Fi l l in fo rms for addi t iona l permission con t ro l area/ in vessels

Establish radiat ion pro tec t ion plans

In i t i a t ion : F i l l in a defect repo r t /wo rk order f o r m

Review and registrat ion in the main con t ro l roofn

Approva l : Dai ly meet ing; discussion of all new defect reports/wvork orders

General approval by plant management and maintenance management

Schedul ing

Main con t ro l r o o m isolat ion, da i ly work permission

Clearance by work supervisor or health physics

g roup

T E C H N I C A L R E P O R T S S E R I E S N o . 2 6 8

Manual on Maintenance of Systems and Components

Important to Safety

mí \ t g r j INTERNATIONAL ATOMIC ENERGY AGENCY, V IENNA, 1986

MANUAL ON MAINTENANCE OF SYSTEMS AND COMPONENTS

IMPORTANT TO SAFETY

T h e fo l lowing S ta tes a re M e m b e r s of t he I n t e r n a t i o n a l A t o m i c Energy Agency :

A F G H A N I S T A N A L B A N I A A L G E R I A A R G E N T I N A A U S T R A L I A A U S T R I A B A N G L A D E S H B E L G I U M B O L I V I A B R A Z I L B U L G A R I A B U R M A B Y E L O R U S S I A N SOVIET

S O C I A L I S T R E P U B L I C C A M E R O O N C A N A D A C H I L E C H I N A C O L O M B I A C O S T A R I C A C O T E D ' I V O I R E CUBA C Y P R U S C Z E C H O S L O V A K I A D E M O C R A T I C K A M P U C H E A D E M O C R A T I C P E O P L E ' S

R E P U B L I C O F K O R E A D E N M A R K D O M I N I C A N R E P U B L I C E C U A D O R E G Y P T EL S A L V A D O R E T H I O P I A F I N L A N D F R A N C E G A B O N G E R M A N D E M O C R A T I C R E P U B L I C G E R M A N Y , F E D E R A L R E P U B L I C O F G H A N A G R E E C E

G U A T E M A L A HAITI HOLY SEE H U N G A R Y I C E L A N D INDIA I N D O N E S I A I R A N , ISLAMIC R E P U B L I C O F I R A Q I R E L A N D I S R A E L I T A L Y J A M A I C A J A P A N J O R D A N K E N Y A K O R E A , R E P U B L I C O F KUWAIT L E B A N O N LIBERIA LIBYAN A R A B J A M A H I R I Y A L I E C H T E N S T E I N L U X E M B O U R G M A D A G A S C A R M A L A Y S I A M A L I M A U R I T I U S MEXICO MONACO M O N G O L I A M O R O C C O NAMIBIA N E T H E R L A N D S NEW Z E A L A N D N I C A R A G U A N I G E R N I G E R I A N O R W A Y P A K I S T A N P A N A M A

P A R A G U A Y P E R U P H I L I P P I N E S P O L A N D P O R T U G A L Q A T A R R O M A N I A S A U D I A R A B I A S E N E G A L S I E R R A L E O N E S I N G A P O R E S O U T H A F R I C A SPAIN SRI L A N K A S U D A N SWEDEN S W I T Z E R L A N D S Y R I A N A R A B R E P U B L I C T H A I L A N D T U N I S I A T U R K E Y U G A N D A U K R A I N I A N S O V I E T S O C I A L I S T

R E P U B L I C U N I O N O F S O V I E T S O C I A L I S T

R E P U B L I C S U N I T E D A R A B E M I R A T E S U N I T E D K I N G D O M O F G R E A T

B R I T A I N A N D N O R T H E R N I R E L A N D

U N I T E D R E P U B L I C O F

T A N Z A N I A U N I T E D S T A T E S O F A M E R I C A U R U G U A Y V E N E Z U E L A V I E T NAM Y U G O S L A V I A Z A I R E ZAMBIA ZIMBABWE

T h e Agency ' s S t a t u t e was app roved on 23 O c t o b e r 1956 by the C o n f e r e n c e on the S t a t u t e of t he IAEA held at U n i t e d N a t i o n s H e a d q u a r t e r s , New Y o r k ; it e n t e r e d i n t o fo rce o n 29 Ju ly 1957 . T h e H e a d q u a r t e r s of t he Agency are s i t ua t ed in Vienna . I ts pr inc ipa l ob jec t ive is " t o acce le ra te and enlarge the c o n t r i b u t i o n of a t o m i c energy t o peace , hea l th and p rospe r i ty t h r o u g h o u t t he w o r l d " .

© IAEA, 1986

Permiss ion t o r e p r o d u c e or t rans la te t he i n f o r m a t i o n c o n t a i n e d in this pub l ica t ion m a y be o b t a i n e d by wri t ing t o t h e In t e rna t iona l A t o m i c Energy Agency, Wagramers t rasse 5 , P.O. B o x 100, A - 1 4 0 0 Vienna , Aust r ia .

Pr in ted by the I A E A in Austr ia November 1 9 8 6

TECHNICAL REPORTS SERIES No. 268

MANUAL ON MAINTENANCE OF SYSTEMS AND COMPONENTS

IMPORTANT TO SAFETY

INTERNATIONAL ATOMIC ENERGY AGENCY VIENNA, 1986

M A N U A L ON MAINTENANCE OF SYSTEMS AND COMPONENTS IMPORTANT TO SAFETY

IAEA, VIENNA, 1986 STI/DOC/lO/268

ISBN 92-0-125386-9

FOREWORD

The Agency's programme for establishing nuclear safety standards for nuclear power plants, referred to as the NUSS Programme, includes the development of three types of documents:

(1) Codes of Practice for nuclear power plants with thermal neutron reactors that establish the objectives and minimum requirements which must be fulfilled to provide adequate safety for these plants;

(2) Safety Guides that provide additional requirements and recommend procedures that should be followed to implement the Codes of Practice;

(3) User 's Manuals, directed to nuclear power plant operators, that normally present possible methods and techniques for solving specific problems.

Work on Codes and Guides was initiated in 1975 in five main fields: governmental organization, siting, design, operation and quality assurance.

In the field of operation, the Code of Practice and eleven Safety Guides were developed and published by 1986. These documents are now used in a number of Member States as a basis for the safe operation of nuclear power plants and by the IAEA to assist Member States in improving safety, for example by means of Operational Safety Review Team (OSART) missions.

To facilitate this use, the Technical Review Committee on Operation has stressed the need for and importance of the development of User 's Manuals in some areas of nuclear power plant operation. The need for such documents was expressed during the International Symposium on IAEA Safety Codes and Guides (NUSS) in the Light of Current Safety Issues held in Vienna in 1984 and during the incorpora-tion of Safety Guide principles into national regulations. The User 's Manuals should provide Member States implementing the Code and Safety Guides with practical examples of management organization, good practices, methods and techniques used in those organizations in Member States having broad experience in nuclear power plant operation. A number of topics have been identified for which the User 's Manuals could provide additional information and facilitate the correct implementa-tion of the Code and Guides in nuclear power plant operation activities.

To implement the recommendations, work was initiated in the Secretariat to develop first those User 's Manuals which are most needed in Member States just starting to operate nuclear power plants. Keeping in mind the difference between User ' s Manuals and Codes and Safety Guides, work on the development of these documents is undertaken outside the NUSS Programme and its established proce-dures for the development, review and approval of documents. For User 's Manuals

it was decided to follow the standard practices used in the development of the Agency's publications such as Guidebooks and Technical Reports. This procedure reduces the time and cost of preparation of User 's Manuals, which are at the lower level in the hierarchy of NUSS Programme documents, and do not contain require-ments for whose formulation a broad consensus of operation experts would be needed.

However, it will be ensured that the Manuals are fully consistent with the Code and Safety Guides through information exchange between the Secretariat and members of the Technical Review Committee on Operation. In addition, members of this Committee will be engaged in the development, review and approval of the Manuals before the documents are recommended to the Director General for publica-tion. If, as a result of changes in national regulations and the further acquisition of operating experience, an operational practice differs f rom the Code and Safety Guide recommendations (the first Safety Guides were published in 1979), this fact will be clearly indicated.

The present Manual on the Maintenance of Systems and Components Important to Safety contains a detailed description of management systems, administrative controls and procedures for maintenance activities and some aspects of surveillance and verification activities. It is directed at the plant management level.

CONTENTS

1. INTRODUCTION 1

2. SCOPE 1

3. M A I N T E N A N C E P R O G R A M M E 2

3.1. General description 2 3.2. Organization and responsibilities 5 3.3. Educational qualification and training of maintenance personnel 5 3.4. Establishment of the maintenance programme 10 3.5. Facilities and services 12 3.6. Stores 13

4. IMPLEMENTATION OF M A I N T E N A N C E PROGRAMME 14

4.1. Maintenance schedule 14 4.2 . Planning 16 4.3 . Work control and administration 18 4.4 . Modification procedure, replacement and repair 28 4 .5 . Maintenance instructions 29 4.6 . Records 32

5. SURVEILLANCE AND VERIFICATION ACTIVITIES 33

5.1. Surveillance 33 5.2. Administrative verification activities 33

ANNEX I. EXAMPLES OF D O C U M E N T S 37

Example 1: Maintenance policy document 39 Example 2: Training facility for maintenance personnel 53 Example 3: Work order/defect report 61 Example 4: Isolation tags ; 65 Example 5: Individual permissions for some types of work 71 Example 6: Summary of a procedure for the control of modifications 81 Example 7: Procedures for the compilation of maintenance instructions... . 85 Example 8: Maintenance instructions and checklists I l l

ANNEX II. DESCRIPTIONS OF PRACTICES 137

Practice 1: The planning process 139 Practice 2: Computerized maintenance management 147 Practice 3: Outage planning and management 155

LIST OF PARTICIPANTS 161

1. INTRODUCTION

The IAEA Code of Practice on Safety in Nuclear Power Plant Operation, Including Commissioning and Decommissioning (IAEA Safety Series No. 50-C-0) hereafter referred to as the Code, was developed as the part of IAEA NUSS Programme. The Code established the general safety aspects of management, commissioning and operation of a nuclear power plant. The first level of detailed guidance on the implementation of the Code was provided by the associated Safety Guides.

The Safety Guide on Maintenance of Nuclear Power Plants (IAEA Safety Series No. 50-SG-07) provides guidance on the maintenance of structures, systems and components of a nuclear power plant. However, a more detailed approach to maintenance activities is needed for implementation of the recommendations in the Guide.

Therefore this Manual provides more comprehensive considerations on the management, organization and implementation of maintenance activities. It also gives illustrative examples of good practices and recommendations from operating and other organizations that are consistent with the requirements and recommenda-tions of the Code and Safety Guides. The Manual is directed primarily towards plant management and should serve as a guideline for the preparation and improvement of the maintenance programme, its implementation and related maintenance activities in the plant.

This Manual shall be used in conjunction with the Code and the Operations Safety Guides, in particular with IAEA Safety Series Nos. 50-SG-07 and 50-SG-05, which contain recommendations of a general character about maintenance activities and radiation protection in an operating power plant.

2. SCOPE

The Manual should serve as guidance at the plant management level for the maintenance of systems and components important to safety. It includes a detailed description of management systems, administrative controls and procedures. The Annexes contain examples of documents and practices adopted by Operating Organi-zations of some Member States. It is not the intention of this Manual to address the technical problem of how to maintain a particular component but rather to cover the programmatic aspects of maintenance. It also contains some aspects of surveillance and verification activities.

The Manual makes only general statements about radiation protection provi-sions in connection with maintenance; detailed guidance can be found in other IAEA documents.

1

3. MAINTENANCE PROGRAMME

3.1. General description

An effective, high quality maintenance programme (see IAEA Safety Series No. 50-SG-09) is required for the safe, reliable operation of a nuclear power plant. To achieve the objectives of such a programme, both plant management and staff must be highly dedicated and motivated to perform high quality work at all levels.

The maintenance programme consists of all preventive and remedial measures, both administrative and technical, necessary to ensure that the plant, systems and components remain in accordance with design assumptions and intent and that the safety status of the plant is not adversely affected after commencement of operation. The programme shall be described in a plant policy document (see Example No. 1 in Annex I). The programme includes:

(1) The establishment of a maintenance organization with a description of techni-cal and supervisory functions and definitions of the responsibilities and authority of each maintenance position;

(2) Establishment and implementation of administrative and control procedures; (3) Selection, training, and qualification of personnel to perform maintenance; (4) Establishment and implementation of preventive maintenance; (5) Establishment and implementation of remedial maintenance (some Member

States use the term 'corrective maintenance'); (6) Establishment and implementation of surveillance and testing; (7) Establishment and implementation of in-service inspections; (8) Establishment and implementation of functional and performance testing

during construction and commissioning; (9) Provision and maintenance of facilities and equipment for maintenance;

(10) Planning and scheduling of all maintenance activities; (11) Procurement and management of stores and spare parts necessary for

maintenance; (12) Approval and implementation of plant modifications; (13) Development and management of maintenance records; (14) Establishment and maintenance of liaisons and/or interfaces with designers,

vendors, subcontractors, any off-site maintenance group, the construction group, and other on-site and off-site groups in the Operating Organization such as the plant operating group, the plant radiation protection group and the quality assurance (QA) group.

A comprehensive maintenance programme to perform these activities for systems and components important to safety (see IAEA Safety Series No. 50-SG-D1) shall be established and implemented in accordance with the quality assurance requirements for items important to safety (see IAEA Safety Series No. 50-SG-QA1)

2

and with the applicable requirements of the Regulatory Body. Many of the elements of this programme will also apply to systems and components that are not important to safety; however, this Manual does not discuss such systems and components.

All maintenance activities, f rom the planning stage to execution, shall be carried out in such a manner that the radiation exposure of both site personnel and the general public is kept as low as reasonably achievable (ALARA). Guidance for the implementation of the ALARA principle is to be found in IAEA Basic Safety Standards for Radiation Protection (IAEA Safety Series No. 9: 1982 Edition) and in IAEA Safety Guide No. 50-SG-05.

The plant management shall be responsible for all plant maintenance and shall establish a maintenance group on the site to conduct the maintenance activities. The responsibility for establishing and implementing the maintenance programme and managing the maintenance group shall be delegated to an individual, hereafter desig-nated the Maintenance Superintendent. The organizational structure of the maintenance group, the responsibilities of the maintenance group and maintenance personnel, and the selection and training of maintenance personnel are discussed in IAEA Safety Series Nos. 50-SG-07 (Section 3) and 50-SG-09 (Section 3).

The maintenance policy document should be comprehensively reviewed and evaluated annually. Whenever a significant error or deficiency in the maintenance programme is identified, an evaluation shall be made whether the maintenance policy document needs to be modified.

The objectives of the maintenance programme are (in decreasing order of priority):

(1) To preserve adequate safety (2) To enhance plant availability (3) To minimize plant costs due to failures in plant systems and components (4) To make the most effective use of available resources.

There are two basic types of maintenance — remedial maintenance and preven-tive maintenance. Remedial maintenance consists of those repairs, replacements and associated activities necessitated by system or component failures. Preventive maintenance covers those inspection, test, surveillance, repair and replacement activities intended to reduce the frequency and impact of system and component failures.

Preventive maintenance is subdivided into mandatory preventive maintenance and discretionary preventive maintenance. Mandatory preventive maintenance refers to those activities required by insurance, operating licence, vendor warranty, government regulations or other plant safety requirements. Discretionary preventive maintenance comprises those activities performed at the discretion of the plant management to improve plant safety, to enhance plant availability, reduce plant costs, or make more effective use of available resources.

3

Indust ry and p lant i n fo rma t i on

Recycle _L

Programme re-evaluation

I n fo rma t i on co l lec t ion and feedback

Fai lures, power loss and remedial main tenance costs, o ther key equ ipment , manda to ry main tenance act ions "N Cri t ica l i tems

f o r analysis

Rankings

Existing preventive maintenance programme and costs A y

Predict ive prevent ive maintenance improvement analysis

Op t ions and predic ted improvement

y Improvements , benef i t /cost analysis

Predicted net benef i ts

Budget constraints O p t i m i z a t i o n analysis

Recommended combina t ions

I Programme approval and imp lemen ta t i on

FIG. 1. Method of optimizing discretionary maintenance.

A type of discretionary preventive maintenance is predictive maintenance. Predictive maintenance consists of those activities performed to predict equipment failures and identify cost effective maintenance activities to mitigate the impact of those failures. Figure 1 provides an overview of a method for obtaining a proper balance between discretionary and mandatory maintenance.

Some plant modifications (see Section 4.4) are not carried out within the above-mentioned objectives of the maintenance programme; however, since they are normally made under the responsibility of the maintenance group, this Manual considers all plant modifications as falling under the scope of the maintenance programme.

3.2. Organization and responsibilities

The plant management shall establish a maintenance group on site to imple-ment the maintenance programme. The responsibility of the maintenance group shall be defined in writing by the plant management. The organizational structure of the maintenance group will vary, depending on a number of conditions, but in every case the Maintenance Superintendent shall retain primary responsbility for implementing the maintenance programme.

The problems of organizational structure and responsibilities for maintenance are covered by IAEA Safety Guides Nos 50-SG-07 and 50-SG-09 and are discussed in the Guidebook "Qualification of Nuclear Power Plant Operations Personnel" (IAEA Technical Reports Series Nos. 242 (1984)).

3.3. Educational qualification and training of maintenance personnel

All maintenance personnel shall be given educational qualification and training in accordance with their level of responsibility in the structure of the maintenance group. Whatever the different qualifications and training practices of different Operating Organizations, the competence of maintenance personnel for their position in the nuclear power plant maintenance group shall be established, preserved and verified.

3.3.1. Educational qualiñcation for maintenance personnel

The activities involved in the maintenance of a nuclear power plant as one of the supporting functions are of a similar nature to those in the traditional industrial technologies. The qualifications from the existing educational systems are thus usually adapted for the managerial, professional, technical and craft maintenance activities.

5

TABLE I. EDUCATIONAL QUALIFICATION REQUIREMENTS

Manager Professional qualification, i.e. university degree in a relevant discipline or equivalent

Professional Professional qualification, i.e. university degree in a relevant discipline or equivalent

Technician Technician's qualification, i.e. qualification in a relevant technology, usually provided by a technical institute or industrial training

Craftsman Craftsman's qualification, i.e. qualification in a relevant craft which is usually provided by a vocational school or by industrial training

Operating Organization practices for selecting educational qualifications are fundamentally similar all over the world. Nevertheless, there is a considerable varia-tion in the proportion of professionals to technicians and craftsmen. Educational qualifications generally required for each function are shown in Table I.

People without a specified educational qualification may have, or may be able to develop, the skills required for the position and may acquire the necessary knowledge through experience and training. Special educational programmes can help develop people's competence beyond the level associated with their educational qualification.

3.3.2. Competence of personnel for positions in nuclear power plant maintenance

The following groups of positions can be distinguished:

— Manager (at the professional level) and supervisor at the technician and craftsman levels. These people are in charge of directing, co-ordinating and controlling the work of others.

— Technical positions at the professional, technician and craftsman levels. These people are generally employed as specialists and have no supervisory responsibilities.

A qualitative evaluation of each of the elements of competence of these groups for all supporting function positions (including maintenance) is summarized in Table II.

6

TABLE II. QUALITATIVE ELEMENTS OF COMPETENCE FOR POSITIONS IN NUCLEAR POWER PLANT MAINTENANCE

Positions Elements of competence

Manual skills Information Intellectual skills Social skills

Manager Professional - Broad,

descriptive/profound Evaluation

Supervisor

Technician Significant Broad, descriptive

Application/ evaluation

Leadership Personal authority Persuasion

Craftsman Significant Broad, descriptive

Comprehension Communication Conciliation

Technical

Professional - Specialized, profound

Evaluation/ application

Technician Significant Specialized, profound

Application/ evaluation

Communication Persuasion Responsiveness

Teamwork Craftsman Important Specialized,

descriptive Recall/

comprehension

Communication Persuasion Responsiveness

Teamwork

3.3.3. Establishing competence

The means of establishing competence are education, training and experience. Education provides general knowledge and intellectual skills. The main purpose of training is to impart specific knowledge of the industry,

of the particular tasks and of a particular position and to teach specific skills. After successful training, a person will be competent to execute a task.

However, by practice his skill and knowledge will normally increase; that is to say that his competence will increase with experience.

7

3.3.4. Training

Three general objectives can be defined for training:

— to complement education in the areas of general technology and science — to impart knowledge of nuclear power plant technology and knowledge of a

specific plant — to develop specific skills.

The extent to which each of these objectives is relevant to particular positions in a nuclear power plant is discussed in the following subsections.

3.3.4.1. General technical knowledge

The depth of general technical knowledge depends on the position of the personnel. It should cover general aspects of nuclear power plants such as:

— need for radiation protection — nuclear reactor principles — general principles of systems important to safety — importance of high standard of quality of maintenance activity.

3.3.4.2. Specific nuclear power plant knowledge

Specific nuclear power plant knowledge required for the competence of personnel shall include the instructions for radiation protection and safety.

The training which should be given to all personnel is:

— classroom instruction and practical work as appropriate to develop knowledge of radiation protection and industrial safety, including fire protection;

— instruction to impart knowledge of the regulations, standards and procedures of the Operating Organization and the safe operation of the plant, including emergency conditions;

— instruction to give a general understanding of quality assurance and quality requirements;

— classroom instruction in technology and science to the extent required by the preceding elements.

The technical educational qualifications of maintenance personnel are closely related to the tasks and duties of their positions in maintenance functions. Accord-ingly, training courses for these personnel are much shorter in duration than the training for personnel in the plant operating group. In addition to the training in safety described above, personnel in maintenance functions should be given the following training:

8

— classroom instruction and guided activities on the plant to develop a knowledge of the plant layout, and systems, components and operating characteristics of the plant at a level and in a degree of detail related to the position;

— classroom instruction and guided activities in the relevant part of the plant to develop the specific knowledge required by the functional post;

— classroom instruction in general technology and science to the extent required by the preceding elements;

— special training, both at manufacturer's facilities and on the site, during construction, fabrication and testing of particular items important to safety.

An indication of the classroom time devoted to training support function personnel, including maintenance personnel, in several countries is given in Table III.

TABLE m . CLASSROOM TIME FOR INITIAL TRAINING OF SUPPORTING FUNCTION PERSONNEL: PRACTICE IN SOME UTILITIES

Managers Engineers Supervisors Technicians Craftsmen

Average time (weeks) 30 20 25 20 10

Range (weeks) 25-40 15-30 20-30 15-30 1-20

3.3.4.3. Specific skills

The level of specific skills of the maintenance personnel should at all times be commensurate with their position in the structure of the maintenance group. Example No. 2 in Annex I describes a training facility for maintenance personnel as operated in one Member State.

Manual skills are most relevant for craftsmen positions and can be developed by training and job experience.

The social skill of being able to follow instructions and procedures in a disciplined manner should be developed by training and experience.

The intellectual skills gained partly by training and experience should be evaluated during recruitment and periodically during employment.

3.3.5. Experience

Experience covers the knowledge gained and skills developed during the occupation of a position; working in the plant under guidance is considered a part of training (on the job training).

9

For maintenance, an important element of experience is detailed knowledge of a particular plant or activity, which can only be obtained by day to day work in a particular position. The knowledge not directly connected with the duties of a par-ticular position, including knowledge of interfacing activities and wider knowledge of the plant (breadth of experience), is also important for maintenance activity.

Arrangements should be made for maintenance personnel to participate in maintenance, inspection and testing during the construction and commissioning stages.

3.3.6. Preserving competence

Maintenance personnel competence, once established, is not necessarily constant, owing to changes of hardware and software, the gaining of experience, or deterioration of information and skills.

In order to maintain high individual competence and to cope with changes in the competence required for a position in the maintenance group, measures should be taken to preserve and to update the competence of personnel by training in the following areas:

— emergency procedures and their exercise — radiation protection and industrial safety, including fire protection — regulations, standards and procedures important to safety and their changes — plant hardware and software changes — tasks which occur infrequently.

3.3.7. Verification, competence and authorization

The extent of formal verification of competence of maintenance personnel varies according to the practice of the operating organization and the requirement of the regulatory body. Certain craftsmen, such as welders, require periodic requalification to demonstrate that the individual continues to possess the necessary skills.

It is the Operating Organization's and plant management's responsibility to establish its requirements on maintenance personnel and to provide any necessary formal verification of competence and authorization of the persons involved in the maintenance programme.

