NMAC & PE (Mechanical & Electrical Maintenance) Jim Heishman / Chris Wiegand NMAC & PE Program Managers Integration Committee Meeting August 30, 2016 August 15, 2016 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Emergency Exits: Waldorf Astoria BR (Mezzanine Level)
NOTE: ALL
RED DOORS ARE EMERGENCY EXIT DOORS
WALDORF ASTORIA BALLROOM
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Get Connected…
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Purpose and Objective of the Presentation Discuss Maintenance Themed Research Projects Elicit advice and recommendations on proposed and future projects and long term strategy Solicit input for communications with the ER Action Plan Committee and Nuclear Power Council
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NPC/EC Equipment Reliability Action Plan Committee
Integration Committees
Engineering Programs (BOPC)
Nuclear Power Council
Executive Committee
ER APC
I&C
You are here
Mechanical / Electrical (PE/NMAC)
Program 65 (Turbine - Generator) BOPC – Balance of Plant Corrosion
I&C – Instrumentation & Controls NMAC – Nuclear Maintenance Application Center PE – Plant Engineering 5 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Combined PE/NMAC Integration Committee Chairs PE Chair: Chris Abernathy, Lead Engineer
NMAC Chair: Andrew Barritt, Mechanical Engineering & Maintenance Supervision
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Integration Committee Member Introductions Please introduce yourself! – Name – Utility – Position – How many years have you been coming to these meetings?
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Agenda – Wednesday (Maintenance Focus)
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Integration Committee Report Format Research Focus Areas and Inputs for 2017 Budget Summary and Supplemental Changes ER APC Requests, Issues, or Concerns Examples of Leveraging ER Products Items to Report to Executive Committee or NPC General Session?
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Together…Shaping the Future of Electricity
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Standardized Task Evaluation (STE) Update Presenter: Heather Feldman Program Manager, Engineering Programs (BOPC) Patty Wade STE Coordinator NMAC and PE Integration Committee Meeting August 31, 2016 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Topics Standardized Task Evaluation Program Foundation – What is it? – What is the value? – Who is in it? – How does it work?
Standardized Task Evaluation Program Administration – Utility Implementation – Workforce Provider Implementation
Standardized Task Evaluation Development Future Plans 12 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Standardized Task Evaluation Program Foundation
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What is the Standardized Task Evaluation (STE) Program? Standardizing Tasks Across the Industry Qualification of supplemental maintenance workers –Tasks include rigging, scaffolding, pump maintenance, valve maintenance –Over 80 EPRI developed modules currently available –44 modules on INPO’s NANTeL “Guidelines for On-The-Job Training and Qualification” INPO’s ACAD 91-006, Rev 1 recognizes STEs as alternate basis for qualification 14 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Value – Standardized Task Evaluation (STE) Program FENOC has realized an improved performance of supplemental workforce in critical outage support tasks by implementation of EPRI’s Standardized Task Evaluations. Source: EPRI Product 1020755 Photo courtesy of United Association
Supplemental valve maintenance at TVA: “Through cooperation between our companies, D&Z has trained numerous personnel onsite and qualified them using their AP3 program. Because of this we receive qualified personnel who we are confident can perform their tasks safely and proficiently during our outages.” Source: EPRI Product 3002006720
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•Easily managed qualification process •Enables a “workready workforce”
•Cuts training time and costs •Efficient use training resources
Who participates in the EPRI STE Program? Utilities
Workforce Provider Organizations
AEP
BHI Energy
APS
Day and Zimmermann
Dominion
Electrical Training Alliance (IBEW/NJATC)
Duke Energy
Instrument Contracting & Engineering Association (ICEA)
Energy Northwest
International Association of Bridge, Structural, Ornamental and Reinforcing Ironworkers
Entergy Exelon
International Brotherhood of Boilermakers, Iron Ship Builders, Blacksmiths, Forgers & Helpers, AFL-CIO
First Energy Nuclear Operating Company
Westinghouse
Nebraska Public Power District
UA of Plumbers and Pipefitters (US and Canada)
OPPD
Areva NP (Canada)
Pacific Gas and Electric Co
IBEW – Local 804 (Canada)
Talon Energy
Infrastructure Health and Safety Assoc (IHSA) (Canada)
SC Electric and Gas
Ironworkers Ontario District Council (Canada)
Southern Nuclear
International Brotherhood of Boilermakers (Canada)
Tennessee Valley Authority Wolf Creek Nuclear CANDU Owners Group (Canada) TVA Fossil (Non-Nuclear) Oglethorpe Power Corp (Non-Nuclear)
16 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
What is a Standardized Task Evaluation? EPRI tools are used to test a worker’s knowledge and skills Tools are available from EPRI’s website Task Analysis
Written Exam
Performance Evaluation
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Standardized Task Evaluation Program Administration
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Program Administration Getting Started – Compare utility tasks with Standardized Task Analysis – Identify and resolve gaps
