Work Management and SAP Nuclear

Danilo SpazianiEBO NPP

18th Annual Nuclear Seminar and Information Meeting

Častá-Papiernička, 28-29th April 2010

2

Agenda

1. SAP Nuclear Project

2. Project implementation

3. Work Management Process: on-line and outage maintenance in SE

4. The IPSEC steps: corrective and recurring maintenance

5. Conclusions

3

1. SAP Nuclear Project

2. Project implementation

3. Work Management Process: on-line and outage maintenance in SE

4. The IPSEC steps: corrective and recurring maintenance

5. Conclusions

Agenda

4

SAP Nuclear Project: Need for Change

The long term goal for Sloveske Elektrarne Nuclear is to achieve Top Decile Performance in Safety, Reliability, Production, and Efficiency and become the

World’s Premier Operator Of VVER Technology

An international benchmarking effort to identify Nuclear Industry Best Practice resulted in recognition of significant gaps in the following programs:

• Work Management

• Equipment Reliability

• Corrective Action

• Operating Experience

• Self Assessment& Benchmarking

• Human Performance Improvement

• Current Software (ARSOZ) not supporting Best Practice Programs

SE needed to establish a model that

specified appropriate safety and

operational standards including

management, quality assurance,

practices and behaviors

55

Electricity Production

CORE PROCESSES

ENABLING PROCESSES

Operate Plant(INPO)

INPO 01-002 Conduct of Operations

Work Management(INPO)(AP-928)

Materials and Services(NEI)

(AP-908)

Manage Configuration

(CMBG)(ANSI/NIRMA CM 1.0-2000)

Equipment Reliability(INPO)(AP-913

ManagementProcesses and

Support Services(NEI)

LossPrevention

(NEI)

Training(INPO)(AP-921)

Nuclear Fuel

(NEI)

SAP Nuclear Project: SNPM

The SAP Nuclear Project is the Implementation Phase of a 3-years MAJOR Process and Organizational Redesign of the Slovenské Elektrárne

Nuclear Organization

Standard Nuclear Performance Model

6

SE Model redesign resulted in new Programs based on Nuclear Industry Best Practice in the following areas:

• Work Management – INPO AP 928

• Equipment Reliability – INPO AP 913 (project ongoing)

• Corrective Action – WEC functionality based on North American Best Practice

• Operating Experience

• Self Assessment&Benchmarking

• Human Performance Improvement

SAP Software System configured and customized to support Nuclear Industry

Best Practice Programs

SAP Nuclear Project: Benefit

Implementation of the SAP Nuclear Project will act as an accelerant to process, organizational, and behavioral

change leading to significant gains in safety, efficiency, plant performance, and organizational behavior

7

Agenda

1. SAP Nuclear Project

2. Project implementation

3. Work Management Process: on-line and outage maintenance in SE

4. The IPSEC steps: corrective and recurring maintenance

5. Conclusion

8

SAP Nuclear – Project Objectives and Strategy

Radiation and Radioactive Waste Management Processes.

ARSOZ is considered as process standard for new implementation.

Strategy:

Replace ARSOZ by SAP functionality.

No Major Process Changes.Small changes will be made to adapt to EH&S and

to align facilities on single processes

Work Management, Equipment Reliability, and Continuous Improvement Processes.

INPO Guidelines are standard

AP-928 (Work Management Process Description)

AP-913 (Equipment Reliability Process Description)

Corrective Action Process - based on Nuclear Industry best practices as key

inputs in process designs

Strategy:

New processes, new organization structure, and new software system.