3.4. Establishment of the maintenance programme

The plant Maintenance Superintendent shall be responsible for developing the maintenance programme and shall be experienced in both general power plant maintenance practices and nuclear maintenance practices.

10

Development of the plant maintenance programme shall be initiated early in the design phase. The primary reason for this is that the requirements of the maintenance programme can be incorporated into the design and construction details of the plant. The maintenance programme shall be based upon and shall preserve the design assumptions and intent. During the design phase, the interaction between design and maintenance should take into account the following:

(1) Location, size, layout, habitability and personnel safety features of maintenance workshops;

(2) Location, size and layout of storage facilities; (3) Maintainability characteristics, arrangement, location, environment, shield-

ing, sheltering and access of systems and components; (4) System and component area habitability factors (noise, illumination, radiation,

temperature, humidity, personnel safety); (5) Provisions to minimize radiation exposure of personnel during maintenance

and surveillance and to reduce radiation levels resulting from such sources as accumulations of radioactive materials;

(6) Plant features (elevators, cranes, lifting and hoisting provisions, personnel safety, communications);

(7) Human anthropometrics and strength; (8) Need for proper and unambiguous labelling and coding.

During plant construction and commissioning, a maintenance programme shall be established and implemented to cover maintenance on all equipment subsequent to delivery to the plant, i.e. stored systems and components prior to installation, installed systems and components before they are operational, and installed systems and components after they are operational. Upon commencement of operation, the maintenance programme shall continue to cover maintenance on all systems and components delivered to the plant, i.e. stored or installed.

The performance of some or all maintenance activities for various systems and components during construction or commissioning may be the responsibility of the vendor or constructor. However, the maintenance group of the Operating Organiza-tion shall be responsible for ensuring that those maintenance activities are adequately performed and that the appropriate records are transferred to the Operating Organization.

The maintenance group shall also ensure that all appropriate records such as as-built drawings, manufacturers' system and component manuals, materials certifi-cation etc. are transferred to the station file in an up to date version and maintained according to quality assurance requirements.

The maintenance activities as a function of time during design, construction, commissioning and operation shall be determined and routinely updated. These activities should include the preparation of procedures, the equipping of maintenance facilities, and the checking out of maintenance equipment as appropriate. The main-

11

tenance group personnel shall be hired, trained and qualified to the extent required by the magnitude of these maintenance activities at any time.

3.5. Facilities and services

3.5.1. Facilities

To implement the maintenance programme, the operating organization shall ensure that electrical, mechanical and instrument workshops are provided with adequate equipment for carrying out all foreseen maintenance effectively, with due regard to radiation protection. The extent to which facilities are provided on and off the site is a matter of policy, but proper attention should be paid to the more stringent standards of decontamination required when reactor components are dispatched from the site and to the difficulty of applying appropriate radiation protection at off-site locations. A further requirement in such cases is the application of controls to achieve the same standard of quality assurance off site as with work on site.

Maintenance of systems and components in a controlled area requires special facilities to keep the radiation exposure of individuals as low as reasonably achieva-ble and to prevent the spread of contamination. These will include active workshops, specific maintenance facilities for particular components, and equipment for removing radioactive contamination from components and maintenance equipment.

The general layout and particulars of the plant should be checked to ensure adequate provision has been made for:

(i) access to components (ii) space for dismantling and storage of components during maintenance

(iii) lifting devices of appropriate capacity (iv) transportation devices and the appropriate routes to workshops, stores

and plant components (v) special equipment necessary for repairs and inspection

(vi) electrical, steam, water, compressed air and other services.

3.5.2. Services

Appropriate specialist services shall be made available to the on-site maintenance group — provided from within the Operating Organization or from outside sources according to the policy of the Organization. Such services may include:

(i) specialist technical information and advice (ii) maintenance of special or proprietary systems and components

beyond the capability of the on-site maintenance group (iii) independent design reviews and safety analyses for modifications

12

(iv) provision of special equipment for testing or maintaining systems and components

(v) review and audit of maintenance activities as appropriate.

3.6. Stores

3.6.1. Responsibilities

Suitable arrangements are required for procuring, receiving, storing, and issu-ing the materials, spare parts and components used in maintenance. The on-site maintenance group may not have direct responsibility for all those areas but it must ensure that adequate spares, components and materials in the correct condition are available for achieving the objectives of the maintenance programme.

3.6.2. Procurement

The maintenance group shall specify the type and quantity of spare parts, components and materials to be held in storage after consultation with vendors and taking into account relevant maintenance experience. Procurement of all items and services for maintenance shall be in accordance with IAEA Safety Guide No. 50-SG-QA3. Spares shall meet the same technical standards and quality assurance requirements as equivalent installed items. It shall be the responsibility of the maintenance group to ensure that these requirements are correctly established and specified to the purchasing unit. Low stock limits and re-ordering levels should be specified by the maintenance group, with account taken of:

— postulated plant failure frequency and importance of the item to safety and availability

— any special manufacturing features — certainty of future supplies — estimated duration of repairs — shelf life of components — anticipated delivery times.

3.6.3. Receipt and storage

Receipt is usually the responsibility of the stores group but plant management shall establish procedures to ensure that adequate expertise is available for inspection and verification of the delivered items.

13

The maintenance group shall ensure that proper storage procedures are established, taking into account the following:

(i) adequate access and handling to prevent damage (ii) correct environment and fire precautions

(iii) periodic examinations and special storage conditions if necessary (iv) retention of identification and documentation (v) prevention of unauthorized access or unauthorized issue of stores.

3.6.4. Issue

The maintenance group shall ensure that procedures are established so that stores are issued only to authorized personnel on production of appropriate documen-tation. The method of issue should not contravene arrangements for the security of the stores or the maintenance of correct environmental conditions. If stores are not manned continuously, then arrangements are required for issue under the control of the shift supervisor with the same standards maintained as when the stores are normally operated.

3.6.5. Records

The stores records provide part of the evidence that the maintenance programme is being correctly implemented and are a necessary input to a continuing review of maintenance effectiveness. Full details are available in IAEA Safety Guide No. 50-SG-QA1. The maintenance group has a responsibility to check that the stores records provide the information required by the maintenance programme and in particular that all quality assurance requirements are fully implemented.

4. IMPLEMENTATION OF MAINTENANCE PROGRAMME

This section discusses the implementation of the maintenance programme described in Section 3.

4.1. Maintenance schedule

A comprehensive schedule of maintenance activities to be performed shall be developed during the establishment of the maintenance programme. This schedule shall be routinely updated and implemented throughout the plant life (including decommissioning).

Maintenance activities shall be scheduled in accordance with two sets of criteria. The first set of criteria, in decreasing priority, are:

(1) To preserve adequate safety (2) To enhance plant availability

14

(3) To minimize costs due to system and component failures

(4) To make the most effective use of available resources.

The second set of criteria, in decreasing priority, are:

(1) Mandatory preventive maintenance (2) Remedial maintenance (3) Discretionary preventive maintenance.

The schedule for mandatory preventive maintenance shall be based on require-ments in applicable regulations, vendor warranties, insurance agreements, operating licence conditions, and other plant safety specifications. These documents shall be systematically reviewed for preventive maintenance requirements during the estab-lishment of the maintenance programme. A procedure shall be established to ensure that any changes in these requirements are incorporated into the maintenance programme and maintenance schedule.

The maintenance schedule shall be modified to incorporate remedial main-tenance in the event of a system or component failure. An evaluation of the failure shall be performed to determine if the system or component may be restored or replaced in accordance with previous specifications or if modified specifications need to be developed.

The purpose of discretionary preventive maintenance is to minimize the impact of system or component failures and of the associated remedial maintenance on plant availability and costs. Therefore only those discretionary preventive maintenance activities that are cost effective should be scheduled. Discretionary maintenance may be identified and scheduled on the basis of the experience and engineering judgement of the Maintenance Supervisor and plant management. However, a preferable approach would be to use a systematic method.1

The maintenance schedule shall include, as appropriate, the following details of each maintenance activity:

(1) identification of the system or component (2) type of activity and classification (3) identification of the maintenance instruction (4) frequency and date of implementation (5) responsibility for implementation (6) prerequisites (7) resources (8) any requirement for data and acceptance criteria (9) verification and approval

(10) reporting requirements.

1 See, for example, A Guide for Developing a Preventive Maintenance Programme in Electric Power Plants, Rep. EPRI-NP-3416, Electric Power Research Institute, Palo Alto, CA (May 1984).

15

FIG. 2. Maintenance planning.

4.2. Planning

The detailed implementation of the maintenance programme requires the estab-lishment of a planning subgroup. This may be set up within the maintenance group.

Many maintenance activities involve co-ordination with operations, radiation protection and possibly other groups on and off the site. For this reason, many Operating Organizations establish a separate planning group to provide a planning service to the maintenance group.

The planning group should provide a service to the station covering the following maintenance aspects:

(1) implementation of the maintenance programme (2) medium and long range planning (3) planning for all work done during major plant outages (4) contingency planning (5) short term day to day work scheduling and co-ordination.

16

An outline of the maintenance planning function is shown in Fig. 2. A brief description of the planning process as practised by one Operating Organization is given in Annex II as Practice No. 1. The resources which have to be matched to the work schedule include personnel, materials, spare parts and equipment. It is essential that, while a control planning group may schedule personnel resources, the actual allocation of engineers and craftsmen to each activity remains the responsi-bility of the maintenance group. Similarly, plant condition monitoring activities may be covered by many station groups, but, while the planning group may be responsi-ble for the collection of data, specified individuals shall be responsible for analysis of the data and initiation of changes to the maintenance programme or test programme.

The detailed planning may be assisted by many proprietary planning systems and is readily combined with a records system for incorporation into a computer program. A short description of such a system used by one Operating Organization is given in Annex II as Practice No. 2. Some computer installations will produce copies of the appropriate maintenance instructions at the same time as work scheduling.

For major plant outages, extensive preparation is necessary for downtime to be reduced to the minimum, radiation exposures to be kept as low as reasonably achievable (ALARA) and for the achievement of the highest standards of safety and quality of the work. To this end, the following aspects need special consideration:

(1) Scheduling of work and allocation of priorities; (2) Specification and timely provision of required manpower, tools, materials,

spares, test equipment and services; (3) Preparation, review, approval and authorization of any special procedures that

will be required for the work; (4) Administrative controls and procedures to meet licensing requirements or

approval of modifications; (5) Pretraining of personnel, includiftg off-site manpower, in special techniques or

radiological protection requirements; maximum use should be made of plant mock-ups to verify the effectiveness of proposed techniques, to train person-nel, and to ensure that radiation doses will be ALARA;

(6) Specification of quality control and assurance requirements and the preparation of appropriate documents;

(7) Planning of sequence of plant system and component release from service, work permit preparation and issue, compatibility with planned work on adjacent plant systems and components, retesting and restoration to service;

(8) Special provisions, as required, for augmenting maintenance shifts during the outage;

(9) Establishment of safe working environments; (10) Provision of intergroup liaison and support;

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(11) Provision of a dynamic planning organization with sufficient personnel to check work progress, identify deviations from objectives, specify remedial actions and replan to minimize downtime.

A description of the outage planning and management as practised by one Operating Organization is given in Annex II as Practice No. 3.

4.3. Work control and administration

4.3.1. Applicability

Preparation and execution of maintenance work, replacements, repairs and modification of systems and components in the plant shall be done in accordance with maintenance work control procedures. These procedures authorize specified work on specified systems and components and, where safety of personnel and plant is involved, provide assurance that safe conditions will be maintained during the work.

The maintenance work control procedure need not be used for routine work which is normally within the workers' ability to perform without a work permission. Examples include the following:

— minor seal adjustments — stopping small leakages — taking routine samples from circuits — routine measurements of radiation level — routine monitoring during rounds — house services.

In the case of sudden events where immediate measures have to be taken, certain specified steps in the formalized procedures may be deferred or deleted on the authority of the shift supervisor. The deferral or deletion of each stage shall be recorded.

4.3.2. General aspects of the maintenance work control procedure

The maintenance work control procedure shall be based on the following:

— guarantee of the safety status of the plant — assurance of personnel safety including radiation protection and industrial

safety — adherence to the licensing conditions and technical specifications of the plant — adherence to other statutory requirements and specifications, especially quality

assurance specifications — minimizing outage time

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— information from all groups in the plant related to the system or component — documentation of all work done on the plant.

Organizational measures to ensure the above aspects comprise:

— daily work programmes (usually set up in daily talks with all groups as appropriate)

— use of a work permission procedure — detailed planning and safety review of complex work taking into account

ALARA principles — establishment of a special procedure for work in areas with high radiation or

contamination levels.

4.3.3. Reasons for maintenance work

Maintenance work is carried out for:

— failures or irregularities which are identified during routine work or inspection rounds

— failures which were automatically identified by the process computer, annunciator, or instrumentation

— preventive maintenance which is initiated by a Maintenance Superintendent — in-service inspections — modifications and replacements.

For all this type of work a written work order or a defect report is necessary. Usually, the maintenance group has a daily meeting with the operation group

and with other groups as appropriate when the work orders and defect reports are discussed. Approval of the work shall be given by the station management. The work permission should be given by the shift supervisor on a daily basis. As necessary, preliminary planning shall consider detailed technical clarification, radiation protection planning, maintenance preparation and any interface activities.

4.3.4. Format and utilization

Forms shall be designed and utilized for work orders and defect reports. Some Operating Organizations use a single form for both (see Annex 1, Example No. 3).

The minimum items to be completed on the form to initiate work are:

— component identification and location — kind of work or defect — date and signature of the initiator.

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N) O Initiation: Fill in a defect report /work order form

Review and registration in the main control room

Approval: Daily meeting; discussion of al? new defect reports/work orders

General approval by plant management and maintenance management

Additional release at the working place

necessary?

Yes

FIG. 3. Flow diagram for general work control procedure.

The description must be complete in order to demonstrate the extent of the work and to avoid unnecessary preparations. There should be several copies of the form for a work order or defect report announcement:

— original, after identification and approval, for the designated work leader — first copy for the main control room — second copy for schedule control — third copy for financial registration (if appropriate) — fourth copy, if necessary, for radiation protection and registration of doses — fifth copy or original for documentation of the work.

Figure 3 is a flow diagram of work control procedure.

4.3.5. Recording and approval

The first registration of the form is generally undertaken by the shift supervisor who checks the following items:

— completeness of the text — urgency depending on the status of the plant — reduction of operating functions and consequences for the safety of the plant — necessary status of the plant (or system) for doing the maintenance work — any obligation to inform the licensing authority.

The shift supervisor signs the form and passes it on for approval and work preparation.

4.3.6. Technical clarification

Technical clarification shall be given in co-operation with the necessary plant personnel groups as follows:

— investigation of the reason for the defect or failure if necessary — any necessary modifications or replacements — determination of the kind and extent of maintenance work, proof tests, and

function tests — constraints imposed by operational limits and conditions — quality assurance aspects following the specifications and classification of the

components — if necessary, the engagement of consultants — if necessary, initiation of licensing procedures.

Completion of clarification shall be documented on the form and then passed to maintenance work preparation.

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4.3.7. Preparation of maintenance work

Complex maintenance work and work which needs special safety preparations should be planned by the maintenance group or the planning group. Working plans should consider the following:

— status of the plant — description of the extent of work — necessary software (drawings, welding plans, assembly descriptions, etc.) — protection measures, safety measures and special indications (escape routes,

shieldings, fire protection measures) — checklist for taking out of service of systems, components, valves, etc. — status of systems in the neighbourhood if necessary — list of necessary devices, materials and instruments — list of necessary devices for industrial safety and fire protection — list of necessary provisions for radiation protection (control instruments,

masks, contamination control equipment, decontamination materials, etc.) — study of transport routes and transport facilities — schedule for number and qualification of required personnel — list of tests which should be performed (X-ray tests, ultrasonic tests, pressure

tests, etc.) — state of cleanliness of relevant parts and working places — checklist for normalizing the system or component — function tests.

If there are high radiation levels or aerosol concentrations, the personnel may require appropriate instructions and training (if appropriate with a mock-up) to ensure a safe and fast working sequence.

4.3.8. Radiation protection planning

According to established procedures, the radiation protection group shall specify on the form its involvement in the maintenance work. There are three possible categories:

(1) Participation in the establishment of working plans; (2) Participation of the radiation protection group before work commencement; (3) No participation of the radiation protection group in work planning.

An example of radiation protection involvement in maintenance work as applied in one Member State is presented in Fig. 4.

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Scheduled maintenance or modification work

Review by the departments responsible for the preparation and implementation of the scheduled maintenance or modification work

Specification of the fundamental radiological protection measures and the appointment of qualified persons

Signing of the work order by the radiological protection officer

Preparation of the radiological protection measures according to the instructions contained in the work order

Reporting on the completion of the radiological protection tasks +

Cancellation of the radiological protection measures J

Documentation of the radiological protection measures ]

Planning of work preparation by the responsible departments in consultation with the radiological protection officer

Establishment of a co-ordinated work order including basic radiological protection measures

Preparation of a plan for the determination of work-related radiation exposure

Appointment of qualified persons for radiological protection measures

Preparation of the radiological protection measures in accordance with the co-ordinated work order, and if necessary, specification of additional radiological protection measures at the locality concerned

Cancellation of the radiological protection measures

Documentation of the radiological protection measures

FIG. 4. Example of radiation protection planning procedure for maintenance work. (Note: 1 rem = 10~2 Sv).

4.3.9. Isolation procedure

Isolation involves the removal of the systems and components from service and establishment of working conditions safe from system and component hazards.

Usually the operations personnel (shift supervisor) has already determined the isolation procedure by reviewing the work order or defect report. If not, this shall be done after the work preparation procedure is completed.

The shift supervisor shall determine the time and give orders for isolation (electrical/mechanical). The system used in one Operating Organization is described below.

The isolation procedure undertaken by the shift supervisor is documented by means of a checklist on the form (e.g. on the reverse side of the copy for the control room). In addition, a record is maintained in the main control room of all systems and components removed from service. After determination of an isolation procedure on a checklist, it is verified by a competent person in the operation group.

— Each component which is isolated is given a tag listing any actions permitted. The tag also shows the component identification, the isolation number, the isolation status (e.g. closed/open), the normal status and the reason for isola-tion (see Example No. 4 in Annex I) and is signed by the shift supervisor.

— If electrical motor-driven components have to be isolated, three tags with the above mentioned content are necessary. One of them is put on the cover of the buttons in the control room, one in the switch gear and one on the component.

— If the isolation procedure is necessary for more than one maintenance activity, each one needs its own tag.

— If isolated components have connections with a hazardous operating system the closed valves are locked.

— A second person (a shift supervisor or an authorized person) monitors the isolation measures by means of the checklist.

— Special procedures are applied for electrical isolation.

4.3.10. Work permission

Permission to start work on a general daily basis, when required, shall be given by the shift supervisor. Permission shall be given by signing the form for a work order or defect report.

In addition, for some types of work (e.g. in controlled areas, in vessels, work involving fire hazard) individual permission is necessary (see Example No. 5 in Annex I). Special arrangements may be required when the work involves more than one operating shift.

25

4.3.11. Execution of the work

Work will be controlled by the maintenance group. This group is responsible for:

— selection of qualified personnel — instructions to the relevant personnel — seeing that an approved supervisor is nominated in the case of off-site

personnel.

At each working location, a designated person in each working group (work leader) shall be responsible for:

(1) Before the start of the work:

— checking the completeness of work permissions — checking local isolation measures to the extent practical — checking industrial safety measures — checking fire protection measures — ensuring radiation protection provisions are established;

(2) During the course of the work:

— initiating additional protection measures if necessary — ensuring that protective measures are adhered to — co-ordinating all measures with other working groups in this area — reporting stops and restarts of work to the shift supervisor and health

physics group if they are unscheduled; leaving unfinished work in a safe condition

— monitoring the work sequence, including hold-points — ensuring the quality of execution — reporting any changes of work sequences or significant abnormalities to the

maintenance management and, if necessary, to the radiation protection group. In these cases, maintenance management has to decide how to continue.

4.3.12. Work completion

The designated work leader is responsible for cleaning the area used for maintenance activités and devices and for restoring systems or components to their required status before normalization.

The work leader shall report the completion of work to maintenance manage-ment. The management shall specify any additional verification, monitoring, or testing that are considered necessary. Completion of work shall be documented on

26

the form and approved by signature of the work leader and, as appropriate, by maintenance management, who shall pass the form back to the shift supervisor for normalization.

4.3.13. Normalization

Normalization involves the restoration of the systems or components to operable status.

The shift supervisor is responsible for the normalization of systems and components. Normalization shall be confirmed on the isolation checklist with date and time.

If a function test is required, then permission for it shall be given by the shift supervisor, who shall state:

— the status of the plant — other work which is being undertaken.

The isolation tags remain on the components or, if necessary, are supplemented by function test signs.

If the function test is not successful, a new work order and new isolation measures shall be necessary.

After completion of a successful function test, the shift supervisor shall initiate final normalization and all tags and signs shall be removed. The normalization measures shall be performed in accordance with a checklist, normally in reverse sequence to the isolation measures.

A verification of normalization shall be performed by the shift supervisor or by another designated person.

4.3.14. Restoration to service

The shift supervisor shall confirm the normalization and any function testing by signing and cancelling the work order. The system or component shall be placed in service or standby status. The control room record showing system and component status shall be updated accordingly.

4.3.15. Evaluation and documentation

After completion of the maintenance work, the performance of the equipment shall be evaluated. The maintenance group shall identify the need for and, as appropriate, initiate the following:

— additional maintenance work to be scheduled — repair or modification reports to be prepared — radiation exposure accumulation for the maintenance work

27

— documents to be modified — system and component history records to be updated — any required changes to the maintenance schedule and/or procedures in the

light of experience.

The appropriate work documentation shall be filed for record purposes.

4.4. Modification procedure, replacement and repair

4.4.1. Modifications

Modifications may be necessary to rectify component failures discovered during maintenance, to repair components following failures in operation, to reduce the frequency of faults, to improve safety, maintainability or operability, to satisfy new regulatory requirements, or to incorporate a non-identical replacement plant component. Modifications may include physical changes, changing of set points, and changes to procedures.

4.4.2. Replacement

The replacement of a component by an identical one during maintenance does not constitute a modification providing all quality assurance procedures are complied with to demonstrate that it is identical. If, owing to obsolescence or difficulties of supply, an identical component is not available, then a procedure is necessary to substantiate the equivalence of an alternative one, the use of which shall not invalidate the assumptions made in relevant plant safety analyses.

4.4.3. Classifícation of modiñcations

In accordance with quality assurance requirements, the Operating Organization shall arrange an independent review of proposed modifications to systems and com-ponents important to safety. The plant maintenance policy document shall require the plant management to classify modifications as minor or major so that those judged to be major can be submitted to an independent assessment by qualified persons and to the approval of the Regulatory Body if so required. The document shall include criteria for making this judgement. For example, all modifications shall be considered major if, incorrectly conceived or inadequately executed, they could significantly increase the probability or severity of a radiological hazard.

4.4.4. Modiñcations significant to safety

Notwithstanding these general criteria, the Operating Organization should specify those plant systems and components (such as primary coolant boundary,

28

emergency electrical supplies, reactor protection equipment) that are considered so significant to safety that no modifications to them can be judged minor. Guidance for this classification can be found in IAEA Safety Series No. 50-SG-D1. In addition, the requirements of the Regulatory Body shall be taken into account.

4.4.5. Co-ordination of modifications

A suitable procedure, e.g. plant modification control procedure, issued by the plant management, shall clearly allocate responsibility for co-ordinating plant modifications and implementing the on-site classification and review process, for liaison with the independent assessment process, for administering controls relating to the implementation and documentation of approved modifications, and for disseminating information to specified bodies.

Irrespective of the organization involved, it shall remain the responsibility of the station manager to ensure that at all times the state of the plant is consistent with that assumed in the relevant safety analyses.

4.4.6. Modification control procedure

A procedure used for the control of modifications in one Operating Organiza-tion is described in Annex I (Example No. 6).

4.5. Maintenance instructions

The extent of documentation required for a maintenance instruction will depend on the complexity of the systems and components concerned and on the policy of the Operating Organization. Nevertheless, to secure uniformity and confor-mance with quality assurance requirements, maintenance instruction preparation shall be in accordance with an administrative procedure describing the method, format and level of detail required in the instructions. The instruction should provide sufficient information for a competent person to complete the required task in a safe and efficient manner without direct supervision.