Administer Written Exam and Performance Evaluation – INPO Accredited Training Department – AP3 (EPRI Administration Protocol for Portable Practicals) Compliant Organization
Qualification – Record qualification in EPRI registry, PADS, utility database, and/or workforce provider database 19 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
AP3 Compliant Organizations Enables work force providers to administer STEs
• United States BHI Energy Day & Zimmermann United Association of Plumbers and Pipefitters International Association Bridge, Structural, Ornamental and Reinforcing Iron Workers
• Canada Bruce Power Ontario Power IHSA 20 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
STE Task Qualification Registry Over 15,500 Individuals have successfully completed both a written and performance standardized task evaluation in a given task. • Over 9,000 individuals have successfully completed both a written and performance standardized task evaluation in PERFORM INDUSTRIAL RIGGING • Over 1,500 individuals have successfully completed both a written and performance standardized task evaluation in PERFORM STANDARD RIGGING
• Over 1,000 individuals have successfully completed both a written and performance standardized task evaluation in CALIBRATE GENERAL INSTRUMENTATION
21 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Uses – Examples Site Usage
Industry Usage
• Utility administers STE and enters qualification into utility system • Workforce provider administers STE and enters qualification into EPRI registry and utility accepts qualification
• Registry used to enable portability and work ready workforce
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Standardized Task Evaluation Development
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Working Groups Purpose – Periodic meetings to review and revise existing STEs or to create new STEs
EPRI acknowledges utility and workforce provider support at the working groups. 24 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
STE Task Listing Task listing is available at: – https://membercenter.epri.com/programs/065756/Lists/Attachments/Unique%20Pages/ebc69b 482cac40a3ac2aab68222a270c/STE%20Task%20Listing.pdf
Task listing reviewed on August 3-4, 2016
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EPRI Standardized Task Evaluation Program • Sample Evaluations Include: EM01.05 Electrical Safety for Qualified Worker EM01.06 Clean & Maintain Electrical Cabinets, MCC, Load Center and Switchgear IC04.01 Calibrate General Instrumentation IC06.01 Maintain Air Operated Positioners MM03.01 General Valve Maintenance MM05.06 Maintain Centrifugal Pumps
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Evaluations Developed Using the Systematic Approach to Training (SAT) Process
Source: EPRI Product 3002006470 27 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Future Plans
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Future Plans Support existing STEs as broader implementation occurs Continue to refine task list Potentially expand to areas beyond maintenance tasks – Radiation protection tasks – Alignment of STEs with standardized training and procedures – Chemistry tasks – Engineering tasks
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Together…Shaping the Future of Electricity
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EPRI Standardized Task Evaluation Program Resources EPRI STE Program Brochure (2015) Product: 3002004945 http://www.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002004945 Success Story 3002006720, Standardized Task Evaluation Program Enables Workforce Providers to Accelerate Qualification Efforts, Reduce Training Costs – (2015) http://www.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002006720 EPRI Standardized Task Evaluation Program Implementation Guide, Revision 1 Updated 7/2015 - Product: 3002006470 http://www.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000003002006470 Administration Protocol for Portable Practicals (AP3) – Product1015074 http://www.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000000001021072 Success Story – Dominion – Product 1024815 http://www.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000000001024815 Success Story – First Energy – Product 1020755 http://www.epri.com/abstracts/Pages/ProductAbstract.aspx?ProductId=000000000001020755 31 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
NMAC Valve Update 2016 Deliverables Nick Camilli Sr. Technical Leader Nuclear Power Council – NMAC IC August 31, 2016
© 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Refresher – Key Drivers of Valve Projects Operating Experience – Valve events continue to be the most prevalent in OE reviews
Technology Changes/Knowledge Transfer – Guides are updated to keep up with technology changes and to facilitate knowledge transfer at utilities/plants
Regulatory Changes – Guides are updated to reflect changes in NRC and code requirements
Gaps in existing product catalogue – New guides are developed to address specific needs 33 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
2016 Valve Products 3002008055 Evaluation Guide for Valve Thrust and Torque Requirements
3002008045 Motor-Operated Valve Application Guide Vol:1
#1
3002008047 Motor-Operated Valve Application Guide Vol:2
3002008056 Air-Operated Valve Application Guide
3002007696 Valve Specialist Guide
3002007711 Purge Valve Maintenance Guide
34 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Issue 1) There is significant overlap between the AOV and MOV application guides with regard to Section 5 – methods for determining required thrust or torque. 2) Based on current EPRI internal QA guidance, these required thrust/torque methods need to be published in a QA document.