Improve EBO and EMO safety and operational performance

New Integrated system

SAP Nuclear Competence Centre

Bu

ild

up

S

AP

Nu

cle

ar

Co

mp

ete

nc

e C

en

tre

9

SAP Nuclear Project – SE Approach

2008

Change Management

Go-Live:

EAM

Template

Tender

EAM 80%

Baseline

4 – 6/08 7 – 9/08 10 – 12/08 10 – 12/094 – 6/09 7 – 9/091 – 3/08 1 – 3/10

EH&S

Concept

Development

of RICEFW

Implementation

EH&S

Baseline

2009

4 – 6/10

Limited Production

(Planning 2010)

EMO/EBO

ARSOZ – running

200-300 End Users

2010

Full production

EMO

Full production

EBO

Tra

inin

g

of

Tra

ine

rs Tra

inin

g

En

d U

se

rs(2

00

)

Training of end Users

(cca. 2800)

Migration 1 Migration 2 3

Sup. 1 Sup. 2 Sup. 3

Preliminary Go-Live:

10

Agenda

1. SAP Nuclear Project

2. Project implementation

3. Work Management Process: on-line and outage maintenance in SE

4. The IPSEC steps: corrective and recurring maintenance

5. Conclusion

11

As defined in the INPO AP-928 the Work Management process is used to Identify,

Plan, Schedule, Execute, and Close work in a manner that helps ensure high levels of

safe and reliable plant operation.

The process encompasses the following steps:

Work Identification

Planned Maintenance – Preventative and Surveillance

Corrective Maintenance

Modification Activities - Investment

Work Planning

Technician Instructions

Parts, Tools, Blocking, R-Orders, etc.

Work Scheduling

Daily, Weekly, quarterly, cycle online schedules

Outage schedules

Long Term Schedules

Work Execution

Work Close

Work Management in SE

IPSEC

On-line

Outage

12

Work Management: Online Activities

Work management is the process by which maintenance, modifications, surveillances testing, engineering support, and any work activities that require

plant coordination or schedule integration are implemented

Processes are simple, efficient, incorporate human factors considerations, and ensure effective performance during all phases of plant operation

Planning and scheduling are applied to activities that impact plant operation or require detailed work instructions.

The duration of the scheduled work activities are reviewed against technicalspecifications and Probabilistic Risk Assessment (PRA). Work is scheduled to optimize safety system availability and to ensure maintenance can be performed

within allowed regulatory or administrative time limits

13 Weeks Cycle

13

E-10

Sch

edu

le E

-10

E-12

Sco

pe E

-12

E-11 E-9 E-8 E-7 E-6 E-5 E-4 E-3 E-2 E-1 E-0 E+1

Sco

pe F

reeze

Sch

edu

le F

ree

zing

Work

Pack

age R

eady

Sch

ed

ule

E-4

Work

Exe

cutio

n

Revi

ew

- F

eedb

ack

s

Rig

ht W

ork

Me

etin

g

Sco

pe

Eva

luatio

n

Me

etin

g

Coo

rdin

atio

n

Me

etin

g

Sco

pe F

reeze

Meetin

g

Cyc

le M

g /

Work

Wee

k M

g

Turn

ove

r

Sch

edule

Fre

eze

Meetin

g

Tech

nic

al R

igor

Re

view

Work

Wee

k

Turn

ove

r

Pla

n o

f th

e D

ay

Meetin

g

Post

Wo

rk

Week

Critiq

ue

Meetin

g

Planning

Scheduling

Engineering

Parts - Materials – External Resources

Operation - PRA

Operation - Clearance

Work Groups

Work Manager

E-28

Sco

pe E

-28

Long a

head

scope m

eetin

g

Scope Cooling

Cycle Manager

Schedule Cooling

Work Management: On-line 13 Week Cycle

14

Work Management: Refueling Outages

Each phase is characterized by set of predefined milestonesaccurately scheduled in order to optimize the whole

Outage Management process

The Outage Management process defines a structured approach for the preparation, the execution and the assessment of refuelling outages by

following the Work Management principles through the IPSEC steps implementation over a period of 21 months

M-19 M-18 M-11 M-10 M-9 M-8 M-7 M-6 M-5 M-4 M-3 M-2 M-1 M-0 M+1

WCD

preparation

Execution

phase

Outage

scope

freeze

Identify

long lead

material

Identify pre-

outage

team

Pre-outage

readiness

assessmen

Outage

activities

execution

Set outage

golas

Design

scope

freeze

Engineering

scope

freeze

Perform

ALARA

evaluation

Identification Phase Preparation Phase

Work

schedule

tracking

Outage

review

process

Feedback &

lessons

learned

Issue

Schedule

Rev. A

Issue

Schedule

Rev. B

Issue

Schedule

Rev. 0

Issue

Schedule

Rev. 1

Operations

planning for

Wos

Complete

planning

process

Evaluation

phase

15

Agenda

1. SAP Nuclear Project

2. Project implementation

3. Work Management Process: on-line and outage maintenance in SE

4. The IPSEC steps: corrective and recurring maintenance

5. Conclusions

16

The IPSEC Steps: Why SAP

Why SAP?