Routine maintenance activities that require skills normally possessed by competent personnel may not require detailed step by step instructions but any general administrative procedural controls or general safety instructions should be specified. Such controls and instructions would cover items such as:

— register of personnel authorized to carry out specific maintenance activities such as welding on pressure parts, lifting tackle inspections, crane operation, etc.

— control and use of lifting equipment — use of protective clothing

29

u> o

Instructions CW (circulating -water) pumps

-SECTION-

— SECTION -

- S E C T I O N -

SECTION-

- SECTION -

-SECTION-

- SECTION

— SECTION

-SECTION

-SECTION-

-SECTION

SECTION

-SECTION

- c 1 7.1

- C 1 8.1

- c 9 I 9.1

- c 1 0

I 10.1

I 11

I 11.1

- C " 1 12.1 „ ' 13.1

- Introduction

- Maintenance frequency schedule

- Lubrication schedule

-Safety precautions

- Recommissioning procedure

-System fault finding

- Preventive maintenance

- List of work specifications — — — — — —

- Motor — corrective maintenance

- List of work specifications

-Speed reducing gears — corrective maintenance

- List of work specifications

- Pump - correct ve maintenance

- List of work specifications — '-'

- Valves — corrective maintenance

- List of work specifications

• Instruments — corrective maintenance

• List of work specifications

- Instruments — calibration

-Motor

-S .R . Gears

- Pump

- Valves

- Instruments -

— List of work specifications

»Measuring the insulation resistance

• Examining the gear teeth Cleaning the oil filter

• Cleaning the cooling and flushing water filter

• Inspecting glands

• Functional checks

• Examining the thrust and journal bearing

- Examining the lower journal bearing

» Examining the mechanical seal

» Removing

' Dismantling

• Inspecting and repairing

• Assembling

• Replacing

• Overhauling the cooling and flushing water filter

• Fault finding

FIG. 5. Example of breakdown of maintenance instructions for a complete system.

— provision of safe access — work in confined spaces — work at elevated temperatures — use of portable tools and equipment — use of machines and machine tools — control of electrical and radio interference — access to high voltage compartments and structures — testing of high voltage apparatus and earthing of cables — leak sealing in pipework and valves — arc and gas welding and cutting — protection of eyes — noise control — safety with chemicals — fire precautions.

On major plant items the maintenance instructions may be subdivided, e.g. the switchgear, control panel, motor and pump of a circulation unit (see Fig. 5). In such cases particular attention is required to interface points that may have to be addressed in more than one document or a general introduction to the instructions.

The production of concise yet precise documents is assisted by the presentation of information in logical and readily assimilated form, making the maximum use of visual aid afforded by relevant illustrations. Maximum use should also be given to check sheets and simplified means of data recording for input to plant history records.

Detailed maintenance instructions issued to craftsmen shall be compiled in accordance with quality assurance requirements (see IAEA Safety Series No. 50-SG-QA5) and include the following, where appropriate:

(1) Identification of the plant systems and components (2) Specification of the necessary tools, material and equipment (3) Sufficient information in an appropriate form for the task to be performed in

a safe, practical and efficient manner, including specification of personnel qualifications as appropriate

(4) Breakdown of the task into sequential steps with sufficient detail for the work to be done by a competent person without direct supervision

(5) Provision of adequate drawings and illustrations (6) Identification of special tools or techniques needed at appropriate steps in the

sequence (7) Details of interfaces with complementary work carried out by other personnel (8) Warnings of potential danger to plant or personnel and clear specification of

precautions to be taken (9) Radiation protection provisions

31

(10) Identification of hold points where progress to the next step is dependent upon independent review. (Checklists for signature by persons authorized to carry out this function are a useful aid to achieving compliance with the instructions.)

Annex I contains an example of a procedure for the compilation of maintenance instructions (Example No. 7) and examples of maintenance instructions and checklists as adopted by Operating Organizations in some Member States (Example No. 8).

4.6. Records

Administrative controls and procedures shall be applied with appropriate allo-cation of responsibility to specific personnel, to ensure the systematic generation, processing and retention of maintenance records. The arrangements shall be adequate to provide the following:

(1) Objective evidence that the maintenance programme is being implemented fully in accordance with the quality assurance programme;

(2) Plant and component history records with sufficient detail about maintenance work carried out to facilitate a continuing review of maintenance effectiveness, utilizing performance indicators;

(3) Adequate information for the feedback of experience to plant designers and other parts of the operating organization;

(4) Data for reliability analyses; (5) Basic data for planning maintenance activities; (6) Evidence of conformity with Regulatory Body requirements.

The methods used may involve the use of documents, microfilms and computers according to the policy of the Operating Organization. Whichever method, or combination of systems, is used, attention is required to the ease of retrievability of the records for consultation or review and the need to guard against accidental loss when establishing storage facilities. The maintenance instructions should be compiled in such a manner as to readily generate the appropriate record of the work or inspection carried out, identification of the maintenance and opera-tional personnel involved, and any necessary certificiation by supervisors or inspec-tors. The checklists referred to in Section 4.5 are examples of this type of combination of instructions and records.

The principles of record retention systems are covered in detail in the Safety Guide on Quality Assurance Records System for Nuclear Power Plants, IAEA Safety Series No. 50-SG-QA2. Maintenance records should not be considered in isolation. Compliance with the general station records system is obviously required but possi-ble combination with planning systems, stores inventory control, radiological dose control, etc. should be investigated to improve the efficiency of the records system.

32

5. SURVEILLANCE AND VERIFICATION ACTIVITIES

This section considers only those surveillance and verification activities relevant to maintenance.

5.1. Surveillance

5.1.1. Surveillance activities

Before any system or component important to safety is returned to service after maintenance or repair, surveillance should be performed to confirm that the objec-tive of the maintenance or repair actions has been achieved, that the limits and condi-tions for normal operation associated with that system or component have been fulfilled and that the plant can be operated safely. This should include the surveil-lance of connected systems in the work area that may have been disturbed by maintenance or repair action.

The procedures for surveillance activities should be a part of the maintenance instruction.

For surveillance of maintenance activities the following should be established: — criteria and responsibilities for performing work inspection of maintenance

activities according to written procedures — provisions and responsibilities for the identification of appropriate inspection

hold points related to maintenance activities — methods, responsibilities and acceptance criteria for performing functional

testing of systems or components following maintenance work and/or prior to their being returned to service.

5.1.2. Inspections

Inspections for verification of maintenance activities shall be carried out by appropriately qualified individuals not directly involved in performing the work. These should include monitoring the maintenance and repair activities, inspections at determined holdpoints and final inspection as necessary. Inspection may be unan-nounced and should include direct observation of the specific maintenance activity as well as examination of documentation. Results and findings of these inspections shall be transmitted to the appropriate maintenance supervisors for information and for corrective action if required.

5.2. Administrative verification activities

Depending on the general policy of the Operating Organization, a systematic and planned control should be established to verity maintenance activity concerning systems and components important to safety.

33

5.2.1. Items to be verified

It should be verified that:

(1) Written procedures have been established for initiating requests for maintenance;

(2) Criteria and responsibilities for review and approval of maintenance requests have been established;

(3) Criteria and responsibilities that form the basis for designating the activity as important to safety or not important to safety have been established;

(4) Criteria and responsibilities have been designated for performing work inspec-tion of maintenance activities;

(5) Provisions and responsibilities have been established for the identification of appropriate inspection hold points related to maintenance activities;

(6) Methods and responsibilities have been designated for performing functional testing of systems or components following maintenance work and/or prior to their being returned to service;

(7) Administrative controls for maintenance activities require that the following records will be prepared, assembled and reviewed for transfer to records storage: (a) approvals of maintenance requests (b) identification of the personnel who performed the maintenance task (c) identification of the personnel who inspected the maintenance work (d) reason for doing the maintenance work (e) description of the maintenance action taken (f) identification of the post-maintenance functional testing performed (g) identification of personnel who performed the post-maintenance testing (h) identification of replacement parts or materials used (i) identification of test and measuring equipment used

(8) Responsibility to assemble and review the records identified in item (7) above for transfer to record storage has been established;

(9) A programme has been established for reviewing completed remedial maintenance records to assess the adequacy of the preventive maintenance programme, to identify repetitive failures of parts and components, and to identify design deficiencies;

(10) Provisions for an effective management of technical documentation have been made;

(11) Responsibilities have been assigned to ensure implementation of records review identified in item (8) above;

(12) Special authorization has been given for activities involving fire hazards and a firewatch has been established.

34

5.2.2. Work control items

It should be verified that methods and responsibilities for work control have been clearly defined. Points to be verified include:

(a) Permission to release systems and components for maintenance shall be granted by the operating group.

(b) Prior to removal of systems and components from service for subsequent release for maintenance, the operating group is required to verify that the system or component can be removed without violating operational limits and conditions. Additionally, when it is necessary, they shall determine how long a system or component may be allowed to be out of service. Granting of such permission shall be documented.

(c) When testing of systems or components important to safety is required by operational limits and conditions such testing shall be documented.

(d) The status of systems and components shall be clearly identified. (e) Procedures and responsibility to ensure that necessary measures, such as

tagging components, have been implemented correctly. (f) Procedures and responsibility for returning systems and components to service

have been established.

5.2.3. Administrative control of locking devices

It should be verified that procedures for the locking devices and the locked-open or locked-closed valves and circuit breakers are clearly defined and include the following:

— the type of locking devices which are acceptable — the responsibilities for authorizing the removal of the locking devices.

5.2.4. Implementation of maintenance controls

It should be verified that in maintenance activities:

— only the latest applicable issue of any document is used — only approved procedures are used — only qualified personnel are used — a file is maintained which would include qualification records of procedures

and personnel — criteria are established to use mock-ups or specify whether special training is

required — procedures for cleaning systems and components important to safety during

maintenance are developed and implemented — the housekeeping responsibilities are established.

35

Annex I

EXAMPLES OF DOCUMENTS

This Annex contains examples of various documents currently in use for the establishment and implementation of the maintenance programme described in this Manual. Each example is a copy of a document used by one particular Operating Organization. The document used by other Organizations may vary to accommodate their particular policies and practices; it is therefore possible that minor inconsisten-cies exist between the text of this Manual and individual examples and between examples.

The Section numbers under the titles refer to Sections in the main text.

37

EXAMPLE 1

MAINTENANCE POLICY DOCUMENT

(Section 3.1)

This example is a portion of the policy manual of one Operating Organiza-tion in the USA that describes that organization's maintenance programme. The text has been edited slightly to eliminate terminology that is unique to the Operating Organization. The organization operates several multiunit stations. Other portions of the policy manual cited by this portion are not included in this example. In this example structures, systems and components important to safety are referred to as safety related structures, systems and components.

39

3.3. MAINTENANCE

3.3.1. GENERAL

In order to assure the safe, reliable and efficient operation of a nuclear station, a comprehensive maintenance programme for the station's safety related structures, systems and components shall be established. Maintenance for non-safety-related structures, systems and components shall be performed under the station's work request system. Within the station organization, maintenance responsibilities generally are separated into two categories. The maintenance of station structures and mechanical equipment is performed by the station's mechanical maintenance section under the direction of the Mechanical Maintenance Engineer. Instrumenta-tion and electrical equipment are maintained by the instrument and electrical section under the direction of the Instrument and Electrical Engineer.

3.3.2. MAINTENANCE ACTIVITIES

3.3.2.1. Introduction

A nuclear station shall establish a maintenance programme for safety related structures, systems and components which provides for:

(a) Maintenance for such items so as to assure an adequate degree of reliability. (b) Planning prior to performance of maintenance functions in order to minimize

radiation exposure, manpower and outage time.

A station's maintenance programme for safety related instrumentation may consist, in full or in part, of the station's periodic testing programme for such instrumentation — see Section 3.2.2.

The requirements of this Section 3.3.2 shall be applicable to, but not necessar-ily limited to, safety related structures, systems and components.

3.3.2.2. Organization

3.3.2.2.1. Station Manager

The Station Manager shall have the final responsibility for the implementation of the requirements of this Section 3.3.

3.3.2.2.2. Superintendent of Maintenance

The Superintendent of Maintenance shall be responsible for assuring the maintenance of station structures, systems and components.

41

3.3.2.2.3. Mechanical Maintenance Engineer

The Mechanical Maintenance Engineer shall be responsible for directing the performance of station maintenance activities affecting structures and mechanical equipment.

3.3.2.2.4. Instrument and Electrical Engineer

The Instrument and Electrical Engineer shall be responsible for directing the performance of station maintenance activities affecting instrumentation and electrical equipment.

3.3.2.3. Performance of maintenance

(a) Each nuclear station shall establish a Work Request system which applies the provisions of appropriate maintenance procedures to a specific main-tenance activity. The administration of this system shall be in accordance with Section 4.7. Maintenance shall be performed under the control of the Work Request system in accordance with written procedures (see Section 3.3.3) which conform to applicable codes, standards, specifications, criteria etc. Where appropriate, these procedures may reference sections of related approved drawings or vendor documents.

(b) For maintenance activity which affects the pressure boundary of systems or components classified as ASME Boiler and Pressure Vessel Code Class 1, 2 or 3, a Code Authorized Inspector shall be provided an opportunity to review the proposed activity prior to the beginning of work if required.

3.3.2.4. Preventive maintenance

Each nuclear station shall develop a preventive maintenance programme/schedule. The programme/schedule shall describe the type of maintenance to be performed and when the maintenance is to be performed. The preventive maintenance programme/schedule should be developed from manufac-turer's recommendations and past experience with similar types of equipment. The programme/schedule should be periodically updated during station life to reflect experience gained with equipment.

3.3.2.5. Equipment failures

In the event of the failure of equipment, the cause shall be evaluated; and equipment of the same type shall be evaluated as to whether or not it can be expected to continue to function in an appropriate manner.

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3.3.2.6. Replacement materials and components

Replacement material intended for use in maintenance of electrical and mechanical equipment shall be evaluated to assure conformance with applicable ratings and/or specifications.

If evidence indicates that components have performed unsatisfactorily or marginally, a replacement programme should be planned in advance of any large scale replacement. Replacement components should have received sufficient testing, or should be units with experience histories, from which it may be concluded that the probability of unsatisfactory performance is acceptable. An augmented in-service testing and inspection programme should be implemented until such time as a suita-ble level of performance has been demonstrated. In the case of components which have performed marginally, consideration shall be given to phased replacement to permit in-service performance of the new component to be evaluated and thereby minimize the possibility of a hidden deficiency producing a systematic failure.

3.3.2.7. Scheduling of maintenance

Maintenance shall be scheduled so as not to jeopardize station operation or the safety of a reactor or reactors. Planning shall consider the possible safety conse-quences of concurrent or sequential maintenance, testing or operating activities. Equipment required to be operable for the mode in which a reactor, or reactors, exists shall be available, and maintenance shall be performed in such a manner that a station's Technical Specifications, or other applicable licence or regulatory limits, are not violated.

3.3.2.8. Status of structures, systems and components

Structures, systems and components which are in an other than operable or normal status due to the performance of maintenance or due to failure to meet main-tenance requirements shall be identified as such in accordance with Section 3.1.3.

3.3.3. PROCEDURES

3.3.3.1. Maintenance Procedures and Temporary Maintenance Procedures

Where appropriate, Maintenance Procedures should be written early in station life for maintenance activities which are expected to be of a recurring nature. As experience is gained in operation of the station, existing Maintenance Procedures shall be upgraded, consolidated or deleted, and additional Maintenance Procedures developed as necessary.

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Temporary Maintenance Procedures may be used, where appropriate, for maintenance activities which are of a non-recurring nature. Examples of such uses are:

(a) To direct special maintenance activities, e.g. infrequent replacement of major items, implementation of station modifications etc.

(b) To provide guidance in unusual situations not within the scope of Maintenance Procedures.

Maintenance Procedures and Temporary Maintenance Procedures shall be sufficiently detailed that qualified workers can perform the required functions without direct supervision. Written procedures, however, cannot address all contin-gencies and Maintenance Procedures and Temporary Maintenance Procedures, therefore, should contain a degree of flexibility appropriate to the activities for which each is applicable.

The administration of Maintenance Procedures and Temporary Maintenance Procedures shall be in accordance with Section 4.2 and Section 4.3, respectively, and the following items shall be considered in the preparation and review of these procedures:

(a) Title

Each procedure shall contain a title descriptive of the maintenance to be performed.

(b) Purpose

The purpose for which the procedure is intended shall be stated. This statement of applicability should be as clear and concise as practicable.

(c) References

Reference should be made to that specific material necessary in the preparation and performance of the procedure. This should include applicable drawings, instruc-tion manuals, specifications, sections of the station's Final Safety Analysis Report (FSAR) and Technical Specifications, etc. These references should be listed in a manner as to allow ready location of the material. References should be given by both the utility and vendor designations where appropriate.

(d) Personnel requirements

Procedures should specify, as applicable, any special qualifications of personnel required for the maintenance action. Manpower and time estimates for performance of a maintenance activity should be included in the procedure or as part of each applicable Work Request.

44

(e) Safety considerations

General safety requirements should be included in the procedure and detailed information should be either included or referenced in the procedure or each applicable Work Request.

(e.l) Equipment clearance and isolation

Permission to release equipment for maintenance shall be granted by the responsible Shift Supervisor. Prior to granting permission, the Shift Supervisor shall verify that the equipment can be released and, if so, how long it may be out of service. The granting of permission by the Shift Supervisor shall be documented. (When one subsystem of a redun-dant safety system has been removed for maintenance, particular attention should be given to the potentially degraded degree of protection.)

After permission has been granted to remove equipment from service, it shall be made safe to work on. Measures shall provide for protection of equipment and workers. Equipment in a controlled status shall be clearly identified. Strict control measures of such equipment shall be enforced. Physical barriers shall be provided as required. Adequate provisions shall be made to allow for documentation equipment isolation.

Conditions to be considered in preparing equipment for maintenance include, for example, shutdown margin; method of emergency core cooling; establishment of a path for decay heat removal; temperature and pressure of the system; separation of work and hazardous material; venting, draining and flushing; entry into closed vessels; hazardous atmospheres; handling hazardous materials; and electrical hazards.

Procedures may contain checklists (normally as enclosures) of positions of valves, breakers, etc. necessary for the equipment to be safe to work on. Using these checklists, personnel performing maintenance may verify the safe condition of the equipment on which the maintenance is to be performed.

(e.2) Health physics considerations

Maintenance actions shall be reviewed for health physics con-siderations. If a Radiation Work Permit is issued, maintenance personnel should be cognizant of its requirements.

(e.3) Special safety,considerations

Precautions shall be specified, as appropriate, which alert the individual performing the task of those situations for which important

4 5

measures need to be taken early or where extreme care must be used to protect personnel and equipment or to avoid an abnormal or an emergency situation.

(f) Station (or unit) status

The procedure shall identify the station or unit status necessary to perform the specified maintenance. Appropriate provisions shall be made to document compliance with the status specified.

(g) Prerequisites

Each procedure shall list those items which are to be completed and those con-ditions which are to exist prior to performing the specified maintenance. Appropriate provisions shall be made to document compliance with the prerequisites listed.

(h) Repair parts

Each procedure should list the repair parts known or anticipated to be required in performing the specified maintenance. The procedure should at least specify those parts necessary to restore the equipment to its 'as found' condition following maintenance. Spare parts should be listed by name, drawing and piece number, stock identification, etc., as appropriate. Repair parts may be identified in the procedure as well as in the applicable Work Request(s) (i.e. a general description of parts required in the procedure with identification of parts by stock number, piece number, etc., for a specific job in the applicable Work Request). Adequate provision should be made to allow for documenting what parts were used and any additional information necessary to determine where each part was installed.

(i) Special tools

Each procedure should contain a listing of special tools known or anticipated to be required in performing the specified maintenance. Such tools as lifting gear, protective covers, stud tensioners, seal welding machines, etc., should be included as appropriate. Procedures may contain information and/or references for the listed special tools such as calibration requirements, instruction manuals or procedures, etc.

(j) Acceptance requirements

Each procedure shall specify the standards for the acceptability of the equip-ment upon which maintenance has been performed. This may include a listing of testing and inspection requirements such as hydrostatic testing, cleanness inspec-tion, etc. References should be made to procedures for performing these tests and inspections as appropriate.

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(k) Interference item

Attention should be given to the removal and replacement of any interference items which could significantly add to the radiation exposure, manpower or outage time involved in the particular maintenance activity.

(1) Procedure

This section shall contain directions in the degree of detail necessary for quali-fied personnel to perform the required maintenance without direct supervision. References to documents other than the subject procedure should be included as applicable. References shall be identified within these directions when the sequence of steps requires that other tasks (not specified by the subject procedure) be performed prior to or concurrent with the procedure step. For procedures which require tests or inspections prior to continuation of the maintenance sequence, hold points shall be incorporated into the procedure and adequate provisions made to allow documentation of compliance with the specified tests or inspections. Cautionary notes, applicable to specific steps, shall be included, as appropriate, and should be distinctly identified. Additional explanatory information may be included in the applicable Work Request for a particular maintenance action.

(m) Restoration

Each procedure should contain information as to the steps necessary for returning the equipment to an operating status. Operating personnel shall place the equipment in service and verify and document its operational acceptability or unac-ceptability. When placed back into service, the equipment may require special surveillance initially during a run-in period.

(n) Enclosures

Diagrams, drawings, photographs, checklists, etc., should be attached to a procedure as appropriate. In particular, checklists should be utilized to avoid or simplify lengthy or complex procedures and be attached as enclosures.

3.3.3.2. Instrument Procedures and Temporary Instrument Procedures

Where appropriate, Instrument Pocedures should be written early in station life for instrument related activities which are expected to be of a recurring nature. As experience is gained in operation of the station, existing Instrument Procedures shall be upgraded, consolidated or deleted, and additional Instrument Procedures developed, as necessary.

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Temporary Instrument Procedures may be used, where appropriate, for instrumentation related activities which are of a non-recurring nature. Examples of such activities are:

(a) To direct special instrumentation related activities; e.g. implementation of station modifications, testing following station modifications, etc.

(b) To provide guidance in unusual situations not within the scope of Instrument Procedures.

Instrument Procedures and Temporary Instrument Procedures shall be suffi-ciently detailed that qualified workers can perform the required functions without direct supervision. Written procedures, however, cannot address all contingencies, and Instrument Procedures and Temporary Instrument Procedures, therefore, should contain a degree of flexibility appropriate to the activities for which each is applicable.

The administration of Instrument Procedures and Temporary Instrument Procedures shall be in accordance with Section 4.2 and Section 4.3, respectively, and the following items shall be considered in the preparation and review of these procedures:

(a) Titie

Each procedure shall contain a title descriptive of the activities to be performed.

(b) Purpose

The purpose for which the procedure is intended shall be stated. This statement of applicability should be as clear and concise as practicable.

(c) References

Reference should be made to that specific material necessary in the preparation and performance of the procedure. This should include applicable drawings, instruc-tion manuals, specifications, sections of the station's FSAR and Technical Specifica-tions, etc. These references should be listed in a manner as to allow ready location of the material. References should be given by both the utility and vendor designa-tions where appropriate.

(d) Test equipment

Each procedure should contain a listing of special test equipment known or anticipated to be required in performing the specified activities. Test equipment should be listed by type and model number. Procedures may contain information and/or references for the items listed such as instruction manuals or procedures, etc.

48

(e) Prerequisites

Each procedure shall specify those conditions that must be met prior to perfor-mance of the activities specified by the procedure. Appropriate provisions shall be made to document verification of compliance with the prerequisites specified.

(f) Limits and precautions

Limits on parameters being controlled and corrective measures necessary to return a parameter to its normal control band shall be specified as appropriate. Where appropriate, quantitative control guides shall be provided; for example, an appropriate step of a procedure should say, "Manually adjust output to maintain X ± Y volts", rather than "Manually adjust output to maintain voltage."

Precautions shall be specified, as appropriate, which alert the individual per-forming the task to those situations for which important measures need to be taken early or where extreme care must be used to protect personnel and equipment or to avoid an abnormal or an emergency situation.

(g) Required station (or unit) status

The procedure shall specify the station or unit status necessary to perform the required activities. Appropriate provisions shall be made to document compliance with the status required.

(h) General description

Each procedure should contain a brief descripton of the operation of the overall instrumentation system for which the procedure is applicable.

(i) Major components

Each procedure may contain a description of the major instrumentation compo-nents for which the procedure is applicable. This should include any appropriate references where additional information can be found.

(j) Equipment specifications

Each procedure should contain instrument specifications appropriate to the specified activities. These specifications may include operating ranges, normal and alarm setpoints, computer inputs, etc.

