for operations began on a trial basis at Belews Creek Steam Station January 5, 1981. An evaluation of this schedule was made at the end of six months. The detailed results of this evaluation are included later in this report. Belews Creek operators are continuing _

to work the 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> schedtile awaiting final approval for itc continuance.

Overall the 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> schedule has worked very well, both for station management and the operators. Our recommendation is that the 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> schedule be approved as the normal schedule for operatore at Belews Creek Steam Station.

At the end of the trial period, we secured the operators' reaction to the schedule and compared the specific items listed in the original proposal to the Personnel Resources Committee.

97.7% (43 of 44) operators want to continue the 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> schedule. 97.7%

(43 of 44) desire to remain on the 7 AM, 7 PM shift change times. 93.2%

(41 of 44) want to remain on the two week rotation between day shift and night shift.

Some typical comments received from the operators are:

"Everyone seems to appreciate the consideration given to the operators."

"This system is great ["

'"Best thing that has been done for the benefit of the operators in a long time."

"The 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> schedule is a big improvement over old schedule."

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"Having worked the old schedule for 5 years, I think the 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> shift is one of the top benefits to us the operators."

"I love it."

"The 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> shift has been beneficial to my family as well as me.

Makes me not dread 3rd shift.now. Not working 2nd means a lot."

Results of specific items are:

a) Sickness allevance (other than appointment time) - 4.3% less (6 mos '81' vs 6 mos '80')

b) Sickness allowance for appointments - 24% less (6 mos '81' vs 6 mos '80')

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- Enclosure (1)  !

Pagn 4 of 4 12 Hour Shift Schedule Belews Creek Steam Station Page 2 c) Percent Overtime Off-schedule hours) - 3.2% (6 mos '81') vs 9.0% (12 mos

'80') a 64% reduction.

.d) Medical only injuries - 0 (6 mos '81') vs 3 (12 mos '80') ((2) Jan - June

'80', (1) July - Dec. '80') -

e) Disabling injuries - fl (6 mos '81') vs 1 (12 mos '80' [(1) Jan - June '80',

(0) July - Dec '80]

f) Resignations - fl (6 mos '81') vs 1 (12 mos '80') (occurred 3/80, female operator]

g) Requests for transfer - 0 (6 mos '81') vs 1. (12 mos '80')

The following items were also evaluated.

a)

Employee morale the concensus of station management, shift supervision, and operators themselves is that morale is definitely higher.

b) Productivity - difficult to measure. Supervisors opinion is that r productivity is better; operators are able to complete many jobs in a 12 hour1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> period rather than leave them partially complete and resuma the next day; equipment is kept cicaner; less time in each 24 hr. period used to change shifts; better communications with 2 shifts per 24 hr.

period.

c) Ability to obtain personnel for off-schedule overtime - no problem during the first 4-1/2 months. In the last 1-1/2 months there were two occurrences when there was some difficulty in obtaining operators for emergency callout. One occurence was at 5 PM on a Saturday. So far we do not consider this a major problem. We will continue to monitor this closely, and if it becomec necessary, we plan to establish an assigned "on call" list to cover emergency needs. We have discussed these two occasions with the operators.

d) Qvality of work - Supervision's input is that quality has not suffered If anything, it has improved because of higher morale and nost of the items listed under " productivity."

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Enclosure (2)

Page 1 of 2 DUKE POWER COMPANY P. o. som ss? BELEWS CREEK STEAM STATION TELEPMoNti AntA see WALNUT COVE. N. C. 27o52 February 27, 1984'

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Julian D'Amico General Manager Fossil Production Duke Power Company Charlotte, NC

Subject:

Twelve Hour Operations Shift Belews Creek Steam Station File BC-108.65 l

Dear Sir

• Attached are the current statistics of most pertinence to the twelve-hour shif t schedule. All other factors or opinions are unchanged from those mentioned in the previous review with the exception that there have been no further problems obtaining people for off-schedule overtime.

I hope this suffices for your present need of information related to this itect. If not please let me know.

Sincerely yours,

, .w John E. Ellington '

Superintendent of Operations JEE/ jaw '

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Attachments 1 i

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Page 2 of 2 12 Hour Shif t Schedule Fossil Production Belews Creek Steam Station Program Evaluation

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1) Sickness Allowance Base Data Twelve llour llistory 1980 1981 234 days (1876 hours0.0217 days <br />0.521 hours <br />0.0031 weeks <br />7.13818e-4 months <br />) 179 days (2153 hours0.0249 days <br />0.598 hours <br />0.00356 weeks <br />8.192165e-4 months <br />) 23.5% less (14.8% more) 1982 l 110 days (1316 hours0.0152 days <br />0.366 hours <br />0.00218 weeks <br />5.00738e-4 months <br />) l 53.0% less (29.9% less) 1983 185 days (2224 hours0.0257 days <br />0.618 hours <br />0.00368 weeks <br />8.46232e-4 months <br />) 20.9% less (18.6% more)