SAP advantages:

• For every management level:

- flexible approach to important information on time

- data reliability

- approach to the same information for every user (limited only by position)

- easier decision process

• For every organization element:

- improvement of the management for operations and transactions

- easier data processing and distribution

- easy maintenance

- used all over the nuclear industry

R/3

CO

AM

IM\PS

WF

ISHR

SD

PP

QM

FI

PM

MM

SAP

EH&S

Implemented

Modules

in SE, a. s.

The IPSEC Steps: Why SAP

Modules Description:

SD Sales and DistributionMM Materials ManagementPP Production Planning and ControlQM Quality ManagementPM Plant MaintenanceHR Human ResourcesEH&S Environmental Health and SafetyIS Industrial SolutionsWF Work flowIMPS Investment managementAM Asset Management CO Controlling FI Financial PS Project system

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The IPSEC steps: Corrective Maintenance

Maintenance work isIdentified

Notification is reviewed and

converted into a work order

Work is Planned and Scheduledand the work order is released

Maintenance work is assigned and

Executed

Work progress work and status

SAP

SAP

Maintenance notification is created in SAP

SAP / WEB

Work order is “Technically Closed” by the Planner

(TECO)

Accounting settles the work order and business

close.

End

19

Work order is autogenerated

(Identified) in SAP from Maintenance

plans

Work is Planned and Scheduledand the work order is released

Maintenance work is assigned and

Executed

Work progress work and status

SAP

SAP

Work order is “Technically Closed” by the Planner

(TECO)

Accounting settles the work order and business

close.

End

The IPSEC steps: Recurring Maintenance

Create/ Update Task List/ Maint.Plan

Identify changes to

the Plan

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AP-928

AP-913

Identify Plan Schedule Execute Close

-Object

-Symptoms

-When

Create Notif.

-Object

-When

-What steps

-Resources

-Internal Labor

-Contractors

-Services

-Materials

-Tools

-When

-What steps

-Avail. Res.

-Avail. Eqpmt

-Capacity

Create WO

Release WO

Schedule WO

-Shop papers

-Use resources

-Parts

-Materials

-Tools

-Purchasing

Print Work Order

Assign WO

Perform Work

-Work complete

-Time recorded

-What was done

-Labor used

-Parts used

-Materials used

-Return tools

Complete WO

Complete Notif.

Analyze

-Usage history

-Performance

-KPIs

Continuous

Improvement

The IPSEC steps: Identification

21

1. Initial problem discovery

Operator identifies problem during normal rounds / personal identifies issues

Captures data

Tags equipment

2. Problem entered in SAP as a Notification

3. Initial Review – Shift Supervisor

Operability review (task generation)

Approval

4. Work Control Team Review – daily SOC meeting

Create work order

Code work order to online or outage

Set priority and preliminary schedule target (5 priorities)

5. Work Order Coding

Assign WO to main Work Management Cycle (online – outage)

Code WO out of Work Management Cycle (FIN team – minor maintenance – recurring activities)

The IPSEC steps: Identification

WHAT

22

Identify Plan Schedule Execute Close

-Object

-Symptoms

-When

Create Notif.

-Object

-When

-What steps

-Resources

-Internal Labor

-Contractors

-Services

-Materials

-Tools

-When

-What steps

-Avail. Res.

-Avail. Eqpmt

-Capacity

Create WO

Release WO

Schedule WO

-Shop papers

-Use resources

-Parts

-Materials

-Tools

-Purchasing

Print Work Order

Assign WO

Perform Work

-Work complete

-Time recorded

-What was done

-Labor used

-Parts used

-Materials used

-Return tools

Complete WO

Complete Notif.