(k) Procedure

This section shall contain directions in the degree of detail necessary for qualified personnel to perform the required activity without direct supervision. References to documents other than the subject procedure should be included as

4 9

applicable. References shall be identified within these directions when the sequence of steps requires that other tasks (not specified by the subject procedure) be performed prior to or concurrent with a procedure step. For procedures which require authorization prior to continuation of the procedure sequence, hold points shall be incorporated into the procedure and adequate provisions made to allow documentation of the specified authorization. Cautionary notes, applicable to specific steps shall be included, as appropriate, and should be distinctly identified. The procedures shall also contain information neccessary for returning affected items to an operable status and appropriate requirements for verifying and documenting operational acceptability or unacceptability. Additional explanatory information may be included in the applicable Work Request(s) for a particular activity.

(1) Enclosures

Data sheets, checklists, diagrams, etc. should be attached to a procedure, as appropriate. In particular, checklists should be utilized to avoid or simplify lengthy or complex procedures and be attached as enclosures.

3.3.3.3. Temporary Procedures for Implementation of Modifications

As deemed appropriate, a Temporary Procedure for Implementation of a Modification may be used for implementation of a station modification. Such a procedure shall be sufficiently detailed that qualified workers can perform the required functions without direct supervision. Written procedures, however, cannot address all contingencies and should therefore contain a degree of flexibility appropriate to the activities for which each is applicable.

The administration of each Temporary Procedure for the Implementation of a Modification shall be in accordance with Section 4.3, and the following items shall be considered in the preparation and review of each procedure.

(a) Titie

Each procedure shall contain a title descriptive of the activities to be performed.

(b) Purpose

The purpose for which the procedure is intended shall be stated. This statement of applicability should be as clear and concise as practicable.

(c) References

Reference should be made to that specific material necessary in the preparation and performance of the procedure. This should include applicable drawings,

50

instruction manuals, specifications, sections of the station's FSAR and Technical Specifications, etc. These references should be listed in a manner as to allow ready location of the material. References should be given by both the utility and vendor designations where appropriate.

(d) Tools and/or test equipment

Each procedure should contain a listing of special tools and/or test equipment known or anticipated to be required in performing the specified activities. Equipment should be listed by type and model number. Procedures may contain information and/or references for the items listed such as instruction manuals or procedures, etc.

(e) Personnel requirements

Each procedure should specify, as applicable, any special qualifications of personnel required to implement the subject modification. Manpower and time esti-mates for performance of the activity should be included in the procedure or as part of the applicable Work Request(s).

(f) Prerequisites

Each procedure shall specify those conditions that must be met prior to perfor-mance of the activities specified by the procedure. Appropriate provisions shall be made to document verification of compliance with the prerequisites specified.

(g) Limits and precautions

Limits on parameters being controlled and corrective measures necessary to return a parameter to its normal control band shall be specified as appropriate. Where appropriate, quantitative control guides shall be provided; for example, an appropriate step of a procedure should say "Manually adjust output to maintain X ± Y volts", rather than "Manually adjust output to maintain voltage."

Preçautions shall be specified, as appropriate, which alert the individual performing the task to those situations for which important measures need to be taken early or where extreme care must be used to protect personnel and equipment or to avoid an abnormal or an emergency situation.

(h) System or component status

For system and/or components affected by the subject modification, the proce-dure shall specify the required status. Appropriate provisions shall be made to document compliance with the status required.

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(i) Procedure

This section shall contain directions in the degree of detail necessary for quali-fied personnel to perform the required activity without direct supervision. References to documents other than the subject procedure should be included as applicable. References shall be identified within these directions when the sequence of steps requires that other tasks (not specified by the subject procedure) be per-formed prior to or concurrent with a procedure step. For procedures which require authorization prior to continuation of the procedure, hold points shall be incorpo-rated into the procedure and adequate provisions made to allow documentation of compliance with the specified authorization. Cautionary notes, applicable to specific steps, shall be included as appropriate, and should be distinctly identified. The procedure shall also contain information necessary for returning affected items to an operable status and appropriate requirements for verifying operational acceptabil-ity or unacceptability. Additional explanatory information may be included in the applicable Work Request(s) for a particular activity.

(j) Enclosures

Data sheets, checklists, diagrams, etc. should be attached to a procedure, as appropriate. In particular, checklists should be utilized to avoid or simplify lengthy or complex procedures and be attached as enclosures.

3.3.4. INDEPENDENT VERIFICATION

Each Instrument and Maintenance Procedure, both temporary and permanent, and each Temporary Procedure for Implementation of a Modification shall provide for Independent Verification, upon removal from service and restoration to service, of those components which could affect the ability of a system to perform a safety related function. Independent Verification shall also be included in procedures for implementing modifications that affect equipment which, if improperly aligned, could result in the release of radioactive liquids or gases from the station. Independent Verification shall be documented.

3.3.5. DOCUMENTATION

Equipment histories shall be maintained on the station's QA Condition structures, systems and components. These histories shall contain a description of maintenance performed and sufficient documentation to assure identification of any replacement parts used. These records shall be identifiable and retrievable and shall be retained for six (6) years, or for the service life of the particular item(s) for which the records are applicable, whichever is greater. Completed Work Requests may be used in part for this documentation provided the procedures utilized in performing the work are identified in the Work Request.

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EXAMPLE 2

TRAINING FACILITY FOR MAINTENANCE PERSONNEL

(Section 3.3.4.3)

This example is a brief summary of the facilities and programme at a training centre for maintenance personnel as operated by one Operating Organization in Japan.

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M A J O R TRAIN ING COURSES

• C O M M O N

T R A I N I N G FACILITIES T R A I N I N G D E S C R I P T I O N

NDT EQUIPMENT

0 METAL MICROSCOPE 0SAMPLE POLISHER 0 PENETROMETER ONDT TOOLS

1 SET 1 UNIT 1 UNIT 1 SET

NDT OF METAL SURFACE AND

VOLUME

# M E C H A N I C A L

T R A I N I N G FACILIT IES T R A I N I N G D E S C R I P T I O N

REACTOR VESSEL 0 REACTOR VESSEL HEAD 1 UNIT DISASSEMBLY,ASSEMBLY AND INSPECTION OF THE VESSEL HEAD AND ITS ATTACHMENT

STEAM

GENERATOR

0 PRIMARY SIDE CHANNEL HEAD 0 TUBE EXAMINATION

EQUIPMENT.

0 STEAM CENERATOR MANIPULATOR

1 UNIT

1 SET

1 SET

WORK INSIDE STEAM GENERATOR PRIMARY SIDE CHANNEL HEAD (MAINLY EDDY CURRENT TEST)

MAIN COOLANT PUMP

OPUMP SHAFT SEALS 1 SET DISASSEMBLY,ASSEMBLY AND INSPECTION OF MAIN COOLANT PUMP SHAFT SEAL ASSEMBLIES

FUFL MANIPULA

-TOR CRANEANO

OTHERS

OFUEL MANIPULATOR CRANE

0 DUMMY FUEL AND NFBC

0 HANDLING TOOLS OF FUEL

AND NF8C*

OFUEL LOADING SIMULATOR

1 UNIT

1 SET

1 SET

1 UNIT

FUEL HANDLINC OPERATION

( UNLOADING AND LOADING

OF FUEL AND

NFBC* REPLACEMENT)

SMALL AUXILIARY

PIPES OF

THE LOOP SYSTEM

ROOM

0PUMPS:VERTICAL PUMP

HORIZONTAL PUMP

CANNED PUMP

OVALVES(IOTYPES)

0 INSTRUMENTS! 4 TYPES)

0 SUPPORTING STRUCTURES

1 UNIT

1 UNIT

2 UNITS

20 UNITS

8 UNITS

2 UNITS

DISASSEMBLY,ASSEMBLY AND

INSPECTION OF PUMPS AND

VALVES.

* Non-fuel-bearing components.

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ELECTRICAL & INSTRUMENTATION

T R A I N I N G FACILITIES T R A I N I N G D E S C R I P T I O N

SWITCHCEARS OMETALCLAD

0 POWER CENTRE

0 CONTROL CENTRE

2 BOARDS

2 BOARDS

1 BOARD

DISASSEMBLY,ASSEMBLY AND

INSPECTION OF SWITCHGEARS

MAIN COOLANT

PUMP MOTOR

0 MOTOR FLYWHEEL

OOIL COOLER TUBING

0 UPPER BEARING

1 UNIT

1 UNIT

1 UNIT

DISASSEMBLY AND ASSEMBLY

OF THE BEARING AND NON-

DESTRUCTIVE TEST OF FLYWHEEL

CONTROL-ROD

DRIVE MECHANISM

0 ELECTRICAL CONTROL DEVICE

0 POSITION INDICATOR

ASSEMBLY

1 SET

1 SET

ADJUSTMENT AND TESTOF

ELECTRIC CONTROL CIRCUITS

CONTROL BOARDS

AT CENTRAL

CONTROL ROOM

0 PROTECTION AND CONTROL

RACKS.

0 EX-CORE NUCLEAR

INSTRUMENTATION

4 BOARDS

1 SET

ADJUSTMENT AND TEST OF

VARIOUS PROTECTION AND

CONTROL ASSEMBLIES

LOCAL INSTRUMENTS

0 TRANSMITTER (WATER LEVEL, PRESSURE, FLOW VOLUME )

5 SETS ADJUSTMENT AND TESTOF

SUCH LOCAL

INSTRUMENTS AS

PNEUMATIC INSTRUMENT

AND CONTROLLERS

LOCAL INSTRUMENTS

0 CONTROLLER OOTHER INSTRUMENTS

1 SET

ADJUSTMENT AND TESTOF

SUCH LOCAL

INSTRUMENTS AS

PNEUMATIC INSTRUMENT

AND CONTROLLERS

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EDUCATION AND TRAINING PROGRAM AT THIS CENTRE

SERVICE YEARS

E O U C A T I O N * ^ ^

1 2 3 A 5 6 7 8 9 10 n 12 13 14 15 16 17 18 19- No. OF DAYS

SY

STE

MA

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SY

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(MATURITY) 1 to

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(MASTERY) I

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TECHNIC Al MANACt-MfNT EDUCATION

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QC EOUCATION /BASIC,MIDDU. \ UENIOK CLASSES/ m

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SY

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SMCIAITY EDUCATON

O N VARIOUS MAINTENA-

NCE TECHNIQUES

AVERACE 5 SMCIAITY EDUCATON

O N VARIOUS MAINTENA-

NCE TECHNIQUES

AVERACE 5 SMCIAITY EDUCATON

O N VARIOUS MAINTENA-

NCE TECHNIQUES (MAIN COOLANTPUMP.NDTetC. )

1 1 I I 1 ! I ! 1 1 1 1 1 1

AVERACE 5

5 7

MAJOR MAINTENANCE W O R K SCHEDULE IN A N N U A L

PROGRAM A N D PRACTICAL TRAINING A T THIS CENTRE

PRACTICAL TRAINING

58

EDUCATION A N D T R A I N I N G P L A N A T T H E CENTRE

FISCAL

N . YEAR

EDUCATION

1983 (3 .4Q) 1984 1985 FISCAL

N . YEAR

EDUCATION

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(ID 1 35 1050 2 40 1200 2 42 1260

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(III) 3 45 900 3 73 1460

SY

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SPECIALTY EDUCATION 2 34 340 3 59 590

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APPLIED EDUCATION 2 27 135 2 44 220

SY

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1 20 60 1 25 75

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IC

ED

UC

AT

ION

PR

OG

RA

M

SUBTOTAL 6 162 2662 14 268 3880 15 343 4465

SPEC

IALT

Y ED

UC

ATI

ON

O

N V

AR

IOU

S M

AIN

TEN

AN

CE

TEC

HN

IQU

ES

MECHA-NICAL 5 32 128 9 46 265 9 53 309

SPEC

IALT

Y ED

UC

ATI

ON

O

N V

AR

IOU

S M

AIN

TEN

AN

CE

TEC

HN

IQU

ES

ELECT-RICAL 2 10 45 4 17 64 4 20 70

SPEC

IALT

Y ED

UC

ATI

ON

O

N V

AR

IOU

S M

AIN

TEN

AN

CE

TEC

HN

IQU

ES

INSTRU-MENTA-TION

3 14 70 5 25 102 5 26 106

SPEC

IALT

Y ED

UC

ATI

ON

O

N V

AR

IOU

S M

AIN

TEN

AN

CE

TEC

HN

IQU

ES

SUBTOTAL 10 56 243 18 88 431 18 99 485

TO T A L 16 218 2905 32 356 4311 33 442 4950

59

EXAMPLE 3

WORK ORDER/DEFECT REPORT

(Section 4.3.4)

This example contains a translation of a work order/defect report as adopted by an Operating Organization in the Federal Republic of Germany.

61

WORK ORDER No.

System No.

Descr ipt ion ot the delect

Room No. - Cell No. Un i t N o . .

Determined Dale. Time. Signature

noted Shift supervisor. Operations management

Performed by

Work to be per formed

Number of persons Man-hours

Requirements

Isolat ion

Work f l o w chart

Repair repor t

Ad jus tment /Tes t ing required

Yes No Urgency« © ( Ï Ï ) ( Ñ ) ( Ô )

Cost i tem

Isolat ion requirement No.

I o

Collect ive dose > 5 man- rem YesQ NoQ

Radiat ion p ro tec t ion at wo rk pos i t ion : con t i nuous /no t cont inuous

Extra protect ive c loth ing

Breathing apparatus

Dose l im i ta t i on mrem/man-day

Indiv idual d o s e > 1 rem Yes • No Q

Dose warn ing inst rument , l im i t - . m R -

Radiat ion p ro tec t ion w o r k f l ow chart required

Dose rate before w o r k / d u r i n g wo rk

Aerosol ac t iv i ty before w o r k / d u r i n g w o r k

Contaminat ion before w o r k / d u r i n g w o r k

A i r /wa te r measurement: iod ine/noble gas/n-dose rate

Work ing pos i t ion: shielding/suct ion/shoe change

Othßr

ï l

Measures determined

Date Signature .

Work posi t ion indoc t r ina t ion and cleared Work completed

- Date Signature Date Signature -

Special safety precaut ions

High temperature w o r k permission required

Guard required at wo rk posi t ion Yes No No

Clearance f r o m .

Date/Signature Maintenance supervisor

Radiat ion pro tec t ion

Secur i ty and industr ia l safety

Operat ions management

extended un t i l

Indoc t r ina t ion by electrical group

mechanical group

Accepted and responsible at w o r k pos i t ion Narne-

WORK C L E A R A N C E T ime -

Extended (Date/Signature)

Ready for per formance testing

Performance tested and isolated state restored

Date .

Date .

Date .

Date •

Signature .

Signature .

Signature .

Signature •

Clearance for per formance testing

W o r k clearance for remaining wo rk

• Sh i f t supervisor

Work completed

Tested b y / f o r

Maintenance supervisor

Date .

Date .

T ime -

T ime _

Signature -

S igna tu re .

Immedia te ly ( Û ) Urgent ( Ï Ï ) Next o p p o r t u n i t y ( Ô ) Next outage

63

EXAMPLE 4

ISOLATION TAGS

(Section 4.3.9)

This example contains (a) copies of an isolation tag and an isolation sticker as adopted by one Operating Organization in the USA, (b) a control room isolation tag checklist as adopted by another Operating Organization in the USA, (c) an English translation of an isolation tag adopted by one Operating Organization in the Federal Republic of Germany, and (d) an English translation of isolation stickers adopted by another Operating Organization in the Federal Republic.

65

E X A M P L E 5(e)

® Tag ordered by

Tag put on by

Date T i m e .

Placement verified by

Tag removed by

Date . Time .

Ordered removed by

TO #

W R #

EQUIP _

T A G G E D .

REASON.

POS TAGGED . SUPERVISOR RES WORK

TO # _

WR # .—

EQUIP _

T A G G E D .

LOC

Completed date —

Signed

Tag # .

Tag # -

. Time .

©

DANGER THIS EQUIPMENT

MUST NOT BE OPERATED

UNTIL THIS TAG HAS BEEN PROPERLY REMOVED

Remarks

No.-No.. No..

67

E X A M P L E 5(e)

DATE:

EQUIPMENT CLEARED:

E Q U I P M E N T C L E A R A N C E A N D R E L E A S E O R D E R

— ORDER NUMBER: PAGE . OF .

PREPARED BY:

MWR NUMBER: INDEPENDENT VERIFICATION REQUIRED: Y e s Q N o Q

LOCATION DESIRED POSITION

TAGS PLACED

BY VERIFIED

BY NORMAL POSITION

RETURNED TO

NORMAL BY

VERIFIED BY

REMARKS:

CLEARANCE ISSUED TO: CLEARANCE RELEASED BY:

SIGNATURE BADGE

NUMBER DATE TIME SIGNATURE DATE TIME

EQUIPMENT REMOVAL FROM SERVICE GRANTED BY:

START WORK AUTHORIZED BY:

TAGS REMOVED AND EQUIPMENT RETURNED TO SERVICE:

DATE:

DATE:

DATE:

TIME

TIME

TIME

68

E X A M P L E 4 ( c )

Danger! Do not operate!

Isolation Mechanical circuit

Isolation book No

Component No

Operating condition before isolation: O p e n / C l o s e d

Isolat ion status:

Reason

Date Signature

E X A M P L E 5(e)

Cont ro l r o o m actuator

Ins t rument rack

Add i t iona l use such as fuse, c i rcui t -breaker , or local actuator

C o m p o n e n t

Tag contro l book

Isolation No. Sheet No. — Comp. No. -

Serial No.

Name

D o

Isolation No. Sheet No Comp. No. -Circuit No. -Process control system

Shift_sugeryisor_

n o t o p e r a t e

. Serial N o . -

operational Q

non-operational O

earthed O

simulated Q

Name Shi f t supervisor

D o n o t opera te

Isolation No Sheet No Serial No— Comp. No. Ac t iv i t y

Name Shi f t supervisor

D o n o t opera te Isolation No Sheet No Serial N o . . Comp. No.

open closed

Maintenance posi t ion Q Q

Normal posi t ion Q Q

Name _Shif t sugeryisor_

Isolation No. . Sheet No Comp. No. —-

. Serial No.

Process /^n contro l operational l _ ; o p e n s y s , e m non -ope ra t i ona l OclosedO

earthed Q

simulated Q

Name Shi f t supervisor

7 0

EXAMPLE 5

INDIVIDUAL PERMISSIONS FOR SOME TYPES OF WORK

(Section 4.3.10)

This example contains English translations of permission forms for: (a) isola-tion, (b) confined spaces, (c) fire hazard areas (2 pages), (d) radiation controlled areas (2 pages), and (e) radiation controlled areas (2 pages). Items (a) through (d) are as adopted by one Operating Organization in the Federal Republic of Germany and item (e) is as adopted by one Operating Organization in Czechoslovakia.

71

E X A M P L E 5(e)

73

E X A M P L E 5(e)

Unit :

Safety Precaution Form ACCESS PERMISSION

flrrtpr Nn

System No. .

Isolation No. Isolation must be suitable for access

Text:

Building Component

^ Media, vessels, rooms

Safety precautions

v

A B C 0 E F G H 1 Other

^ Media, vessels, rooms

Safety precautions

v W

ater

Ste

am

o Aci

d/A

lka

li

Sol

vent

Unv

entil

ated

ro

om

! S

hafts

/pits

Rev

olvi

ng p

arts

Gas

es

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Cleaning X X X

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Rinsing w i th X

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

A ir analysis expl

-toxic (mpc)

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

A ir analysis expl osive (<50% f lamihi l i ty l imi t ) 0 O

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Ar t i f ic ia l vent i lat ion X X X

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Low voltage/isolation transformers X X X X X X X

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Venti lation-dependent breathing protect ion X X X

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Special protective clothing 0 0 X X O O

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Observer X X x X X X X

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Safety rope Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Fire protect ion X X x X X X X

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

No smoking X X x X X X X

Saf

ety

prec

autio

ns w

hen

ente

ring/

acce

ssin

g d

uri

ng

wo

rk

Prevent movement 0 O O o o X

Foreman/Dept. • a t e Time Signature Access permission granted

Prescribed precautions noted (Work leader at work posit ion)

Analycic valnpc tnv p»'

Precaution suff icient according to analysis

Clearance fire brigade

Access permission cancelled and local precautions cancelled (Work leader at work posit ion)

Other/Remarks/Special measures

1 X 1 = necessary | 0 | = not necessary | | = may be necessary

74

E X A M P L E 5(e)

75

- J Os

NO WELDING!

during power operat ion in the fo l low ing rooms:

UNIT A UNIT B

Room No. Room No.

Switchgear building + 8 m switch distr ibutor

Switchgear bui lding + 12 m switch room

Switchgear building + 12 m computer room

Switchgear building + 12 m neutron f lux measurement

3423

3521

3523

3527

Switchgear bui ld ing + 8.80 m all switchgear rooms (except offices)

Switchgear bui ld ing + 12.95 m all switchgear rooms (except offices)

0 4 0 1 -0435

0 5 0 1 -0535

Reactor bui ld ing 21 m p la t fo rm

The prohib i t ion of welding on the 21 m plat forms in the reactor buildings

can be restricted or cancelled after consul tat ion w i th the Technical Department.

Notes:

1. The fo l lowing precautions must be taken whenever work involving naked flames is carried ou t :

1.1. Clear space

1.2. Cover

1.3. Insulate

1.4. Mount f i re watch

1.5. Check repeatedly

2. In the case of electric welding the welding earth should be connected to the part being welded at a point as close by as possible (max. 3 m).

(Possible interference w i t h measurement lines and sensors by electromagnetic fields.)

3. In the case of inert-gas shielded arc welding, the actual work should be preceded by a brief tr ial during which contact should be maintained w i th the contro l room by telephone.

E X A M P L E 5(e)

S a f e t y P r e c a u t i o n F o r m

System/Component

Uni t : R A D I A T I O N P R O T E C T I O N P E R M I S S I O N

Uni t : Svstem No.

Executing Radiation protect ion Date

Dept. Order No. Room No. clearance required rrom: y [ m B

G Mask • Compressed air breathing apparatus • Plastic suit

• Shielding ' ~

D Lead mats

• Lead bricks

• Concrete bricks

• Partitions S ? o 'z: c =j

•S-o

• Complete protect ion suit

Thickness Remarks

• Dose rate - max. expected value

O Decontamination: O before • during

• Component closed

O Component open

approx. appro*.

m- rem/h m r e m / h

• after work

Personal protection equipment

• Texti le gloves • Cap/hood

O Rubber gloves • Goggles

• Rubber boots

• Paper suit

Eg ! » 8 3

£ S O) — J3 O

Radiation protection measures a) Measurements

• Dose rates O Neutrons • 7 + 0

• Noble gas activity • Contamination measurement

• Aerosol activity • Iodine activity

b) Addit ional dosimeters

CD Addi t ional dosimeters as indicated in Section 4.

c) Radialion protection monitor ing

• continuous • cyclic • once before starting work • r Remarks:

Radiation protection off icer: Date Name (pr im in capitals) Signature

Deviations

• none Q carried out the fol lowing changes: Q addit ional measures fixed as fol lows:

Radiation protection clearance form: Date Signature

granted: Signature (Rad, prot. grp.)

Safety precautions noted (Work leader at work posit ion): Date Signature (Work leader at work position}

Work commenced: t i m e ~ Signature (Work leai.ier at work position)

Work ended: Signature (Work leader at work position)

see over V 4 N 1 3 2 2

77

Daily clearance for work by radiation protect ion group

Date Time Commencement of work

Work leader at work posit ion Signature

Radiation protect ion group Signature

V4N1322

78

E X A M P L E 5(e)

ORDER "R" No:

1. For Date Time Foreman of working group

Location of work (Unit, Floor, Room)

Order for the following work to be performed:

Members of the working group

Name No. of dosimeter Signature

The order was issued

By Date Time

Signature

(Print)

2. I permit the work to be done under the condition

Signature of Shift Chief Engineer

3. Permitted duration of work per one worker.

Radiational situation:

Time

Gamma exposure

Neutron exposure

Concentration of airborne contamination

Concentration of rad gases

Beta surface contamination

Prescribed protection appliances: rubber gloves, cotton gloves, respirator,

gaiters, rubber boots, goggles, hood, helmet, rubber apron, protection suit,

hermetic protection suit

79

Additional precautions of rad. safety

Signature of shift dosimetrist

4. Instruction on radiation safety and on usage of protection appliances given on:

Date at Time The members of working group acknowledge the

receipt of instruction by their signatures in Heading 1.