2) Sickness Allowance for Appointments l 1980 1981 1982 1983' 82 hours9.490741e-4 days <br />0.0228 hours <br />1.35582e-4 weeks <br />3.1201e-5 months <br /> 102 hours0.00118 days <br />0.0283 hours <br />1.686508e-4 weeks <br />3.8811e-5 months <br /> 120 hours0.00139 days <br />0.0333 hours <br />1.984127e-4 weeks <br />4.566e-5 months <br /> 77 hours8.912037e-4 days <br />0.0214 hours <br />1.273148e-4 weeks <br />2.92985e-5 months <br /> (24.4% more) (46.3% more) (6.1% less)

3) Overtime off-schedule l

1980 1981 ~982 1983 7405 hours0.0857 days <br />2.057 hours <br />0.0122 weeks <br />0.00282 months <br /> 2953 3106 2385~

(60% less) (58% less) (68% less)

4) Medical only injuries 1980 1981 1982 1983 3 2 4 4 S) Disabling Injuries 1980 1981 1982 1983 1 0 1 0

6) Resignations 1980 1981 1982 1983 1 1 0 0

7) Requests for Transfer 1980 1981 1982 1983 1 0 2* 2*

• Same person accounts for three of these four requests.

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Enclosure (3) 1YPICAL 12 HOW SHIFT ROTATION EaEaEaEaEaaaaaIaIaaa 34434734'334341425234 0 = OFF DAYS D = DAY SHIFT (0700 - 1900)

N =~ NIGHT SHIFT (1900 - 0700)

T = TRAINING (8 m. WORK DAYS) o 10TATION CYCE 00PPLETED EVERY 10 WEElG.

o 0FF 6 EEENDS OUT OF 10. -

o MAXIMLN CONSECUTIVE 12M. SHIFTS WORED IS 4.

OCCURS 4 TIES IN 10 EEKS.

o mXIHN CONSECUTIVE 84R. DAYS WORED IS 5.

OCCURS ONE IN 10 EEKS.

o DlRING 10 EEK CYCLE ONLY 4 PERIODS WORED ON NIGHT SHIFT.

6 RRIODS WDRED ON DAYS.

o DLRING 10 EEK CYCLE 1 WRIOD OF 7 CONSECUTIVE DAYS OFF.

(AT LEAST 5 PER YEAR) f

Enclosure (4) 1 e ,

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SCHEDULE COMPARISONS 8 HR. 12 HR,

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MAX,CONSECbTIVESHIFTDAYSWORKED 7 4 HOURS / DAY 8 12' ROTATING SHIFT YES YES NUMBER OF SHIFTS / DAY 3 2 DAYS WORKED / YEAR 273 192**

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TOTAL HOURS WORKED / YEAR 2184 2128 DAYS OFF/ YEAR 92 173 WEEKENDS OFF/ YEAR 21 31 l

l '9 DAYS PER 10 WEEK CYCLE ARE 8 HOUR DAYS l

• • 45 DAYS ARE 8 HOUR DAYS 3

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Enc.losura (5)

Il EPPLOYEE ABSENTEEISM } '.

1981 1982 1%L3 1984(2)

OCONEE NUCLEAR STATION 2.23% 1.60% 1.56% 1.23%

PCGUIRE MELEAR STATION 1.77% 2.34% 2.25% 2.70%

TOTAL OPERATIONS HOURLY M LOYEE ABSENTEEISM DUE To SICKNESS M (1) % _ TOTAL OPERATIONS HOURLY MLOYEE fhNHOURS AVAILABLE (2) TmOUGH MAY 31ST s

Enc 10 sura (6) -

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s McGUIRE NUCLEAR STATION REPORTABLE OCCURRENCE  !

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Enclosurs (8): ',

• a g(1) 1981 1982 1983 ' 198f4(2)

OCOEE NUCLEAR STATION 12 8 6 0 MCGUIE NUCLEAR STATION 19 9 12 3-NOTES: (1) NRC REPORTABLE ERRORS COMMITTED By SHIFT OPERATIONS PERSONNEL (2) TEROUGH MAY 31sT i

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DUKE NUCLEAR CAPACITY FACTOR

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LEeENDe CLAes ----- DUKE POWER CAPACITY FACTOR == THE RATIO OF ACTUAL ENERSY PRODUCTZON OVER A eZVEN PERIOD OF TZNE TO THE MAX ENEROY PROD. CAPASILITY.

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4 DUKE NUCLEAR AVAILABILITY

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Enclosure (11) '. -

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! NUCLEAR FORCED OUTAGES OTATUS A8 OF MAY S1,t864 - PACT I8 MONTM AVERASE l

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Enclosure (12)' '. .

l FORCED LOAD REDUCTIONS i eTATue As OF NAY 31,8984 -

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ATTACHMENT 2 June 8, 1984 Mr. H. B. Tucker-Vice President, Nuclear Production Department Duke Power Company P.0~. Box 33189 -

Charlotte, N.C. 28242

Dear Mr. Tucker:

As you requested, I have attached the Utility Advisor Evaluation Team's report

~

of the evaluation of the Catawba Nuclear Station Shift Advisor Program conducted June 6-8, 1984.

I would appreciate receiving a copy of your revised Shift Advisor program description.

Should you desire additional information, we will be pleased to discuss this with you.

4 Yours very truly,

/

,seC' 4 P. L&ider Supervisor Safety Engineering Group Office of Nuclear Safety Commonwealth Edison Company JPL/jd cc: E. L. Thomas Enclosure i