Analyze

-Usage history

-Performance

-KPIs

Continuous

Improvement

AP-928

AP-913

The IPSEC steps: Planning

23

1. Review – check history – equipment data

2. Preliminary requirements

Check for duplicity

Safety Classification

Approach grade

3. Define Work Scope

Work Steps / operations relationships

Timing

Resources

Support and permits

Work Clearance requirement

4. Materials/Services

5. Documents/Tools

6. Costs – Plan/Actual

7. Statusing for WOs

The IPSEC steps: Planning

HOW

24

AP-928

AP-913

Identify Plan Schedule Execute Close

-Object

-Symptoms

-When

Create Notif.

-Object

-When

-What steps

-Resources

-Internal Labor

-Contractors

-Services

-Materials

-Tools

-When

-What steps

-Avail. Res.

-Avail. Eqpmt

-Capacity

Create WO

Release WO

Schedule WO

-Shop papers

-Use resources

-Parts

-Materials

-Tools

-Purchasing

Print Work Order

Assign WO

Perform Work

-Work complete

-Time recorded

-What was done

-Labor used

-Parts used

-Materials used

-Return tools

Complete WO

Complete Notif.

Analyze

-Usage history

-Performance

-KPIs

Continuous

Improvement

The IPSEC steps: Scheduling

25

The IPSEC steps: Scheduling

The scheduling is the process necessary to prepare a database containing all the information needed to model the sequence of work tasks required to accomplish the approved online/outage scope, minimizing the plant risk

and optimizing duration, cost and resources mobilization

The main scheduling technique is based on “System window”

principle where all planned maintenance, in service inspection and testing activities on a piece of equipment or a train of a system

are planned to be performed during a pre-defined time period

CDF minimization

FEG 1

FEG 2WCD

WCDWO 1

WO 2

WO 3WO 4

System 1

WO operations

System Window

Functional Equipment Group

Work Clearance Document

time

WHEN

26

Maintenance work isidentified

Notification is converted into a work order

Work is plannedand the work order

is releasedPlanning to

perform initial sequencing of

operations

Run SAP interface to

external software

SAP

Reports run toidentify order for initial

coding (sys cond)Maintenance notificationis created in

SAP

SAP / WEB

Scheduler to schedule

operations andWCD’s in external

software

Run Interface in reverse and send operation data

back to SAP

End

Orders codedto online or

outage

Maint Plan Maintenance plan auto generate

orders

SAP

Finalize and print schedule and

SAP WOs

Perform initial work center

capacityevaluations

SAP – Primavera

The IPSEC steps: Scheduling

27

Order data:Order number, type

Short text

Functional Location

Main Work Center

FEG

Due date

Overdue date

Revision code

Basic start / end date & time

System Status / User status

Add / drop field ( custom)

WCA

FEG of WCA

WCD number

Operations:

Operation #

Operation short text

Control key

Duration

Number of persons

Work center of operation

Early start / finish date & Hours

Actual start / finish date and hours

Relationships data

WCD basic data:

WCD #

WCD Description

WCD Functional Location

System Status / User Status

Revision code of the WCD

FEG of the WCD

Order data:Work Order number

Revision Code

WCA number (linked to Work Order)

WCD number (linked to Work Order)

Operations:

Restriction start date

Restriction start time

Restriction end date

Restriction end time

Activity ID

Project ID

Position on Critical Path

WCD basic data:

Date & time tags hanging start

Date & time tags hanging end

Date & time tags removal start

Date & time tags removal end

Primavera Project ID

Primavera Activity ID

Position on Critical path

SAP

SAP

Primavera

Scheduling Process

Interface - data synchronization

The IPSEC steps: Scheduling

28

AP-928

AP-913

Identify Plan Schedule Execute Close

-Object

-Symptoms

-When

Create Notif.

-Object

-When

-What steps

-Resources

-Internal Labor

-Contractors

-Services

-Materials

-Tools

-When

-What steps

-Avail. Res.

-Avail. Eqpmt

-Capacity

Create WO

Release WO

Schedule WO

-Shop papers

-Use resources

-Parts

-Materials

-Tools

-Purchasing

Print Work Order

Assign WO

Perform Work

-Work complete

-Time recorded

-What was done

-Labor used

-Parts used

-Materials used

-Return tools

Complete WO

Complete Notif.