Signature of work foreman

5. I confirm by my signature that I am aware of all conditions for performing a

job given in Headings 2. and 3. of this Order.

Signature of work foreman

6. I allow work on Date at Time

Signature of equipment responsible engineer

7. The work was carried out from to hours.

Net working time

Protection appliances and personal dosimeters have been returned. The work-

ing area has been cleaned up, decontamined, rubbish removed.

Equipment responsible engineer

Signature of shift dosimetrist

Foreman of working group

8. Closing of order at hour min.

Level of contamination at working area after accomplishment of work

Individual doses

No. of dosimeter Dose No. of dosimeter Dose

Signature of Shift Dosimetrist,

80

EXAMPLE 6

SUMMARY OF A PROCEDURE FOR THE CONTROL OF MODIFICATIONS

(Section 4.4.6)

This example is a summary of the procedure adopted by one Operating Organization in the United Kingdom.

81

SUMMARY OF A PROCEDURE FOR THE CONTROL OF MODIFICATION

1. Each modification proposal is referred in the first place to the Station Manager concerned. If the Station Manager wishes to proceed with the proposal he decides whether the modification proposal shall initially be treated under this Procedure as Category I, II or III in accordance with the criteria set out at Section 2 below. In making this decision, the Station Manager may if he wishes consult any Headquarter Department or Division from which a Nuclear Safety Committee member has been nominated.

2. For the purpose of obtaining safety clearance, each proposed modification is placed in one of the following categories:

Category I — A modification affecting nuclear safety which, if inadequately conceived or executed, might lead to a serious increase in the risk of radiologi-cal hazard; or which involves significant alteration to the principles on which safety arguments have been based.

Category II — A modification affecting nuclear safety which, if inadequately conceived or executed, might lead to a significant but less serious increase in the risk of radiological hazard, and which involves no significant alteration to the principies on which safety arguments have been based.

Category III — A modification which could not lead to a significant increase in the risk of radiological hazard.

3. A Category I modification requires endorsement by the Nuclear Safety Committee and agreement by the Regulatory Body before it may be put into effect. The procedure for obtaining the necessary safety clearances is set out below.

A Category II modification requires agreement by Headquarters Departments and Divisions before it may be put into effect, with retrospective report to the Nuclear Safety Committee and Regulatory Body.

A Category III modification requires no safety clearance off site.

4. The safety submission is distributed in the first place for consideration by the Departments and Divisions from which Nuclear Safety Committee members have been nominated. If the proposal is submitted as Category I but all Safety Committee members consider that it might have been placed in Category II, the proposal may be referred back to the Station Manager for reconsideration of the category.

5. The safety submission includes adequate detail for the safety of the plant as modified to be properly assessed; the amount of detail required will vary from case to case, depending on the safety significance of the proposal.

83

The safety submission would include details of inspections and tests to be carried out during and on completion of the modification (including, when appropri-ate, inspections and tests during manufacture), to confirm that the modification has been properly executed, that the modified plant operates as intended, and that there is no interference with other parts of the plant.

6. On completion of examination in accordance with the procedures set out in Section 3 above, each Category I modification proposal is referred to the Nuclear Safety Committee. The Committee will ensure that the principles on which the safety arguments are based are sound and that adequate demonstration of safety has been provided in every area having nuclear safety significance. If satisfied, the Committee will endorse the proposal. Endorsement may, if appropriate, be subject to qualifications or conditions.

7. In the case of a Category II modification proposal, if the Headquarters Departments and Divisions agree that the propsal is satisfactory from the point of view of safety and falls in Category II, the Station Manager is so informed and the modification may be put into effect subject to any qualifications or conditions of the agreement.

As soon as practicable after this agreement, a report will be made to the Nuclear Safety Committee giving brief details of the modification and informing the Committee that it has been agreed under the Category II procedure. On receiving this report, if any member of the Committee thinks that the proposal should more properly have been classified as Category I, he may call for additional details and, if he so wishes, for further discussion in Committee.

A copy of the report made to the Nuclear Safety Committee and the Minutes relating thereto will be passed to the Regulatory Body.

8. As appropriate, a Category I or II modification will be subject to an indepen-dent design assessment. Such an assessment must be made by an agency other than the staff of the station concerned or the group primarily responsible for the design of the modification.

9. Category III modifications are subjected to independent review as specified by the Station Manager. A record of all such modifications is maintained on the station and shall be available for inspection. Periodic checks are made to ensure the correct-ness of the decision to include such items in this category.

10. The Station Manager issues a station procedure with nominated responsiblities to ensure that the modification procedure is applied correctly and expeditiously to all appropriate station activities.

84

EXAMPLE 7

PROCEDURES FOR THE COMPILATION OF MAINTENANCE INSTRUCTIONS

(Section 4.5)

This example contains (a) a copy of a procedure for preparation and control of maintenance procedures as adopted in one Operating Organization in the USA and (b) a copy of instructions for preparing maintenance instructions in one Operating Organization in India. In the Indian example, maintenance instructions are referred to as maintenance manuals. The texts of these documents have been edited slightly to eliminate terminology that is unique to the organizations. Other documents cited by these documents are not included in this example.

85

PROCEDURE FOR PREPARATION AND CONTROL OF MAINTENANCE PROCEDURES

1. PURPOSE

This procedure provides the measures to control and co-ordinate the prepara-tion, review, approval, issuance, and periodic review of Maintenance Procedures and revisions thereto (Ref. 6.6).

Maintenance Procedures should generally not be used as the mechanism for performing modifications or other one-of-a-kind functions.

2. RESPONSIBILITIES

2.1. The preparer of a Maintenance Procedure shall be responsible to:

2.1.1. Research various documents to determine requirements applicable to the maintenance to be performed.

2.1.2. Prepare the procedure in accordance with the format and content guidance in this procedure and using the Writer's Guide for Maintenance Procedures.

2.2. The Engineer-Maintenance (or designee) shall be responsible to:

2.2.1. Review Maintenance Procedures

2.2.2. Ensure that periodic reviews of Maintenance Procedures are accomplished.

2.3. The Senior Health Physicist (or designee) shall be responsible to review Maintenance Procedures which involve significant radiation exposure or potentially contaminated equipment.

2.4. The site QC supervisor (or designee) shall be responsible to review Maintenance Procedures for safety related equipment.

2.5. The Station Superintendent or Assistant Station Superintendent shall be responsible to:

2.5.1. Approve Maintenance Procedures and revisions thereto and cancellation memorandums.

2.5.2. Provide approved Maintenance Procedures Plant Operation Review Committee (PORC) Approval Forms or Review Forms, and Safety Evaluation Forms (if needed) to the Administrative Staff for distribution and filing.

87

3. PREREQUISITES

None.

4. DEFINITIONS

None.

5. PROCEDURE

5.1. Format and content

5.1.1. All pages shall have, in the upper right corner, the procedure number, the revision number, the page number and the total number of pages in the procedure (Ref. 6.6).

5.1.2. The first page of procedures shall identify the company and the station and shall contain a descriptive procedure title (Ref. 6.6). In the upper right corner of the first page shall be the initials of the procedure preparer (or person primarily responsible for preparation) and the procedure approval signature (in addition to the data in paragraph 5.1.1 above). In the upper right corner shall also be the Effective Date of the procedure (Ref. 6.6).

5.1.3. Procedures shall contain the following parts and should adhere to the format shown in Fig. 1.

(1) Purpose

Statement of purpose or applicability of the procedure (Ref. 6.6). Include the equipment name and the equipment number.

Example This procedure provides instructions for replacement of the seals on

the Reactor Recirculation Pump (1AP201, 1BP201 for Unit 1 and 2AP201, 2BP201 for Unit 2).

If the procedure is applicable to a class of components, such as all operators of one type, the class must be described, but each application need not be listed.

(2) Related maintenance

List any Maintenance or Preventive Maintenance Procedures which should be considered for accomplishment at the same time this procedure

88

N - X X X - Y Y Y (PROCEDURE TITLE)

1. PURPOSE

2. RELATED MAINTENANCE

3. REFERENCES

4. PREREQUISITES

5. PRECAUTIONS

6. SPECIAL TOOLS A N D SUPPORT SERVICES

7. PROCEDURE

8. RETURN TO NORMAL

AN EXAMPLE OF S U B P A R A G R A P H S IS AS FOLLOWS:

7. PROCEDURE

7.1. X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 7.2. X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

7.2.1. X X X X X X X X X X X X X X X X X X X X X X X X X X (1) X X X X X X X X X X X X X X X X X X X X X X X (2) X X X X X X X X X X X X X X X X X X X X X X X

(A) X X X X X X X X X X X X X X X X X X X (B) X X X X X X X X X X X X X X X X X X X

7.2.2. X X X X X X X X X X X X X X X X X X X X X X X X X X 7.3. X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

FIG. 1. Format of procedure.

is being performed. Procedure revision numbers should not be included. This is intended to aid in work planning. Number each entry.

(3) References

List each reference document used in preparation of the procedure (Ref. 6.6). These reference documents include those required for perform-ing work, such as applicable drawings, manufacturers instruction books and vendor data. Include document identification number, title or brief descrip-tion of the document, and the document revision number. If applicable, list Technical Specification. Number each reference.

(4) Prerequisites

Include those independent actions, either physical or administrative, or procedures which must be completed and conditions which must exist prior to use of the procedure (Ref. 6.6). Prerequisites applicable to only certain sections of the procedure shall be so identified if included here, or shall be identified at the appropriate step (Ref. 6.6). Number each entry.

89

(5) Precautions

Include those precautions needed to alert the individual performing

the task to those important measures which should be used to protect equip-

ment and personnel, including the public, or to avoid an abnormal or

emergency situation (Ref. 6.6). Routine precautions, which a trained crafts-

man is expected to take, such as normal electrical safety methods, need not

be stated (Ref. 6.6). Precautions covered in the procedure section need not

be repeated here. Number each entry.

(6) Special tools and support services

List special tools (such as calibrated torque wrenches or pressure test

gauges) and support services (such as drop lights, scaffold, and air hose)

needed to accomplish the task. Consumable materials (such as rags,

solvents, gaskets, and lubricants) should be listed. Include lubricant desig-

nation when applicable. For maintenance actions in posted radiation areas,

the tool and support services list should be detailed; in other cases basic

hand tools may be assumed to be available. Number each entry.

(7) Procedure

Provide the steps to perform the task in the degree of detail necessary

to ensûre safety and correct performance without undue reliance on memory

or direct supervision and in consideration of the skills normally possessed

by trained craft personnel (Ref. 6.6). A goal of the procedure is to attain

consistent results each time the procedure is used even if the work is

performed by different individuals.

When needed, precautions shall be inserted between steps, preceding

the step to which the precaution applies, and shall be typed in all capital

letters (Ref. 6.6).

The applicable steps from technical manuals shall be included in the

text of the procedure (rather than making a general reference to the

technical manual) unless, as determined by the Engineer-Maintenance (or

designee), the technical manual is both extensive and detailed and specific

reference can be made in the procedure to the technical manual steps to be

followed.

Where needed, this section shall identify Health Physics check points

for activities such as area surveys and swipe surveys. When such check

points are specified, completion of the check points shall be documented in

the body of the procedure, or an attachment to the procedure (such as a

traveller), or on a checklist associated with the procedure.

This section shall provide instructions for performing and document-

ing the results of required inspections and tests associated with the work

90

process (Ref. 6.6). Acceptance criteria for each inspection and test shall be

provided (Ref. 6.6) unless the inspection or test is performed to obtain data

(such as for trending) and not to evaluate the adequacy of the maintenance

action. This shall be accomplished in one or a combination of the following

methods:

(a) Delineate the test or inspection method and acceptance criteria in the

body of the procedure with provision to document the results in the body

of the procedure, on an attachment to the procedure (such as a traveller),

or on the Maintenance Request Form (MRF), or on a checklist associated

with the procedure.

(b) In the procedure section or associated traveller or checklist, refer to

the inspection procedure for the method and acceptance criteria. In this

case, the results shall, at least, be recorded in the procedure section, or

associated traveller or checklist, or on the MRF.

(8) Return to normal

This section shall contain instructions as to the mode or condition in

which the equipment is to be placed or left after completion of the main-

tenance action (Ref. 6.6). Generally, the instructions should place the

equipment (or verify its placement) in as near a normal configuration as

practicàblè, subject to conditions governed by local blocking permits (if

any). This may include verification of valve positions which were altered

in accordance with the maintenance procedure, removal of jumpers,

reconnection of lifted leads, proper positioning of locking tabs, etc. All

procedures shall include instructions regarding clean up of the work area,

including support services and equipment, and a cleanliness inspection to be

signed off by the operating shift, supervision of the group performing the

work, or plant staff maintenance group, unless the activity covered by the

procedure clearly will not impact plant cleanliness.

5.1.4. When appropriate, figures, forms, tables, appendices, check-off lists,

and travellers shall be used. They shall be handled in one of the following

ways:

(1) They may be included as a part of the basic procedure by including

them in the page numbering sequence for the basic procedure. In this case,

a revision to the figure, form, table, etc. would require revision of the

complete procedure.

(2) They may be prepared as separate documents (procedures). In this

case, the figure, form, table, etc., shall be identified with the basic proce-

dure, but shall be page numbered, revision-controlled, and approved as an

independent document and shall be listed on the Maintenance Procedures

Index.

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5.2. Procedure numbering

5.2.1. Maintenance Procedure numbers shall begin with the letter ' M ' followed by the appropriate system number from the Station System Number List, followed by the appropriate sequential number within the system (for example: M-015-001, M-015-002, etc.). For generic maintenance procedures which apply to a class of equipment contained in various systems, system number 500 may be used.

5 .2.2. After initial issuance, if a document listed on the Maintenance Proce-dures Index is cancelled, that document number shall not be re-used. This ensures that permanent procedure files can be properly maintained.

5.3. Procedure preparation

5.3.1. The preparer shall determine and review appropriate reference materials and utilize the Wri ter ' s Guide for Maintenance Procedures. Pertinent information may be found in: the Wri ter ' s Guide for Maintenance Procedures; the FSAR; vendor instruction books; equipment information files; applicable utility commitments to USNRC Regulatory Guides and other documents, and appropriate industry codes and standards. Equipment history records, when available, should also be consulted.

5 .3.2. When affected procedures are written, due consideration will be given to the corporate commitment to maintain exposure to radiation as low as reasonably achievable (ALARA). Guidelines for this implementation are given in the Administrative Procedure A-3. Therefore, during preparation of proce-dures involving significant radiation exposure or potentially contaminated equipment, the preparer shall refer to Administrative Procedure A-3 and should discuss the maintenance action with a Health Physics representative to aid in including Health Physics check points in the procedure.

5 .3.3. For Maintenance Procedures prepared by contractors, the procedure shall be prepared by or reviewed for technical adequacy by an appropriate engineer on the contractor staff. Discussion of the procedure scope and techniques with Maintenance Division supervision, Maintenance Division Maintenance Engineer, or the plant staff Engineer-Maintenance is recommended prior to drafting the procedure.

5 .3.4. For Maintenance Procedures prepared by the utility or under utility supervision, if determined to be appropriate by the individual directing the procedure preparation, the preparer shall obtain review of a draft (typed or handwritten) by the Engineer-Maintenance staff, Maintenance Division super-vision, or the Maintenance Division Maintenance Engineer.

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5.3.5. The preparer shall:

(1) Have the procedure typed and prepared for review.

(2) Perform a Safety Evaluation for the procedure in accordance with Administrative Procedure A-5, if required.

Note: Maintenance activités that do not result in a change (temporary or permanent) to a system after completion of the maintenance do not require a Safety Evaluation. Maintenance activities that replace components with replacement parts procured with the same (or equivalent) purchase specification do not require a Safety Evaluation. If the procedure being prepared may require a Safety Evaluation, refer to Administrative Procedure A-5.

(3) Provide the procedure and Safety Evaluation (if needed) to the Engineer-Maintenance for review.

5.3.6. The Engineer-Maintenance (or designee) shall review the procedure and Safety Evaluation (if needed).

5 .3.7. The preparer shall resolve any comments and return the procedure and Safety Evaluation (if needed) to the Engineer-Maintenance.

5.3.8. The Engineer-Maintenance (or staff) shall:

(1) Submit the procedure and Safety Evaluation (if needed) for PORC review in accordance with Administrative Procedure A-4.

Procedures which involve significant radiation exposure or potentially contaminated equipment shall be sent to and reviewed by the Senior Health Physicist (or designee).

Procedures which involve safety related equipment shall be sent to and reviewed by the site QC supervisor (or designee).

(2) Provide a copy of the procedure to Maintenance Division if the procedure was prepared by Maintenance Division personnel.

5.4. PORC review

5.4.1 . PORC review is accomplished in accordance with Administrative Procedure A-4.

5.5. Approval

5.5.1. If all PORC reviewers initial 'REVIEWED AND APPROVED' on the PORC Approval Form for the procedure (see Administrative Procedure A-4),

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the Station Superintendent or Assistant Station Superintendent shall sign and enter the Effective Date in the upper right corner of the first page of the procedure.

5.5.2. If any PORC reviewers initial 'REVIEWED AND APPROVED WITH COMMENTS' on the PORC Approval Form for the procedure, after comment resolution per Administrative Procedure A-4, the Station Superinten-dent or Assistant Station Superintendent shall sign and enter the Effective Date in the upper right corner of the first page of the procedure.

Note: If the procedure is needed for use, the Administrative Staff may have a copy of the procedure sent directly to the user(s) prior to continuing with normal distribution.

5.5.3. The Station Superintendent or Assistant Station Superintendent shall provide the PORC Approval Form(s) and associated documents to the Administrative Staff for distribution and filing.

5.6. Issuance

5.6.1. The Administrative Staff shall distribute and file documents as indicated on the PORC Approval Form, as required by Administrative Procedures A-2 and A-5, and as described below. This ensures that procedures are distributed to appropriate personnel and that outdated or inappropriate procedures are not used (Ref. 6.6).

5.6.2. The Administrative Staff shall:

(1) Update the Maintenance Procedures Index (see paragraph 5.6.4) to reflect the procedure number, procedure title, revision number, the Effective Date of the procedure, and the date the last periodic review was completed (see paragraph 5.9.1). Procedure cancellation also requires updating the Index.

The Index need not be re-issued solely because of completion of a periodic review. Procedure Periodic Review Forms may be accumulated for three months and then the Index shall be updated and issued. This provision does not apply when the Index revision is caused by a procedure revision.

(2) Distribute the procedure, cancellation memorandum, and Maintenance Procedures Index in accordance with Administrative Procedure A-2.

5.6.3. The Administrative Staff shall maintain a supply of the latest revision of each Maintenance Procedure and the Maintenance Procedures Index. These are available to plant staff personnel who are not on routine distribution for these documents.

9 4

5.6.4. An updated Maintenance Procedures Index shall be issued when a new procedure is issued, when a revision to any document listed on the Index is issued, when a document is cancelled, and when the Index is updated to record completion of periodic procedure reviews (see paragraphs 5.6.2.1 and 5.9). The Index does not require PORC review nor an approval signature, but does require a revision number and date.

Documents which are listed on the Index and are subsequently cancelled shall continue to be listed with the notation CANCELLED, so that the document number is not re-used.

5.7. Procedure revision

5.7.1. Revised procedures shall be issued as complete documents. The issuance of only those pages which have been revised is not permitted.

5.7.2. When a procedure is revised, the complete procedure shall be thoroughly reviewed. Therefore, a procedure revision constitutes a periodic review (Ref. 6.6) (refer to paragraph 5.9).

5.7.3. Revisions to maintenance procedures shall be prepared and approved in accordance with paragraphs 5.3 through 5.5.

5.8. Cancellation

5.8.1. If a document listed on the Maintenance Procedures Index is to be cancelled, the Engineer-Maintenance (or designee) shall prepare a memoran-dum to the Station Superintendent giving the reason(s) for cancellation. The memorandum shall be processed for PORC approval in accordance with Administrative Procedure A-4.

5.8.2. If approved by the PORC, the cancellation memorandum shall be signed by the Station Superintendent or Assistant Station Superintendent and shall be issued in a manner similar to a procedure using paragraph 5.6.

5.9. Periodic review

5.9.1. To ensure systematic review and feedback, each document on the Maintenance Procedures Index shall be reviewed at least every five years from the Effective Date and following unusual incidents which reflect adversely on the adequacy of the document (Ref. 6.6), as determined by the PORC or the Engineer-Maintenance. As noted in paragraph 5.7.2, a procedure revision con-stitutes a periodic review; however, in the case of a procedure revision, the Procedure Periodic Review Form is not used.

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The date of the last periodic review (as entered on the Maintenance Procedures Index) is the Effective Date (in upper right hand corner of first page of the procedure) for new and revised procedures and the date the Engineer-Maintenance signs the Procedure Periodic Review Form (see Administrative Procedure A - l ) in other cases.

5.9.2. The Engineer-Maintenance is responsible for the performance of periodic reviews and for ensuring that reviews are completed when required.

5.9.3. The reviewer shall document completion of the review on the Procedure Periodic Review Form and provide the form to the Engineer-Maintenance who shall also sign the form.

5.9.4. The Engineer-Maintenance (or designee) shall provide the Procedure Periodic Review Form to the Administrative Staff.

5.9.5. The Administrative Staff shall:

(1) Update the Maintenance Procedures Index to reflect the date of the periodic review (see paragraph 5.9.1).

(2) Issue the updated Index in accordance with paragraph 5.6.

(3) File the Procedure Periodic Review Form.

6. REFERENCES

6.1. Administrative Procedure A - l . 6.2. Administrative Procedure A-2. 6.3. Administrative Procedure A-3. 6.4. Administrative Procedure A-4. 6.5. Administrative Procedure A-5. 6.6. Final Safety Analysis Report (FSAR), Section 13.5.1.13.

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INSTRUCTIONS FOR PREPARING MAINTENANCE MANUALS

1. INTRODUCTION

The Station has three maintenance wings, Mechanical Maintenance, Electrical Maintenance, Control Maintenance and these maintenance wings have to plan, organize and execute the different maintenance activities pertaining to different mechnical, electrical and control equipment of the station. Besides the above maintenance wings, fuelling machine operation and maintenance will be carried out by a separate wing. The categories of maintenance activities in the station can be broadly classified as:

(i) Preventive maintenance/routine maintenance; (ii) Breakdown maintenance/corrective maintenance; (iii) Poison outage maintenance/opportunity maintenance; (iv) Planned shutdown maintenance; (v) Annual shutdown maintenance/major overhaul.

Modification and new installation will also be carried out by the respective main-tenance wings at the request of operation or technical sections after the appropriate approval by competent authorities.

Maintenance manuals are prepared as a guide for the maintenance wings for carrying ouut different maintenance activities in an efficient, economic and safe way. This will also enable to adopt a sequential order in doing maintenance jobs so that manpower requirements can be minimized. Manuals can be used as a reference source for evaluating spare parts requirement and estimating annual maintenance cost.

1.1. Purpose of this report

This report is prepared to define the scope of the maintenance manual to be prepared and to standardize wherever possible the method of writing and to organize the information in a definite sequence.

1.2. Purpose of maintenance manual

1.2.1. Maintenance guide

Manuals are written as a permanent record and guide for correct, safe and economic performance of maintenance works on the station equipment.

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1.2.2. Reference source

Manuals will give complete maintenance information on different equipments pertaining to each system. This is a source of reference for procurement of spare parts, other hardware, consumables and lubricants for any particular equipment/system.

1.2.3. Planning source

Manuals will deal with all maintenance jobs in sequential time schedules with manpower requirement and as such this can also be used for planning manpower requirement and scheduling plant/station outage time.

1.2.4. Cost estimate data

Manuals will give an annual maintenance cost estimate for each system/subsystem/equipment and this will be the basic information for preparing the yearly maintenance cost estimate.

1.2.5. Training and qualifying material

These manuals can be used in the station training centre for training different categories of maintenance personnel and qualifying them for each system/equipment as competent maintainers.

1.3. Scope

Generally maintenance manuals will be prepared for systems/subsystems. If a system maintenance manual is not feasible for any system, manuals can be written for equipment also. All equipment pertaining to a system/subsystem will be dealt with independently in the particular system maintenance manual. Equipment to be included in the system manual will be chosen depending upon the equipment complexity, reliability requirements, failure rates, etc. or where safety of the equipment or personnel need particular attention.

Each maintenance wing will write on separate coloured sheets for their respec-tive equipment pertaining to each system and all the separate manuals prepared by different maintenance wings will be compiled together to form the system maintenance manual.

Maintenance instructions will also be prepared on general procedures that maintainers are required to follow in handling various types of equipment like pumps, valves, relays, motors, switch gears, etc. or doing work in a repetitive nature.

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2. O R G A N I Z A T I O N O F T H E M A N U A L

2.1. General

Generally all maintenance manuals will be prepared system/subsystem-wise according to the station USI*. In case a system maintenance manual is not feasible for any particular system, manuals will be prepared on individual equipment. Systems maintenance manuals will deal with all the various equipment of that particular system (Mechanical , Electrical and Control) depending upon the impor-tance, complexity and reliability requirement of the equipment. Each maintenance wing will wri te in separate coloured sheets for their respective equipment pertaining to that particular system and all these separate manuals will be compiled together to form the system maintenance manual .

2.2. Maintenance manuals: Maintenance instructions

General procedures or maintenance instructions to be followed by maintainers will be prepared for different equipment of similar nature and will be included in the system maintenance manual depending upon the suitability. The general procedure will be located in the general section of the manual .

3. S Y S T E M M A N U A L C O N T E N T

3.1. Manual general information section

3.1.1. Title (Mechanical, Electrical, Instrumentation combined)

The title of the manual will indicate the system/subsystem referred to and references are taken f rom station USI system. Generally four-digit USI number for systems is taken as standard and in case of smaller systems, three-digit USI numbering also can be adopted.

Example 1: 33110 Primary heat transport system, maintenance circuit:

3. Reactor boiler and auxiliaries 3. Pr imary heat transport system 1. Main circulating system 1. Main circuit

* USI — a station identification system.

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Example 2: 32400 Moderator auxiliary cooling system:

3. Reactor boiler and auxiliaries 2. Moderator system 4. Auxiliary cooling system.

3.1.2. List of equipment

A complete list of equipment in the system which the manual is dealing with will be listed out with proper USI numbers and equipment numbers.

3.1.3. Maintenance criteria

Maintenance criteria will be written based on the design basis of the system or equipment to enable the user to understand the system requirements. This will show the duty cycle of each equipment, standby availability, reliability requirements, etc. All station equipment will be broadly classified in the following categories depending upon the reliability requirement:

Category A: Equipment, whose failure will cause a safety hazard for the plant/station.

Category B: Equipment whose failure will cause a complete shutdown of the plant.

Category C: Equipment whose failure will cause a partial power/load reduction.

Category D: Equipment whose failure will not affect the station performance, but standby availability will be nil or reduced.

Category E: Equipment whose failure will not affect the station operation.

While writing maintenance manuals, equipment category will be indicated for each equipment. This will facilitate the preparation of a very stringent maintenance schedule for equipment in category A, B and C and to do opportunity maintenance whenever possible.

3.1.4. Mention may be made of the need for trend analysis based on continuous monitoring of data, namely vibration level, noise level, no load current of motors at various time intervals, variation in full load currents or variations in stage pres-sures in turbines. These may need precision instrumentation. However, if trend analysis based on on-line measurement of data is felt essential, these aspects may have to be brought out in the manuals.

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3.1.5. Technical data

A complete technical information/data like PO number and date, supplier 's name, manufacturer 's name, name plate details, bearing details, lubrication details, set points, etc. has to be written in the specified form. (See Appendices A, B and C.)

3.1.6. References

References will be listed out regarding major D C N / E C N / D C P or any other useful informations. Reference will also be made to manufacturer 's manual, instruc-tions, etc. A complete list of drawings supplied by the manufacturer/consultant will be listed out and will be given under this heading:

SI. Title Type of USI Origin of Originator Revised No. reference No. reference reference No. No.

3.1.7. Safety instructions

Special precautions such as radiation hazard or equipment safety or general informations if any will be noted under this heading.

3.1.8. Sub-assembly

Large equipment normally contains smaller sub-assemblies; wherever sub-assembly information is required this has to be listed out with small description of the function, material construction, particular drawing number, part number, etc. This should also include the assembly procedures for sub-assembly items of a com-plicated nature.

3.2. Preventive maintenance

3.2.1. General

Preventive maintenance will be carried out for all systems/equipments to keep the equipments in peak operating conditions or to keep the equipment in a poised state to act in emergency.

3.2.2. Scheduled inspection/maintenance

Schedules in the form of check sheets will be prepared for all major equipment in each system for carrying out different schedules of maintenance checks. This will

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include daily checks, weekly checks, fortnightly checks, monthly checks, quarterly checks, . half-yearly checks and yearly checks and general overhaul whenever applicable (see attached check sheets). This preventive maintenance check sheets should specify clearly all the checks or inspections to be carried out during running of the equipment and shutdown inspection.

Frequency of maintenance checks for different equipment will be initially based on manufacturer 's recommendations and reliability requirement categories. This can also be assessed from the data available on performance and failure rates of similar equipment in other organizations. Efforts may be made to gather such information before preparing the maintenance check sheets. If no such information is available, maintenance handbooks also can be referred to for determining the frequency of checks. This frequency of maintenance checks will be reviewed and revised depending upon the performance of the equipment, if necessary. Preventive maintenance check sheets should also indicate the time and manpower requirements and approximate cost of such maintenance activities.

Station preventive maintenance programmes for different maintenance wings will be computerized and computerized preventive maintenance schedules will be followed.

Until computerized preventive maintenance schedules are followed, a master schedule (bar chart) will be prepared for each system and will be followed.

3.2.3. Periodic overhaul/major overhaul

Large items of Station equipment such as turbine, generator, etc., will have to be dismantled completely for inspection of internals for running damages. This requires a Station outage and special schedules for this work will be made whenever required before the work is done.

Similar major overall schedules will also be prepared for smaller equipment such as DG sets, M G sets, compressors, different pumps, etc. if it is not covered by the P .M. checks.

3.3. Predictive maintenance

A small chapter may be included. Under this, the techniques like signature analysis, partial discharge tests, etc., appropriate to the equipment, can be included.

3.4. Dismantling procedure

3.4.1. Manpower

Total manpower equipment will be listed out in this section taking into consideration the slack time, least time and optimum time for the completion of the entire job.

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3.4.2. Tool list

Some of the equipment may require special tools for dismantling some parts. A complete list of special tools and common tools and instruments required for the job will be listed out in this section.

3.4.3. Consumable/spares requirement

Some of the equipment parts like gaskets, ' 0 ' rings, oil seals, packings, etc. cannot be re-used, once they are dismantled or opened out. Such items which cannot be re-used and are expected to be replaced will be listed out in this section. A complete list of other consumable items required will also be indicated in this section.

3.4.4. Check list

A check list will be prepared to show the clearance/measurement which are to be taken before dismantling, during assembly, after assembly and during test runs of the system or equipment.

3.4.5. Dismantling sequence

Dismantling procedures will be written in the form of arrow diagrams in time scale chart showing each activity with time and manpower requirement. The arrow diagram shall also indicate the least time optimizing all resources of each activity/work. This will also indicate the works to be taken up by the respective maintenance wings. The sequence of steps will be based on the informations available f rom the manufacturer 's manual and the detailed drawing of the equipment.

The repair jobs to be carried out on the equipment will also be indicated in the dismantling procedure arrow diagram.

3.5. Assembly procedure

3.5.1. Assembly procedures will be written as the disassembly procedure described in 3.2.5. This includes procedures for reassembly, checks to be carried out during assembly, etc.

3.5.2. Alignment/load setting/timing, etc.

Equipment alignment procedure will be written wherever required. Manufac-turer 's recommendations will be followed generally.

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In case of load setting in some equipment like PHT pumps, boiler, etc. a detailed procedure will be given for load settings. In case of DG set and diesel operated fire water pumps, procedures for alignment, timing, settings, etc., will be written separately under these headings.

Any other relevant setting to be carried out for any particular equipment which requires a detailed procedure can be written under this heading.

3.6. Testing

Testing procedure/recommended results like timings, contact resistances, calibration, capacities, etc., have to be written wherever applicable.

3.7. Trial run

3.7.1. General

Special instructions to be followed during test run and measurement/clear-ance/settings to be checked during test run will be written under this heading.

3.8. Trouble shooting chart

Probable troubles which are expected and their probable causes in the form of a trouble shooting chart should be included in the manual for each equipment where-ver applicable. Prediction of troubles based on the trend analysis mentioned in 3.1.4 may also be included wherever applicable.

4. DETAILS OF THE MANUAL

4.1. General

Each system maintenance manual written by different maintenance wings will be numbered in a similar manner. Each maintenance wing will write on different coloured paper and each section of the manual will appear on a separate page or pages. This will facilitate the revision of separate sections of the manual without changing the page numbering or content of the remaining section. The list of equip-ment (Mechanical, Electrical, Controls) the manual is dealing with will be listed out with proper USI number, equipment and page number, and will be included after the title page.

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4.2. Manual set up

All system manuals and maintenance instructions will be prepared/printed in 8 V2 " x 11" paper for inclusion in a distinctive loose leaf binder. Each maintenance wing will follow a different colour code for the preparation of manuals.

M.M. — Sky blue E.M. — Light yellow C.M. — Light pink F.M. — Light rose

The maintenance manuals and instructions prepared by the different main-tenance wings will be compiled together and will be included in a loose leaf type binder to form a system maintenance manual.

4.3. Manual identification number

Manuals will be identified by the title from the station system USI.

4.4. Manuals revisions

Revisions will be made to the manual section/sections if better methods are required or new procedures are to be adopted. Revisions also will be made for the frequency for preventive maintenance checks, depending upon the performance and failure rates of the equipment.

The initial issue of each section of manual will be R-0. The revision number and date of issue will be shown at the bottom of each page of the manuals. Only pages requiring revision will be revised. The revised portion will indicate the revision number and date of each revision consecutively, with R-l being the first revision.

4.5. Author and authorization

4.5.1. Maintenance manuals will be prepared by the respective maintenance engineers/supervisors. Author's name and signature will be appended on the title page.

4.5.2. All maintenance manuals prepared in the station for internal use have to be approved by the Station Superintendent or his designate.

5. CONCLUSION

The above instructions are of general nature. Any other relevant particulars which the authors feel essential can be included in the manuals. This includes

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m a n u f a c t u r e r s ' p u b l i s h e d a r t i c les of spec ia l i n t e r e s t s , i m p r o v e d m a i n t e n a n c e

t e c h n i q u e s , g e n e r a l m a i n t e n a n c e i n s t ruc t i ons , d e s i g n d a t a , e tc .

S u c h i n f o r m a t i o n c a n b e a d d e d in t he a p p r o p r i a t e sub - sec t ions of t he

m a i n t e n a n c e m a n u a l .

M A N U A L N U M B E R I N G ( I N D I V I D U A L )

SI. Section Sub-section Sub-section No. number

1. General Title 0 List of equipment 1 General/Maintenance criteria 2 Technical data 3 List of references 4 Maintenance instructions 5 Safety instructions 6 Sub-assemblies 7

2. Preventive maintenance Scheduled inspection 1 Periodic overhaul 2 Predictive maintenance 3

3. Dismantling procedure Manpower requirement 1 Tool list 2 Consumable/ spares 3 Check list for dismantling 4 Dismantling sequence sub-assembly-wise

arrow diagram with resources and time estimate 5

4. Assembly procedure Manpower requirement 1 Tool requirement 2 Consumables 3 Check list 4 Assembly sequence sub-assembly-wise

and arrow diagram with resources and time estimate 5

Alignment/setting 6

5. Testing Special instruction 1 Check list 2

6. Trial run Special instruction 1 Readings/results 2

7. Trouble shooting

8. Recommended spare parts

9. Cost estimate

10. Photographs of disassembly or assembly procedures or any other important events

NOTE: Drawings and sub-assembly sketches should be included wherever applicable.

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Appendix A [to Example 7(b)]

TECHNICAL DATA - ELECTRICAL EQUIPMENT

1.1. Make 1.2. Supplier 1.3. Location 1.4. Systems 1.5. P.O. and date 1.6. Date installed 1.7. Date commissioned

2. Motors

2.1. Type 2.2. Serial No. 2.3. Frame size 2.4. Phase frequency 2.5. Enclosure 2.6. Type of drive 2.7. Mounting 2.8. Service factor 2.9. Insulation class 2.10. Temperature rise 2.11. Efficiency/loss 2.12. Stator resistance Rotor resistance 2.13. Stator temperature maximum 2.14. Sync, speed 2.15. Direction of rotation 2.16. Driven equipment 2.17. Power factor Voltage No. load amp

1. Plant equipment USI No.

2.18. Max. rated 2.19. Brush 2.20. Bearing 2.21. Temperature detector 2.22. Bearing temperature running max. 2.23. Lubrication type No. 2.24. Space heater Resis

Rated amp hp/kW Type maker No. Type maker No.

No. Resistance No. of heaters

Maker Connection

2.25. Any other special features

3. Transformer

3.1. Type 3.2. SI. No. 3.3. Phase 3.4. Temperature 3.5. Cooling 3.6. Temperature rise (°C) 3.7. kVA 3.8. Voltage nominal/max. HV

Frequency

LV LV 3.9. Current HV

3.10. Core and coil weight (kg) 3.11. Total weight (kg) 3.12. Oil quantity 3.13. No. of radiators 3.14. Type of connection

Primary Secondary 3.15. Group 3.16. Built-in protection 3.17. Type of bushing

HV Make LV Make

3.18. Any other special features

4. Switchgear

4.1. Type 4.2. SI. No. 4.3. Cont. Rating Amps. 4.4. Rupturing capacity Symmetrical

Asymmetrical 4.5. Voltage Rating Working

Max. 4.6. Insulation level 4.7. Rated short tune current 4.8. Making capacity 4.9. Clearance: phase to phase: phase to ground 4.10. Maximum operating Pr. (for ABCBS),

Normal working pressure (for ABCBs) 4.11. Air consumption:

One branch: One make:

4.12. Capacity of air receiver 4.13. Rate of rise of restricting voltage 4.14. Rated operating duty 4.15. Control voltage 4.16. Type of protection 4.17. Any other special features

Duty cycle: Closing time: Tripping time:

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Appendix B [to Example 7(b)]

TECHNICAL DATA - MECHANICAL EQUIPMENT

1. System USI 2. Plant equipment USI & No 3. No. ofoffs 4. P.O. number and date 5. Date installed 6. Date commissioned 7. Systems 8. Location 9. Make

10. Supplier 11. Type 12. Model 13. Serial number 14. Size 15. Capacity 16. Head/pressure 17. Rpm 18. Bearing Nos. 19. Lubrication

a) Bearings Qty. required b) Crank case Qty. required

20. Type of drive a) Belt size and Nos. b) Coupling size

21. Gland sealing a) Type of packing b) Size of packing and number c) Lateral ring

22. Mechanical seals a) Make and size

23. Gasket joints a) Type and size

24. Any other specifications

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Appendix C [to Example 7(b)]

TECHNICAL DATA — INSTRUMENTATION

1. Application code No. 2. Equipment code No. 3. Equipment USI No. 4. Instrument FS/ED No. 5. Instrument specification Sheet No./calibration sheet No. 6. Type (electronic/hydraulic/pneumatic) 7. Spares (store bin card No.) 8. Date (installed/commissioned) 9. P.O. No. and date

10. Supplier 11. Model No./S.V. No. 12. Range/span 13. Accuracy/response time 14. Working voltage 15. Air supply requirement 16. Design valves:

PB Reset Der.

17. Action (forward/reverse) 18. Set point (local/remote) 19. Control loop mode 20. Input/output signal details 21. Input impedance 22. Loop resistance 23. Suppression details 24. Chart type and range 25. Chart speed 26. Zero adjustment 27. Ref. junction (local/remote) 28. Alarm contact rating 29. Alarm contact sequence 30. Differential gap 31. Repeatability 32. Type of sensor 33. Mounting details 34. Material of construction 35. Dimensions 36. End connection size 37. Application details 38. Accessories requirements

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EXAMPLE 8

MAINTENANCE INSTRUCTIONS AND CHECKLISTS

(Section 4.5)

This example contains (a) a copy of a maintenance instruction as adopted by one Operating Organization in India, (b) a copy of a maintenance instruction with checksheets as adopted by one Operating Organization in the USA, and (c) a copy of a checksheet as adopted by one Operating Organization in the United Kingdom. In Example 8(a), maintenance instruction is referred to as maintenance manual. The texts of the examples have been edited slightly to eliminate terminology that is unique to the organizations.

I l l

MAINTENANCE MANUAL FOR STANDBY COOLING PUMPS

1. TITLE: STANDBY COOLING PUMP

1.1. List of subassemblies

(a) The pump unit (b) The motor unit.

1.2. Maintenance criteria

The primary heat transfer (PHT) system is normally at a temperature of 250°C and pressure of 85 bars during the reactor operation. If the system has to be cooled down for shutdown/maintenance purposes, steam is blown off through the steam dis-charge valves on the secondary side of the boilers thus lowering the boiler steam pressure and temperature. This brings down the PHT coolant temperature to about 120°C, below which further cooling is difficult. Hence for cooling the system below 120°C and for holding it cold enough to perform the maintenance activities an auxiliary cooling system, namely the standby cooling system is provided.

At either end of the reactor, a pump and a heat exchanger are connected between the reactor inlet header and reactor outlet header. When the reactor is oper-ating, this system is isolated from the main system and the pumps are not operating. These pumps are located in the boiler room and access to them during reactor opera-tion is not available. The reliability required for these pumps is high since they are required to be operating while the reactor is not operating and the maintenance works have to be carried out. Hence all the components of these pumps are designed for unattended operation for a minimum period of 8000 hours, and they can be classified under category 'C ' .

1.3. Technical data

1.3.1. Standby cooling pumps : 33412-P1, P2

1.3.2. Makes:

1.3.3. Purchase order (P.O.) number:

1.3.4. Type: KSMK 8.8.12

1.3.5. Serial numbers

1.3.6. Capacity: 545 m3/h

1.3.7. Fluid: heavy water

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1.3.8. Inlet press: 85 atm

1.3.9. Total head: 21.3 m

1.3.10. Temperature: 21°C to 263°C

1.3.11. Speed: 1480 r p m '

1.3.12. Goal: high pressure and temperature operational (HPTO)

1.3.13. Pump bearings numbers: NU314 DE side (drive end) 7314 BG-NDE side

1.3.14. Primer: type FNC 250 M4/B3, 415V, 3N induction motor

1.3.15. Coupling: spring type

1.3.16. Lubricating oil: IOC turbine oil 11

1.3.17. Anti-reverse clutch: ATV type ALM 25.

1.4. List of references

Si. No. Drg. No.

1. 33412/2501/GA 2. 33412/2502/GA 3. 33412/2505/DD 4. 33412/2506/DD 5. 33412/2507/DD 6 33412/25 Í2/DD 7. 33412/2513/BM 8. 33412/2516/DD 9. 33412/2517/DD

10. 33412/2532/MI

1.5. General description

The standby coolant pump is a radial flow, single stage double suction, double volute horizontal pump, split perpendicular to the axis, designed to run at 1480 rpm, driven by a 415 V, Cl.Ill , 3 phase 50 cycles induction motor. The pump motor unit is mounted on a rigid base plate on 72' floor elevation which can slide on the floor over the lubrite pad bearing surfaces. One of two pumps is in a left-handed arrange-ment and the other in a right-handed arrangement.

The pump volute casing (4) is split perpendicular to the axis at one end for ease of assembly and removal of the rotating assembly. The sealing between the pump casing and the spacer stuffing box (7) is achieved by a spiral wound gasket (10) and a detection O ring (11).

Description

General arrangement drg. CCW motor General arrangement drg. CW motor Pump shaft CW motor Pump shaft CCW motor Sectional drg. CW rotation Sectional drg. CCW rotation Bill of material Mechanical seal assembly Spring type Maintenance manual for pump

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The double suction closed impeller (21) is dynamically balanced and is fixed on to the pump shaft (20) with a sliding fit driven by impeller key (23) and locked in position by impeller nut (22). Removable case wear rings (8) are provided in either end and locked in place by cap screws (18). The pump stuffing boxes are water cooled, and are extra long type for housing the mechanical seals.

The shaft sealing at either end is achieved by means of HPTO seals (31). The pump is provided with two independent coolers for injecting cool clean heavy water across the seal faces, the heavy water being circulated by the pumping holes in the mechanical seal shaft sleeve (25) itself.

The complete rotating assembly is supported on either end by bearing assem-blies (43, 44). The bearings are ring oil lubricated and the lubricating oil is cooled by process water jacket cooling. The oil level is maintained by constant level oilers. Anti-reverse rotating clutch lubricating type (72) is provided at the free end of the pump shaft.

The pump is driven by an electric motor, through a spacer type flexible coupling (1).

1.6. Maintenance instructions

1.6.1. Give due regard to cleanliness in all equipments of nuclear system, which is of utmost importance.

1.6.2. Do not interchange any components unless verified properly.

1.6.3. Use proper tools always.

1.6.4. Match mark all the parts before disassembly.

1.6.5. Never over-tighten or under-tighten any fasteners. Torque them to the specified values.

1.6.6. Don't be conservative. Renew all the gaskets, O rings, lock washers, lock wires, etc.

1.6.7. Use lubricating freely, otherwise galling may result.

1.6.8. Acetone is only to be used for cleaning.

1.6.9. The seal faces should be handled very carefully and no impressions to be left on the seal faces.

1.6.10. Never hammer any of the components.

1.6.11. Never turn the rotating assembly dry when the seals are in position.

1.6.12. When the equipment is being taken out from the system try to collect every drop of heavy water. Mop all the external and internal surfaces for D 2 0 collection, before starting any maintenance activity.

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1.6.13. Not the least! Follow the assembly and disassembly of the components strictly as per the approved procedure.

1.6.14. Always try to contain the activity. Don't spread it.

1.7. Safety instructions

1.7.1. Do not start the work unless valid work and radiological permit is in hand.

1.7.2. Check the field of activity all around the equipment before starting the job for potential hot spots.

1.7.3. Use protective appliances/shields as advised by Health Physicist.

1.7.4. Work only for the duration of time permitted.

1.7.5. Record the radiation dosages received during the period regularly.

1.7.6. Before breaking open any joint in the system or equipment ensure that the system is depressurized and drained.

1.7.7. Always be prepared for the worst, e.g. tritium levels going high consequent upon the system opening.

1.7.8. One person should always be in full plastics for recovery of any D 2 0 spillage likely to happen.

1.7.9. Always use lifting and handling equipment of tested quality.

1.7.10. Decontaminate the components/equipments from loose contamination before working on them.

2. PREVENTIVE MAINTENANCE

2.1. General

All the components of the standby cooling pumps individually and assembly-wise are designed for continuous trouble-free operation without any attention for a minimum period of 8000 hours. However, these pumps will be operating only for very limited periods, that is during the shutdown period of the reactor and these pumps are accessible during that period only while they are operating. The manufac-turer also suggests no maintenance on these equipments unless called for. Hence no planned preventive maintenance programme is envisaged for these equipments, except the replacement of lubricating oil from the pump bearing housing at regular intervals.

116

2.2 . However , during the operation of these pumps predictive maintenance techniques, namely (i) vibration and noise trend analysis, (ii) vibration signature analysis, (iii) p u m p motor unit run down time and (iv) seal leak rate will be under-taken at regular intervals, analysed and corrective steps taken at the earliest opportunity.

2 .3 . The general overhaul of these equipments will be taken in a phased manner once in five years , during long annual shutdowns.

3, D I S A S S E M B L Y A N D A S S E M B L Y

3.1. Manpower requirements

Engineer 1 Supervisor 1 Maintainers 3

3.2. Tool list

Mechanic ' s standard toolbox lA in sq. drive socket spanner set (mm size)

r ing and socket spanners 65 m m size Allen key set (mm size) Eyebolts ' C ' spanners W i r e rope slings 10 m m X 2 m 2 Nos. ' D ' shackles 10 m m 4 Nos. Ventilated plastic suits Ai r masks Mops and plastic buckets Dial gauges with magnetic base and clamp Inside and outside micrometers up to 200 m m Vernier calipers 0—300 m m Torque wrench 0—1000 f t . lbs Lapping machine.

3.3. Consumables

Superior grade kerosene/acetone Silicone grease Penetrating oil Moly grease

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PVC sheets Turbine oil 11 Masking tape Lint free cloth Set of O rings, gaskets and lock washers.

3.4. Disassembly sequence

The pump unit assembly can be subdivided into the following subassemblies before it is completely dismantled.