Analyze

-Usage history

-Performance

-KPIs

Continuous

Improvement

The IPSEC steps: Execute

29

Work Order is Executed

Operations to hang Work Clearance Tags in the field

WCA is approved

Permits are approved

Order is set by Ops to EXEC (Ready to execute)

Maintenance sets Order User status to MWIP (in progress)

Execute the work into the filed

Field operations partially and then finally confirmed

Outage schedule tracking / adjustment

Work executedSAP - Primavera

Schedule tracking

Outage

The IPSEC steps: Execute

30

AP-928

AP-913

Identify Plan Schedule Execute Close

-Object

-Symptoms

-When

Create Notif.

-Object

-When

-What steps

-Resources

-Internal Labor

-Contractors

-Services

-Materials

-Tools

-When

-What steps

-Avail. Res.

-Avail. Eqpmt

-Capacity

Create WO

Release WO

Schedule WO

-Shop papers

-Use resources

-Parts

-Materials

-Tools

-Purchasing

Print Work Order

Assign WO

Perform Work

-Work complete

-Time recorded

-What was done

-Labor used

-Parts used

-Materials used

-Return tools

Complete WO

Complete Notif.

Analyze

-Usage history

-Performance

-KPIs

Continuous

Improvement

The IPSEC steps: Close

31

Time sheet Entry

Materialsusage

Cost

settlement

Technical completion

Notifica-tions

ActivityReports

Work Order

Completion

Work Order and Notification Closed

WO set WOCO status by Maintenance

WCA is completed by Maintenance

WCD set to untag by Plant Operations

Safety tags removed in the field

WCD is closed

Notification has history updated and final

trending completed

All open tasks completed

WO is set to a TECO system status

Notification auto closes

WO archived

The IPSEC steps: Close

The IPSEC steps: Work Management KPIs

Work Management Process needs a monitoring system that incorporates a systematic review of actual results and compares these with expectations established by objectives.

As shown by Nuclear industry experience SE adopted an effective way to perform work management monitoring by using a set of indicators (KPIs) that reflect, in a quantitative manner, the achievements

of the expected results for on-line and outage process.

OutageOn-line

KPIs

•Urgent work/High priority

•Scope stability

•On-line executed work

•Weekly executed work

•Not terminated work

•Scope stability from T-6 T-0

•Deviations from planned work man-hours

•WOs operations planned

•WOs planned

•WCD prepared

•WOs added to weekly plan

•Number of NM notifications

•…

KPIs

•Planned outage duration

•Outage scope

•Scope stability

•Outage cost vs. budget

•Outage total dose vs. dose budget

•Regulatory Body involvement

•WOs operations planned

•WOs planned

•WCD prepared

•Materials and services preparedness

•Outage personnel preparedness

•Timeliness of critical path

•Number of Safety events

•Unplanned work rate

•Not executed work rate

•Number of contaminations events

•Number Human performance error events

•…

Evaluated on weekly and

monthly basis via SAP and

interfaced software

33

Agenda

1. SAP Nuclear Project

2. Project implementation

3. Work Management Process: on-line and outage maintenance in SE

4. The IPSEC steps in SAP: corrective and recurring maintenance

5. Conclusions

34

Conclusions

7 months after the SAP Nuclear Project Go-live it can be stated that:

Work Management process is currently implemented at both SE sites (EBO and EMO)

New way of managing work preparation and execution for on-line and outage

Organizational structure completely redesigned to support process implementation

SAP as implemented and customized capable to support the whole Work Management

process (including clearance and permits)

The usage of Primavera for WOs scheduling safe and reliable also for schedule tracking

KPIs used on weekly on monthly bases for process monitoring and improvement

Remarkable increase of operational and safety standards Work Optimization

Alignment with Nuclear Industry leader organizations

Stronger cooperation between SE Facilities and increased capability of international

benchmarking

SAP Nuclear and Work Management experience as an improvement tool to be exported

inside Enel Group nuclear companies

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Questions?