(i) Motor (ii) Coupling (iii) Anti-reverse rotation clutch (iv) bearing assemblies (v) mechanical seals (vi) Spacer stuffing box (vii) Pump shaft — impeller assembly

Before the disassembly is started, the 8 T electric hoist is taken on to the concerned monorail over the pump.

3.4.1. Removal of motor. The removal of the motor is only necessary if the south side standby cooling pump is to be completely dismantled, otherwise not.

3.4.1.1. The power supply is isolated, breaker raked out, permit issued, electrical and instrument cables disconnected from the motor.

3.4.1.2. Loosen and remove the cap screws fixing the spacer coupling to the motor shaft. Measure the gap between the two coupling halves and record.

3.4.1.3. Loosen and remove the motor holding down bolts to the base frame with lock washers.

3.4.1.4. Sling the motor with two slings, take the load on to the 8 T hoist after centering and slowly lift the motor off its foundation.

3.4.1.5. Move the motor to a convenient location and support the same on wooden planks in the boiler room.

3.4.2. Removal of the coupling. The removal of the coupling is only necessary if the drive end bearing or mechanical seal assemblies are to be removed or the pump is to be fully dismantled, otherwise not.

3.4.2.1. Loosen and remove the screws holding the two coupling covers. Move the covers away and slowly pry off the coupling spring from the coupling teeth.

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3.4.2.2. Loosen and remove the cap screws fixing the spacer coupling to the motor shaft if not already removed. Remove and preserve the spacer coupling. Measure the gap between the coupling halves and record if not done already.

3.4.2.3. Loosen and remove the grub screw (3) holding the coupling hub (1) on to the pump shaft (2).

3.4.2.4. Fix the coupling puller and slowly heat the coupling hub with either a gas torch or an electric hand heater.

3.4.2.5. Remove the coupling hub from the pump shaft. Remove and preserve the coupling key (2).

3.4.3. Removal of anti-reverse rotation clutch. The removal of this clutch assem-bly is only necessary if the non-driving end bearings or mechanical seal assemblies are to be removed or the pump is to be fully dismantled, otherwise not.

3.4.3.1. Drain the oil from the anti-reverse rotation clutch assembly.

3.4.3.2. Loosen and remove the hexagonal bolts (84), end cover (81); spacer (74) and key (82).

3.4.3.3. Loosen and remove the cap screw (87). Remove and preserve the spacer (79).

3.4.3.4. Remove the anti-reverse rotation clutch assembly (72) with its housing (75) and the key (85).

3.4.3.5. Loosen and remove the cap screws (66) and remove the cover (60) with the oil seal (76).

3.4.3.6. Remove the bearing cover (59) and preserve it.

3.4.3.7. If the anti-reverse rotation clutch disassembly is further required, then proceed as follows, after placing the assembly on a clean work bench.

3.4.3.8. Loosen and remove the screws (80) and then the end cover (73).

3.4.3.9. Clutch (75) can be slid off from the clutch assembly (72).

3.4.3.10. The oil seal (76) can be removed from the cover (60) and preserved if needed.

3.4.4. Removal of drive end bearing assembly. This assembly is to be removed only if the pump is to be completely dismantled or DE bearing or mechanical seal has to be attended to, otherwise not.

3.4.4.1. Drain the oil from the bearing housing (44).

3.4.4.2. Disconnect the process water connections to the bearing housing, drain and collect the process water.

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3.4.4.3. Disconnect and remove the bearing retainer (64).

3.4.4.4. Loosen the grub screw (71) and remove the deflector (55).

3.4.4.5. Loosen and remove the cap screws (66) and then the bearing end cover (53).

3.4.4.6. From the face of the bearing housing, measure and record the depth to the face of the space ring (54).

3.4.4.7. Remove the rod (56) and preserve the oil ring (47).

3.4.4.8. Loosen the grub screw (71). Unscrew and remove the bearing sleeve nut (46).

3.4.4.9. Unlock the lock washers (69), unscrew and remove the nuts (68).

3.4.4.10. The bearing assembly (44) and spacer (54) can be removed.

3.4.4.11. Loosen and remove the cap screws (70) and separate the bearing cover (52) from the assembly (44). Now the spacer (54) and bearing (50) can be removed from the housing.

3.4.4.12. Slide the water deflector (48) off from the shaft along with its O ring (51) and remove the spacer ring (63).

3.4.5. Removal of non-drive end (NDE) bearing assembly. This assembly is to be removed only if either the pump is to be completely dismantled or the NDE bearing or mechanical seal has to be attended to.

3.4.5.1. Check that the anti-reverse rotation clutch assembly is removed as per procedure 3.4.3.

3.4.5.2. Drain the lubricating oil from the bearing housing (43).

3.4.5.3. Disconnect the process water connections to the bearing housing drain and collect the process water.

3.4.5.4. Measure and record the depth from the bearing housing face to the outer race of the NDE bearing (49).

3.4.5.5. Unlock the lock washer (58), unscrew and remove the lock nut (57).

3.4.5.6. Remove the rod (56) and preserve the oil ring (47).

3.4.5.7. Remove the spacer/lubricating ring (45).

3.4.5.8. Disconnect the RTD connections and remove the bearing RTD (64).

3.4.5.9. Unlock the lock washers (69), unscrew and remove the nuts (68).

3.4.5.10. The bearing assembly (43) with the NDE bearings (49) bearing cover (52) can be removed.

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3.4.5.11. Loosen and remove the cap screws (70) and separate the bearing cover (52) from the assembly (43). Now the NDE bearings can be removed.

3.4.5.12. Slide the water deflector (48), off from the shaft along with its O ring (51) and remove the spacer ring (63). Beware! The spacer rings of DE and NDE should not get mixed.

3.4.6. Removal of drive end (DE) mechanical seal. This assembly is to be removed only if the pump is to be completely dismantled or the DE mechanical seal is to be attended to.

3.4.6.1. Disconnect the vibration detector connections and remove the probe.

3.4.6.2. Disconnect the air inlet and seal leakage connections from the seal gland plate (32).

3.4.6.3. Unlock the lock washer (30), loosen and remove the lock nut (29).

3.4.6.4. Remove the vibration detector disc (41).

3.4.6.5. Slide off the vapour seal shaft sleeve (26) from the shaft (20).

3.4.6.6. Unlock the tab washers (40), loosen and remove the screws (42).

3.4.6.7. Remove the vapour seal cover (37), and the carbon seal rings (38) with springs (39).

3.4.6.8. Remove and preserve the O ring (91) and also the sleeve key (28).

3.4.6.9. Loosen and remove the seal gland flange cap screws (36).

3.4.6.10. Slowly and carefully remove the seal gland plate (32) with the stationary carbon insert and O ring (34 and 35).

3.4.6.11. Now the seal assembly with the seal sleeve (25) and its O ring (33) can be pulled out from the shaft carefully.

3.4.7. Removal of the non-drive end (NDE) mechanical seal. This assembly is to be removed only if the pump is to be completely dismantled or the NDE mechanical seal is to be attended to.

3.4.7.1. Disconnect the air inlet and seal leakage connections from the seal gland plate (32).

3.4.7.2. Unlock the lock washer (30), loosen and remove the lock nut (29).

3.4.7.3. Remove the spacer ring (27).

3.4.7.4. Slide off the vapour seal shaft sleeve (26) from the shaft.

3.4.7.5. Unlock the lock washers (40), loosen and remove the screws (42).

3.4.7.6. Remove the vapour seal cover (37), the carbon seal rings (38) and the springs (39).

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3.4.7.7. Remove the sleeve key (28).

3.4.7.8. Remove and preserve the O ring (91).

3.4.7.9. Loosen and remove the seal gland flange cap screws (36).

3.4.7.10. Slowly and carefully remove the seal gland plate (32) with the stationary carbon insert and O ring (34 and 35).

3.4.7.11. Now the seal assembly with the seal sleeve (25) and its O ring (33) can be pulled out from the shaft carefully.

3.4.8. Removal of the pump shafl and impeller.

3.4.8.1. Disconnect the seal injection and seal return lines, the inter gasket leak off connections and also the jacket cooling water inlet and outlet lines from the spacer stuffing box side (14).

3.4.8.2. Sling the spacer piece (12 or 13) and move it off.

3.4.8.3. Sling the spacer stuffing box (7) and move it off. Remove and preserve the gaskets (10 and 11).

3.4.8.4. Now sling the pump shaft (20) along with the impeller (21) and the assem-bly can be moved out towards the motor end for the south pump (3341-P1).

3.4.8.5. For the north pump (3341-P2), move the pump shaft impeller assembly towards the NDE side till the impeller is clear from the pump volute.

3.4.8.6. Now man over to pull out the assembly by slightly turning and lifting the shaft.

3.4.8.7. If not loosen the grub screw for the impeller nut and then unscrew and remove the impeller nut (22).

3.4.8.8. Slide the impeller (21) from the pump shaft (20).

3.4.8.9. Remove and preserve the impeller key (23).

3.4.8.10. Move the pump shaft further now till the shaft is free to be tilted in the pump casing. Now tilt the pump shaft in the vertical plane and it can be pulled out.

3.5. Inspection of the components

3.5.1. The pump shaft should be free of any burrs or scratches, etc.

3.5.2. The impeller should not have any deep grooves or scratches on the shroud locations.

3.5.3. The wearing rings should not have any deep grooves on the inner diameters and ovality should not be more than 0.05 mm.

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3.5.4. The seal faces should be absolutely free of any cracks, erosion, etching, corrosion, pitting, heat chocks, etc., and should be highly polished.

3.5.5. The seal faces should be flat to an accuracy of two light bands.

3.5.6. All the gaskets and O rings to be free of nicks, cuts, etc.

3.5.7. All the flange joints and unions mating surfaces should be free of nicks, burrs, etc.

3.5.8. The gear teeth of the flexible coupling should not have any indications of corrosion, pitting, excessive wear, overheating, etc.

3.5.9. The rollers of the anti-rotation clutch assembly should be highly polished and should not have any scratches, etc.

3.5.10. All the measurements before and during assembly are to be recorded as per annexure.

3.6. Assembly procedure

This section covers reassembly in a similar manner and is not included.

3.7. Record of clearances and measurements before and during assembly

3.7.1. Bow in the pump shaft tir max at

3.7.2. Wearing clearance, DE side

3.7.3. Wearing clearance, NDE side

3.7.4. Depth of NDE bearing from bearing housing face

3.7.5. Depth of DE bearing spacer from bearing housing face

3.7.6. Alignment readings: Radial tir max — Angular tir max —

3.7.7. Space between the two coupling faces

3.7.8. Total float of the pump assembly.

4. TESTING AND TRIAL RUN

After the pump motor unit is coupled, the pump is filled with heavy water, properly vented and the condition of mechanical seals and casing joints checked.

The pump motor unit is started and after stabilizing, the seal leak rate, vibration levels at various locations, bearing temperature and noise levels recorded.

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PREVENTIVE MAINTENANCE PROCEDURE FOR THE SAFETY RELATED STANDBY LIQUID CONTROL PUMP

PLUNGER PACKING REPLACEMENT

1. PURPOSE

This procedure defines the maintenance required for the replacement of packing for the standby liquid control pump plunger packing.

2. RELATED PREVENTIVE MAINTENANCE

2.1. PMQ-048-002 Standby Liquid Control Pump Overhaul

3. REFERENCES

3.1. Vendor data

3.1.1. 8031 -M-1-C41 -COO 1 w . „ . Manufacturer Pump Instruction Manual

4. PREREQUISITES

4.1. Discuss the maintenance activity to be performed with a Control Room Opera-tor. Notify QC that maintenance of the safety related standby liquid control pump will be performed.

4.2. The pump shall be isolated and tagged out in accordance with the local permit.

4.3. Equipment operations such as starting or stopping of the pump, positioning of valves, switches, or circuit breakers, etc., as required in this procedure are to be performed by and with the concurrence of the utility operations. The maintenance person shall request the operation from a Control Room Operator.

4.4. If the Maintenance Request Form for this maintenance activity indicates that a Radioactive Work Permit (RWP) is required for its accomplishment, notify Health Physics that the maintenance is to be performed.

4.5. Sign and date Section 4.0 of the Maintenance Department Record Form (MDRF), Appendix C, to indicate compliance with these prerequisites.

124

5. PRECAUTIONS

5.1. Maintenance Supervision shall review the need for and establish any special safety precautions required for performance of this procedure.

5.2. This procedure requires the use of volatile solvents. Ensure adequate ventila-tion is available. Smoking, open flame or hot work are prohibited in the work area while the solvents are in use.

5.3. Sign and date Section 5.0 of the MDRF, Appendix C, to indicate awareness of these precautions.

6. SPECIAL TOOLS AND SUPPORT SERVICES

6.1. Special tools

6.1.1. Stuffing box gland wrench — Spanner #461

6.1.2. Oil spray bottle

6.2. Test equipment

6.2.1. Torque wrench — 0-300 ft.lbs

6.3. Consumables

6.3.1. Anti-seize compound Code No. 119-14420

6.3.2. Light oil

6.3.3. Solvent

6.3.4. Lint free rags

6.4. Spare parts

Part name Qty part No. Mat. code No.

6.4.1. Female adaptor ring

6.4.2. Male adaptor ring

6.4.3. V-rings-packing

6.4.4. Cylinder head gasket

(1) 938-13-A2359-FMR

(1) 938-13-A2359-MR

(6) 938-13-A2359-VR

(1) 619-B6087/1JM#70

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6.5. Sign and date Section 6.0 of the MDRF, Appendix C, to indicate awareness

of the need for these special tools, consumables and spare parts.

7. PROCEDURE

Maintenance Supervision shall be notified immediately if abnormal conditions

which are beyond the scope of this procedure for correction are noted.

Abnormal, as found, conditions and corrective actions taken shall be described

in the REMARKS Section of the Maintenance Data Record Form (MDRF).

A QC inspector shall be present and observe the performance of all steps desig-

nated as a QC WITNESS POINT.

Test equipment shall be undamaged, within the calibration due date, and shall

have the proper calibration tag or sticker attached.

Enter the identification number and date used for all test equipment and/or

calibrated tools used during performance of this maintenance task in Section 5 of the

Maintenance Request Form (MRF).

CAUTION

The following procedure requires disassembly of a safety related pump. To

facilitate reassembly, as a part is removed from the pump it shall have an identifíca-

tion tag affixed to it. Upon completion of examination of the part where practical,

it shall be bagged and stored in a controlled laydown area until required for reassem-

bly. Small items (nuts, bolts, etc.) shall be bagged añer examination, and the bag

tagged accordingly.

7.1. Packing removal and inspection of parts

NOTE

For a detailed pump drawing and component identification see Appendix A.

7.1.1. Remove cylinder head nuts.

7.1.2. Remove cylinder head (367).

7.1.3. Remove cylinder head extension (368) and gasket (619).

7.1.4. Remove plungers (353) from the unit by unscrewing the plungers (353)

from the crosshead stubs (122) and then withdrawing the plunger through the

cylinder bore.

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NOTE

For a detailed drawing of the stuffing box and internais see Appendix B.

7.1.5. Unscrew stuffing box gland (338).

7.1.6. Remove female adaptor ring.

7.1.7. Remove V-ring packing.

7.1.8. Remove male adaptor ring and spring.

7.1.9. Clean all parts thoroughly in solvent, Item 6.3.3.

NOTE

Misalignment due to nicks or high spots will cause unnecessary wear of packing and other parts. Plungers or internal parts should not be re-used if they are scored, worn, or damaged. Job leader shall make the final determination regarding replacement of parts.

7.1.10. Check surfaces of all parts for excessive wear or damage. Replace as neces-sary. Record replacement of any part in the REMARKS Section of the MDRF, Appendix C.

7.1.11. Record completion of Section 7.1 on the MDRF, Appendix C.

7.2. Packing installation and equipment run in

NOTE

For a detailed drawing of the stuffing box and internals see Appendix B.

7.2.1. QC WITNESS POINT. The QC inspector shall verify that the stuffing box spring is installed.

Install stuffing box spring.

NOTE

The flat side of the male adaptor ring must be adjacent to the spring.

7.2.2. Place the male adaptor ring against the spring.

7.2.3. Spray a thin coat of oil, Item 6.3.2, on the packing and the stuffing box internals.

127

CAUTION

Care should be taken not to damage the sealing lip when installing the V-ring.

7.2.4. QC WITNESS POINT. The QC inspector shall verify the sealing lip of

each V-ring points towards the fluid cylinder as they are installed. Each ring joint

will be staggered by 120 degrees in a clockwise direction. Install each of the

6 V-rings individually in the stuffing box with the sealing lip of the V-ring pointing

towards the fluid cylinder. Seat each ring, as it is installed, firmly with the fingers.

Each ring joint will be staggered by 120 degrees in a clockwise direction. Record

completion on the MDRF, Appendix C.

7.2.5. Install the female adaptor ring.

7.2.6. Screw the stuffing box gland (338) into the stuffing box to hold all the parts

in place. Do not tighten.

NOTE

For detailed pump drawing and component identification see Appendix A.

7.2.7. Gently work the plunger (353) through the packing and screw the plunger

into the crosshead stub (122). Tighten securely.

NOTE

• The stuffing box spring applies the proper load on the packing when the gland

is bottomed. No further adjustment is required añer the gland has been tightened.

7.2.8. Screw the stuffing box gland (338) into the stuffing box (337) until it

bottoms out on the stuffing box lip.

7.2.9. Securely tighten the gland (338) to prevent loosening.

7.2.10. Coat cylinder head studs with lubricant, Item 6.3.1.

7.2.11. Install new cylinder head gasket. Record cylinder head gasket replacement

on the MDRF, Appendix C.

NOTE

The cylinder head extension (368) serves as the stop for the suction

valve (320). Therefore, when installing, the prong (stop) must be in a downward

position. The locating pin (650) in the extension must engage in the cylinder head

(367) and pin must be in an upward postion. Care should be taken when installing

the cylinder head extension (368) as not to cock the suction valve spring (334). When

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installing the cylinder head extension "tilting" it will facilitate the installation. If

plunger interferes with installing any of the suction valve stops, rotate main shaft

slightly (by hand) so plunger is moved back to a position where it does not interfere.

7.2.12. Install cylinder head extension.

7.2.13. Install cylinder head.

7.2.14. QC WITNESS POINT. The QC inspector shall either observe the torque

wrench dial indicator or verify the setting and observe the functioning of a break

away torque wrench.

Install cylinder head nuts and torque in increments of 40 ft. lbs to a final torque

of 110 ft.lbs. Record completion on the MDRF, Appendix C.

7.2.15. Request a Control Room Operator to have the blocking tags removed and

clear the local permit, but retain the MRF.

NOTE

A small amount of leakage from the packing may be expected. This will

usually diminish to a very slight amount añer a short period of operation.

CAUTION

If an excessive temperature rise should occur or if steam is observed issuing

from the gland, discontinue pump operation immediately and investigate to deter-

mine the cause of the malfunction.

7.2.16. Request a Control Room Operator to place the system in a condition to run

the pump and then to start the pump.

7.2.17. Run the pump for 1 hour and check pump packing every 10 minutes for

leakage. Record completion of packing leakage check on the MDRF, Appendix C.

7.2.18. Record completion of Section 7.2 on the MDRF, Appendix C.

8. RETURN TO NORMAL

8.1. Ensure that the work area is cleaned up and that proper housekeeping practices

involving tools, equipment, and material used in the performance of the work are

followed. Record completion on the MDRF, Appendix C.

129

Appendix A [to Example 8(b)]

370 317 617 622 341 338 623 632 634 116 112 113 649 620

LIST OF PARTS

Part No. Nomenclature

100 Power frame 112 Connecting rod 113 Connecting rod bol t

116 Connecting rod bearing 117 Crosshead 122 Crosshead stub 123 Crosshead stub deflector 141 Crosshead stub seal cap 154 Crankcase cover 300 Fluid cylinder 317 Discharge valve cover 320 Suct ion valve 321 Discharge valve 334 Suction valve spring 335 Discharge valve spring 337 Stuff ing box 338 Stuff ing box gland 341 Stuf f ing box throat bushing 353 Plunger 366 Stuf f ing box flange plate 367 Cylinder head 368 Cylinder head extension 370 Discharge valve stop 617 Discharge valve cover gasket 619 Cylinder head gasket 620 Crankcase cover gasket 625 . Stuff ing box gasket 623 Crosshead seal cap gasket 632 Crosshead stub seal 634 Crankcase breather 649 A m . st. sq. hd. pipe plug 650 Spring pin (crosshead stub) 650 Dowel pin (cyl. 'hd. to extension)

130

Appendix B [to Example 8(b)]

STUFFING BOX ASSEMBLY

131

Appendix C [to Example 8(b)]

MAINTENANCE DATA RECORD FORM

EQUIPMENT AND PROCEDURE IDENTIFICATION

EQUIPMENT NAME: MRF NO.

EQUIP. NO.

PROCEDURE TITLE. PROCEDURE NO.: PMQ-048-001

Standby Liquid Control Pump Plunger Packing Replacement

4.0. PREREQUISITES VERIFIED

SIGN DATE

5.0. PRECAUTIONS REVIEWED

SIGN DATE

6.0. TOOLS/SERVICES AVAILABLE

SIGN DATE

7.0. PROCEDURE SECTION

RECORD DATA MAINTENANCE QC

PROCEDURE STEP SIGN DATE SIGN DATE

7.1. PACKING REMOVAL AND INSPECTION OF PARTS

7.1.11. Sect. 7.1. Complete SAT UNSAT.

* Explain all unsatisfactory conditions and corrective actions taken in the Remarks Section.

132

MAINTENANCE DATA RECORD FORM

EQUIP. TAG. NO.: PROCEDURE NO. PMQ-048-001

PROCEDURE STEP

RECORD DATA MAINTENANCE

SIGN DATE

QC

SIGN DATE

7.2. PACKING INSTALLATION AND EQUIPMENT RUN IN

7.2.1. Stuffing Box Spring Installed SAT UNSAT*

7.2.1. Stuffing Box Spring Installed

7.2.4. Stuffing Box V-rings Replaced SAT UNSAT*

7.2.4. Stuffing Box V-rings Replaced

7.2.11. Cylinder Head Gasket Replaced SAT UNSAT*

7.2.11. Cylinder Head Gasket Replaced

7.2.14. Cylinder Head Nuts Torqued SAT UNSAT*

7.2.14. Cylinder Head Nuts Torqued

7.2.17. Packing Leakage Check Complete

7.2.18. Sect. 7.2. Complete

SAT UNSAT* 7.2.17. Packing Leakage

Check Complete

7.2.18. Sect. 7.2. Complete SAT UNSAT*

7.2.17. Packing Leakage Check Complete

7.2.18. Sect. 7.2. Complete

* Explain all unsatisfactory conditions and corrective actions taken in the Remarks Section.

133

MAINTENANCE DATA RECORD FORM

EQUIP. TAG. NO.: PROCEDURE NO.

PMQ-048-001

8.0. RETURN TO NORMAL - VERIFIED SIGN DATE

8.1. All tools, equipment and materials removed Wot k area clean

REMARKS:

PERFORMED BY: DATE:

REVIEWED (QC): DATE:

APPROVED (FOREMAN): DATE:

APPROVED (ENG-MAINT): DATE:

134

EXAMPLE 8(c)

E L E C T R I C A L M A I N T E N A N C E D E P A R T M E N T (EMD) FORM: DUN/M/E/55A C O N T R O L ROD A C T U A T O R S E R V I C E TEST SHEET SHEET 1 of 2 SHEETS

135

ELECTRICAL MAINTENANCE DEPARTMENT (EMD) CONTROL ROD ACTUATOR SERVICE TEST SHEET

FORM: DUN/M/E/55A SHEET 2 OF 2 SHEETS

136

Annex II

DESCRIPTIONS OF PRACTICES

This Annex contains descriptions of some practices as adopted by one Operating Organization in Canada. Equivalent practices used by other Operating Organizations may vary to accommodate their particular policies, regulatory require-ments or specific plant designs.

137

PRACTICE 1

THE PLANNING PROCESS

(Section 4.2)

This practice is a description of the planning process as adopted by one Operating Organization in Canada.

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THE PLANNING PROCESS

The principles involved in the planning process are fundamental and well known. A definition taken from the Project Management Institute states that planning is "the process of stating objectives and then determining the most effective activities or accomplishments necessary to meet the objectives".

1. WORK EXECUTION

Each department in the station organization has a defined function within which it controls its own work activities. For example, routine operations performed by the Operations Department require no input from the Planning Department. However, safety system testing is also performed by the Operations Department but the tests are called up and the results are evaluated by the Technical Department and so the scheduling of these tests is co-ordinated by Planning. The general rule is that work that is required by one work unit and is performed by another is requested by means of a Work Order and is co-ordinated by Planning.

An essential element of work execution at a plant is that all work within the plant (operation and maintenance activities) is authorized by and under the general responsibility of the Duty Shift Supervisor who is in charge of operation of the plant for the period of his shift.

2. WORK PLANNING FUNCTION

The functions involved in the planning process are shown diagrammatically in Fig. 1. This shows details of the 'input', 'assessment', 'co-ordination', and 'delivery' functions.

2.1. Input

The primary inputs in the planning and scheduling process are requests to have work done. This is normally by means of the Work Order. All work, with the exception of routine work within a department or emergency work, is channelled through the Planning Department. The department processes approximately 25 000 work requests per year.

Requests for work originate as a result of engineering changes, plant deficien-cies and routine maintenance, all of which must be supported by a Work Order. Safety system testing, fuelling instructions and heavy water management are also co-ordinated by Planning, although these functions are the responsibility of various work groups in the Technical Unit. Secondary inputs include items such as material

141

FIG. 1. Manning schedule process.

supply status, budget information, resource availability, work plans, work priorities, and management direction and decisions.

2.2. Assessments

Job assessment is done by the department responsible for completing the work, normally the Operations or Maintenance Departments. The jobs to be carried out by Operations are assessed by a Shift Supervisor and those to be carried out by Maintenance, by a skilled tradesman. In either case, if the job is complex and non-routine a detailed Work Plan (in logic or step by step format) may be requested which is normally prepared by Technical Unit staff.

Job duration and manhour requirements are estimated and the need for special tools, materials and support from other work groups is identified. This information is fed back to Planning who incorporate it into the Daily Work Programme.

2.3. Co-ordination

The primary means of communications and work co-ordination is through formal planning meetings, of which two are held each work day, one at 9:00 a.m. the other at 11:00 a.m. Both are chaired by Planning Department staff.

The 9:00 a.m. meeting addresses operating problems encountered since the last meeting and establishes priorities from a scheduling and problem solving point of view. Technical problems are assigned to individuals or to a committee to be resolved. A brief update of critical jobs in progress is presented and decisions are made in respect to any new work having a significant operating risk. Work priorities are assigned. Actions arising from the meeting are formalized and followed up by the Planning Department. Those attending this meeting include senior representa-tives from management, planning, technical and operations. The meeting lasts from 20 to 30 minutes.

The main functions of the 11:00 a.m. meeting are work group co-ordination, work activity progress feedback and review of the next day's work programme. The meeting lasts approximately one hour and is attended by the shift (operations) and work group supervisors from each maintenance department.

2.4. Delivery function 'primary'

2.4.1. Daily Work Programme

The Planning Department prepares a Daily Work Programme which is issued every working day. This contains detailed lists of activities for each of the work groups for the next 24-hour period and covers generation, fuelling, heavy water management, safety system testing and maintenance. Critical jobs that are in

143

progress and jobs that are pending in the near term are shown in the section on Short Term Objectives. This is used to advise the shift of upcoming work and also as an agenda for the 9:00 a.m. meeting.

The Daily Work Programme has a number of sections and may run to a document of 30 pages. It is issued at 1600 hours Monday to Friday. The Friday edition covers weekend work.

2.4.2. Medium and long term planning

Medium and long range plans are prepared and issued by the Planning Depart-ment. Medium range plans cover a period of one month and are issued two weeks prior to the beginning of the month. The long range plan which is similar in format to the medium range plan covers a period of 5 years and is revised and issued on a yearly basis.

Activities considered for inclusion in the medium and long range plans are modifications to plant equipment, maintenance on systems which do not impact immediately on plant operation, for example, water treatment plant, standby genera-tors, fuelling machines, heavy water upgrader, etc. Planned maintenance outages are also included on the medium and long range plans.

Plans are considered to be a commitment by management to undertake the activities and expend the financial, human and physical resources necessary to meet the objectives of the plan. They are means whereby work can be levelized.to match available resources. Long range plans alert departments responsible for work both within and outside the station organization of the need to have work plans prepared, support organizations ready, and material ordered in time to allow the activities shown on the long range plans to be executed efficiently and without delays. Typical of the extent of the long term planning is the Turbine Generator sectionalized maintenance programme.

2.4.3. Poison Outage Plan

A natural uranium fuelled heavy water moderated reactor is subject to a forced outage of 36 hours duration if it is tripped from high load following a period of high power operation and if it is not restarted and loaded within 30 minutes. This is due to buildup of neutron absorbing poisons in the fuel. This type of forced outage is termed a 'Poison Outage'.

A Poison Outage Plan is issued every week. The activities included in the plan are jobs whose durations are such that work can be completed in a 36-hour period when the unit is shut down.

At a single unit plant, around the clock maintenance cannot be economically justified and so in the event of a poison shutdown, the Duty Shift Supervisor contacts the needed maintenance personnel at any hour of day or night in order to implement the plan. Staff are placed 'on call' to meet this eventuality.

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2.4.4. Annual outage plans

Annual outage plans are prepared well in advance of the outage. Because of the large costs and the tremendous amount of activities involved, outage planning is carried out in great detail using critical path and resource levelling techniques. The methods used to plan, schedule and control outage work are described in Practice No. 3 of Annex II "Outage Planning and Management".

2.5. Delivery function 'secondary'

Functions in the secondary delivery area are centred on the monitoring and reporting related to the overall maintenance management system. These include such items as work backlog and work performance reports.

145

PRACTICE 2

COMPUTERIZED MAINTENANCE MANAGEMENT

(Section 4.2)

This practice is a short description of a computerized maintenance management programme as adopted by one Operating Organization in Canada.

147

COMPUTERIZED MAINTENANCE MANAGEMENT

1. BACKGROUND

In the utility the use of the computer as an aid to maintenance management was recognized during the early 1960s when a system-wide preventive maintenance program was implemented. This system, although suffering from slow turnaround imposed by the batch type input and update, was quite effective. As computer technology improved, it became possible for the Plant Operations Group to develop and implement during the early part of 1975 an on-line spare parts inventory control system which, although not envisaged at the time, became the first block of what will finally become a totally integrated maintenance management system. Over the inter-vening years development work has continued to a point where today there are in operation on-line control and information systems for:

(1) Equipment records (2) Inventory systems (spare parts and consumables) (3) Work orders (4) Temporary change records (5) Time keeping (6) Design change control (7) Work permits (8) Project management

It is worth noting that development of the system is an ongoing process. Users continue to identify ways to improve a system despite the effort expended in the initial design. Currently there are proposed enhancements to every system and the Work Order System programs are in the process of being completely rewritten.

The on-line, data storage, selective access, data manipulation and report generating capabilities of the computer have revolutionized the utility's approach to planning and maintenance management. No longer is it impossible to deal with bulk data in an attempt to extract needed information. It is at last possible to distinguish the 'wood from the trees'.

2. EQUIPMENT RECORD SYSTEM

The equipment record system is currently in the process of development. The system is designed to provide access to the user groups to permanent equipment records, examples of which are name plate data, work history, spares, drawings, etc. The spare parts, work history and asset costing modules are presently in place.

149

3. MATERIAL INVENTORY SYSTEM

The inventory system permits maintenance planners to interrogate the stores system to establish whether needed spare parts and consumable materials are available. The location of the parts are tabulated. Parts may be identified in a number of different ways, such as by part numbers, by equipment numbers, by sub-assembly, by manufacturer, etc. Inventories can be checked and costs of used components can readily be traced and assigned to appropriate charge numbers. Federal and Provincial Taxes which vary in amount with the use to which the spare part is assigned can be traced and accumulated. Re-ordering of spares is normally on a maximum/minimum basis and purchase requisitions are automatically generated by the computer. A perpetual inventory system is incorporated so that annual stock taking inventories are no longer required.

4. WORK ORDER SYSTEM

The system can be categorized as consisting of four basic subprograms, namely:

(1) Information data bank (2) Preventive maintenance program (3) Scheduling program (4) History

Information data bank

All preventive maintenance and deficiency work orders are input to the computer through a standard screen format. The system allows for the recording of 23 separate records per work order. Provision is made for inquiry, revision or dele-tion to any of the work order records by function selection. The inquiry function is available to all user groups with the remaining functions being restricted through the use of a keyword lock. A total of 20 terminals are in use throughout the plant.

Preventive maintenance system (PMS)

Preventive maintenance work orders entered into the system are held in a master file. The program will accept service intervals on a calendar time, number of operations or hours run basis. To assist the work groups levelize the PMS work load, a histogram may be produced which shows the work load distribution on a weekly basis for a twelve month period.

150

Using the appropriate built-in logic, the computer will transfer work orders to the outstanding file as and when they fall due to be later scheduled through the daily scheduling system by the planning department. PMS work orders are computer generated on a preprinted form for distribution to the work groups. A default system is incorporated to monitor work orders which lapse their due date by a user specified time limit, normally one-third of the service interval.

Scheduling

Scheduling is a fairly simple process once it is determined which work orders are to be included, this being the responsibility of the Senior Planner.

The Senior Planner from a review of the Work Backlog determines on a day to day basis work which shall be scheduled. The timing is determined by the current work on the resident seven day schedule, resource availability and plant conditions. This information is input to the computer through the Work Schedule module. Department and foreman daily work schedules are produced upon user demand.

History

Upon being advised that work is completed (return of the Work Order form to Planning) the computer will transfer the record to the history file. Provision is made to record information in respect to fault found, reason for fault, work carried out and actual manhours utilized. Screen access by equipment is available to all user groups.

5. TEMPORARY CHANGE RECORDS

Temporary changes to plant hardware or software are tracked by means of Temporary Change Records. Permanent changes to plant hardware and software are also tracked by the Temporary Change Records until the plant permanent documen-tation has been updated. Whenever any change is made to the plant which is not shown on the permanent station records, a Temporary Change Record is created. For safety reasons, it is desirable to record all temporary changes in a readily accessible form. Typically there may be 500 to 1000 Temporary Change Records in existence at any one time.

The Temporary Change Records are classified in order of significance of their impact on safety and can be called up on the computer. This record is useful both in operation and when planning work.

151

6. TIMEKEEPING

Manhours expended by the plant staff are entered using an account numbering system. This system permits maintenance and operating costs to be collected by equipment or by plant system. Thus the actual cost of maintenance can be collected against individual items of equipment. Although this is now feasible, breakdown of work into individual jobs involves entering a very large amount of data and a deci-sion as to implementation has not yet been made. The system is, however, used to collect time for the purpose of pay, overtime, vacation and absenteeism which is transmitted electronically to Head Office.

7. DESIGN CHANGE CONTROL

Any change to the station design must be approved by Station Management and in some cases by the regulating authority (The Atomic Energy Control Board). Formal submissions to a committee of Station Management are made by the Technical Unit Staff where a change is judged necessary. Approved changes are listed on the computer which tracks the details of when the change is approved, when it is implemented and when the station records are updated.

8. WORK PERMITS

Work Permits are issued by the Shift to allow safe working conditions for maintenance. Work Permits may be temporarily suspended or permanently surren-dered. Some permits may be temporarily suspended to permit testing thereby making working conditions unsafe and afterwards re-issued when safe working conditions have been restored. Safety of the plant staff and prevention of damage to plant equip-ment depend on this system working successfully and formal rules are rigidly enforced to ensure conformance.

A computer program is provided so that the Work Permits in effect at any time can easily be tracked.

9. REPORTS

The report generating capability of the computer allows unlimited choice to the user. Listings of system data can be produced, sorted by any of the parameters. Out-standing work orders can be sorted by Work Group, material catalogues alpha sort, outstanding Temporary Change Records sort by serial number and work history by equipment.

152

In addition to the data base listings, summary reports and trends are provided which monitor performance and highlight current system status. Typical reports are Work Order summary by risk, which shows the number of work orders and manhours in backlog expressed in terms of priority and unit state under which work can be completed, work backlog trends expressed in manhours and weeks, the former applies to outage category work, the latter to routine on-line work, and work group performance report which summarizes work order transactions.

As an example of the value of these reports, backlog trends are reported on a monthly basis for each Work Group which provide management with an indication of maintenance manpower requirements. They are used to justify overtime, use of contract labour or additions to complement should the backlog become excessive. Eight to ten weeks of backlog work is the normal range for the Mechanical Work Group.

The final category of report available from the system addresses the control aspect. Typical reports in this category include Work Orders awaiting material, PMS work orders in default, Material expediting, Temporary Change Records in default, etc.

153

PRACTICE 3

OUTAGE PLANNING AND MANAGEMENT

(Section 4.2)

This practice is a description of the outage planning and management as adopted by one Operating Organization in Canada.

155

OUTAGE PLANNING AND MANAGEMENT

Outage planning, although following the same basic principles as used in day-to-day planning, is complicated because of the large number of activities involved (3400 during an outage at a power plant) and resource availability (in that large numbers of contract labour are required) and the need for physical resources such as cranes and accommodation for the increased work force present difficulties. The peak manpower required during an outage can reach 300.

In planning, the level of control is directly related to the level of detail used in preparation of the plan. Economics dictate that maintenance outages are planned in extreme detail. Critical path methodology and resource levelling techniques are used as an aid to the development of an optimized plan.

1. OUTAGE PLANNING

Outage planning is never ending. As soon as one outage is completed work commences on the next. Planning activity accelerates to a point when three to four months prior to the outage date sufficient data are available to allow detailed planning to commence.

A planning schedule is produced which shows critical planning activities which must be completed in order to produce a workable outage plan. It is important to note that all departments are involved in the preparation of the plan. The Planning Department, however, having the overall responsibility, spearheads and co-ordinates this effort.

Outage planning is not limited to the outage. Detailed plans are also prepared for outage prerequisite work, unit rundown and unit runup.

All plans are prepared using the building block approach with the following principal steps:

Step 1. Identify activities. Primary work activities are identified through a review of the backlog of deficiency work orders, preventive maintenance work orders, regulatory in-service inspection programme and engineering pending work load.

Step 2. Assessment. All primary work requests are assessed, durations, manhours, skills support activities and material requirements are identified for each activity. Where support activities are necessary, work orders are raised and logic diagrams prepared to show the dependences. Scaffolding, electrical isolation, and insulation removal are examples of support work. All large jobs are incremented into activities of duration that allows for effective control. This increases the accuracy of feedback information and ensures that project bottlenecks are identified before

157

they reach crisis proportions. Establishing target dates for completion of certain phases of the planning process such as shown on the Planning Schedule does not ensure that the tasks are completed in an orderly and timely manner. In actual practice the setting of target dates tends to defer tasks until the latest start date.

To avoid this, monitoring systems are put in place to control the rate of input such that bottlenecks are avoided. Typical of the control system used is the Work Order Assessment production curve. Similar curves are prepared for material delivery, work plans and engineering packages. These are updated on a weekly basis.

Step 3. Prepare system logic network. To make for easier project logic development the work is categorized by system and individual system logics prepared.

Step 4. Review. System logics are reviewed by the Technical Unit and Work Group Supervisors and revised as necessary.

Step 5. Prepare time based schedule. The system diagrams are merged to establish a total project network from which the computer calculates the critical path, this being the longest irreducible sequence of events through the network, schedules non-critical .jobs so as to levelize resources and develops a time based schedule. Manpower demand histograms are preduced which will indicate the maximum level of manpower required to achieve the earliest completion.

Step 6. Review for interference. The schedule is reviewed for interference, for example congestion (too many crafts in one area), work scheduled in areas where X-rays are being conducted, etc. A senior operator is assigned full time to the task of establishing the necessary isolations and work permits. He later assumes the role of permit co-ordinator during the implementation phase. Work permits are used to guarantee safe working conditions.

Step 7. Analysis. Schedule analysis involves the introduction of 'what if?' situations to find a schedule which is acceptable both from a fiscal and practical view-point. The process provides to management alternative plans which can range from maximum effort (shortest schedule) to minimum effort (lengthened schedule) based on eight hours per day coverage.

A cost comparison between the early and lengthened schedules, which includes the energy replacement cost, is made. A time-cost trade-off curve may be produced so that management has the option of selecting the schedule that will result in the lowest total cost.

Step 8. Management approval. Having evaluated the alternatives, manage-ment selects the most appropriate schedule. Limitations such as manpower and budget may induce management to select a schedule which is other than the optimum presented.

158

Detailed resource levelling is performed on the alternative selected to determine the project manpower levels required and a final detailed schedule produced.

Step 9. Foreman review. A meeting is held with each foreman to discuss the work for which he is responsible to ensure that there is full understanding as to the work involved and the deadlines imposed by the schedule. For discussion purposes a schedule showing only that work which the foreman is involved in is available.

2. OUTAGE MANAGEMENT

Outage management can be categorized as having the following basic functions:

(1) Communications (2) Co-ordination (3) Feedback and analysis (4) Control.

2.1. Communications

The primary means of communications to the work group, management and other interested parties is through a plan which is produced daily called the "Outage Daily Work Programme" and through Foreman work schedules.

The Outage Work Programme (an information document) consists of 3 sections:

Section 1 contains the principal jobs and heat sinks in network form. Section 2 is a two-day look ahead bar chart showing jobs in progress and work scheduled for the period. Section 3 consists of individual department two-day look ahead bar chart.

The individual foreman schedule has a dual function, that of communicating to the foreman the work scheduled for his crew for the next 24-hour period and also provide a means of job progress feedback to Planning.

2.2. Co-ordination

Co-ordination is accomplished through formal meetings of which two are held each day. A 9:00 a.m. meeting whose objectives are similar to that described in Practice No. 1 of Annex II and a 3:00 p.m. meeting with work group supervisors to review and co-ordinate group activities scheduled for the next 24-hour period.

159

2.3. Feedback

Job progress and any contingency work is obtained between 8:00 a.m. and 9:00 a.m. each day and the programme is updated. A critical path analysis is completed to determine the impact, if any, of delays or unplanned events on the schedule.

2.4. Control

Control is accomplished by monitoring the total float, this being the amount of time that an activity may slip before impacting on the target end date.

Critical areas (activities with zero or minus float) are resolved by face to face meetings with the person having direct input or interface with the problem at hand. Where possible, extra resources may be obtained or moved from other areas in order to maintain progress according to plan.

160

LIST OF PARTICIPANTS

CONSULTANTS MEETINGS Vienna, Austria

5 to 14 December 1984 and 14 to 18 October 1985

D'Ardenne, W.

Hofmann, W.

Novak, S. (Scientific Secretary) (IAEA)

Simons, H.

Wenk, M.

General Electric Company, 175 Curtner Ave., MC682 San Jose, CA 95125, United States of America

Bundesministerium fur Forschung und Technologie, R3122, Heinemannstr. 2, D-5300 Bonn, Federal Republic of Germany

Division of Nuclear Safety, International Atomic Energy Agency, P.O. Box 100, A-1400 Vienna, Austria

The Old Rectory, Newenden, Hawkhurst, Kent TN 18 5PL, United Kingdom

Nuclear Power Plant Obrigheim, D-6951 Obrigheim, Federal Republic of Germany

ADVISORY GROUP MEETING Vienna, Austria

10 to 14 June 1985

Albrecht, L.

Bertini, A.

D'Ardenne, W.

Higashi, A.

Kacmary, S.

Malherbe, C.

Staatliches Amt für Atomsicherheit und Strahlenschutz, Waldowallee 117,

DDR-1157 Berlin, German Democratic Republic

ENEL-DPT, Via G.B. Martini 3, 1-00198 Rome, Italy

General Electric Company, 175 Curtner Ave., MC682 San Jose, CA 95125, United States of America

Japan Atomic Power Co. JAPCO, Ohtemachi Building, 6-1, 1-Ohtemachi, Chiyoda-ku, Tokyo 100, Japan

Nuclear Power Plant Research Institute, CS-91931 Jaslovské Bohunice, Czechoslovakia

Electricité de France, Département matériel du Service de la production thermique, 3 rue de Messine, F-75080 Paris, France

161

Novak, S. (Scientific Secretary) (IAEA)

Rangarajan, V.

Simons, H.

Wenk, M.

Division of Nuclear Safety, International Atomic Energy Agency, P.O. Box 100, A-1400 Vienna, Austria

Madras Atomic Power Plant (MAPP), Kalpakkam, India

The Old Rectory, Newenden, Hawkhurst, Kent TNI8 5PL, United Kingdom

Nuclear Power Plant Obrigheim, D-6951 Obrigheim, Federal Republic of Germany

162

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It would greatly assist the International Atomic Energy Agency in its current review of its publications programme if you could kindly fill in one of the attached postcards and return it to the address shown. Your co-operation is greatly appreciated. IAEA

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5. How do you normally purchase IAEA publications? Through booksellers [ ]; through direct purchase [ ]; through your national Atomic Energy Commission or similar body [ ].

6. Would you like to have a free subscription to the IAEA publications catalogue? Yes [ ] No [ ]

1. Title of book:

2. Did you purchase the book? [ ] Did you borrow it from a library? [ ]

3. By what means did you learn of its existence? A book notice [ ]; a book review [ ]; the IAEA publications catalogue [ ]; IAEA meetings [ ]; IAEA newsletters [ ]; a professional colleague [ ]; scientific literature [ ]; other means (please specify) [ ]:

4. How do you rate the usefulness of the content? Very useful, not found elsewhere [ ]; useful as a survey [ ]; useful for reference [ ]; useful because of its international character [ ]; useful for training or study purposes [ ]; not very useful [ ].

5. How do you normally purchase IAEA publications? Through booksellers [ ]; through direct purchase [ ]; through your national Atomic Energy Commission or similar body [ ].

6. Would you like to have a free subscription to the IAEA publications catalogue? Yes [ ] No [ ]

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International Atomic Energy Agency Sales and Promotion Unit P.O. Box 100 Wagramerstrasse 5 A-1400 Vienna Austria

Sender:

Name: Address:

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International Atomic Energy Agency Sales and Promotion Unit P.O. Box 100 Wagramerstrasse 5 A-1400 Vienna Austria

It would greatly assist the International Atomic Energy Agency in its current review of its publications programme if you could kindly fill in one of the attached postcards and return it to the address shown. Your co-operation is greatly appreciated. IAEA

1. Title of book:

2. Did you purchase the book? [ ] Did you borrow it from a library? [ ]

3. By what means did you learn of its existence? A book notice [ ]; a book review [ ]; the IAEA publications catalogue [ ]; IAEA meetings [ ]; IAEA newsletters [ ]; a professional colleague [ ]; scientific literature [ ]; other means (please specify) [ ]:

4. How do you rate the usefulness of the content? Very useful, not found elsewhere [ ]; useful as a survey [ ]; useful for reference [ ]; useful because of its international character [ ]; useful for training or study purposes [ ]; not very useful [ ].

5. How do you normally purchase IAEA publications? Through booksellers [ ]; through direct purchase [ ]; through your national Atomic Energy Commission or similar body [ ].

6. Would you like to have a free subscription to the IAEA publications catalogue? Yes [ ] No [ ]

1. Title of book:

2. Did you purchase the book? [ ] Did you borrow it from a library? [ ]

3. By what means did you learn of its existence? A book notice [ ]; a book review [ ]; the IAEA publications catalogue [ ]; IAEA meetings [ ]; IAEA newsletters [ ]; a professional colleague [ ]; scientific literature [ ]; other means (please specify) [ ]:

4. How do you rate the usefulness of the content? Very useful, not found elsewhere [ ]; useful as a survey [ ]; useful for reference [ ]; useful because of its international character [ ]; useful for training or study purposes [ ]; not very useful [ ].

5. How do you normally purchase IAEA publications? Through booksellers [ ]; through direct purchase [ ]; through your national Atomic Energy Commission or similar body [ ].

6. Would you like to have a free subscription to the IAEA publications catalogue? Yes [ ] No [ ]

Sender:

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City: Postal Code: Country:

International Atomic Energy Agency Sales and Promotion Unit P.O. Box 100 Wagramerstrasse 5 A-1400 Vienna Austria

Sender:

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International Atomic Energy Agency Sales and Promotion Unit P.O. Box 100 Wagramerstrasse 5 A-1400 Vienna Austria

I N T E R N A T I O N A L S U B J E C T G R O U P : II A T O M I C E N E R G Y A G E N C Y Nuclear Sa fe ty a n d E n v i r o n m e n t a l P r o t e c t i o n / N u c l e a r S a f e t y V I E N N A , 1 9 8 6 P R I C E : A u s t r i a n Schi l l ings 3 8 0 , -