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Current Situation
Overlap 36 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Resolution Separate AOV Evaluation Guide content into two documents: – Evaluation Guide for Valve Thrust and Torque Requirements Single source document covering all valve types for determining valve required thrust/torque, independent of actuator Includes new balanced disk globe valve research – AOV Application Guide How to calculate actuator capability and margin (valve requirements removed)
Revise the MOV Application Guide, Two Volumes – Remove Section 5 (valve requirements) and replace it with a reference to the new valve evaluation guide – Make all documents QA 37 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Resolution – What this looks like big picture Valve Requirements (How to determine thrust/torque requirements for all valves)
Advantages Eliminate duplication QA
EPRI Test Reports
Actuator Capability (How to determine actuator capability and margin independent of valve)
AOV Application Guide Evaluation Guide for Valve Thrust and Torque Requirements (How to determine thrust/torque requirements)
MOV Application Guide
Future Application Guides?
Design Basis Package for Calculation Support (ASME Appendix III & IV)
38 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
New Research – Balanced Globe Investigation Understanding the Need Sideloading
Imbalance Area
Likely not an issue for most applications Limiting case for most is at closed position Need better prediction technique and screening criteria
Understand “area upon which DP Acts” effect for unbalanced/caged valves Previous work focused on uncaged valves Current guidance uses guide area for Tpattern caged valves
Goal: Remove conservatism! More accurate predictions = better resource allocation 39 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Approach for Sideloading/Imbalance Area Investigation Scope: T pattern, Cage Guided, Balanced Plug Test Specimen 1
Development
Validation
CFD Model
Apply Methodology to Specimen
CFD Analysis Flow Loop Testing
– Fisher 4” 150 lb Model ED
Develop Sideloading Methodology
Test Specimen 2 – Masoneilan 4” 150 lb Model 41611
Validate with Flow Loop Results Apply Methodology to Specimen #2 Test Specimen #2 in Flow Loop Validate Methodology to Specimen #2
Selected based on review of TAG globe valve population 40 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Test Matrix Fisher
Masoneilan
Quick Open Cage – Flow Under – 3 flow rates (up to 45 ft/s) – Flow Over – 3 flow rates – Hot Water Tests – 3 flow rates > 150°F – Upstream Elbow Testing 3 configurations/3 flow rates Flow Under/Flow Over Linear Cage – Flow Under – 3 flow rates – Flow Over – 3 flow rates
Linear Cage – Flow Under – 3 flow rates – Flow Over – 3 flow rates
Added scope due to discussions with Fisher & Masoneilan
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Results – Step 1: Screening to Use Validated Model Clearance is Wide
Cage Controlled
Control Type?
Port Controlled
Use Validated FDPT Model Screening -Two Point Model -Multi-Point Model (Disk Bands)
Cage-toBody Clearance?
Clearance Check
Clearance is Narrow or unknown
𝑟𝑏 −𝑟𝑐 ℎ > 0.12 𝜋𝑟𝑠2 Use Generalized Model with user-defined CDPT Coefficients
Use Generalized Model with user-defined CDPT Coefficients
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Results – Step 2: Screening for FDPT Approach Close Stroke – Two Point Model Open Stroke – Multi-Point Model
Disk Style B Section 8.2.5 & Section 10.2 Flow Over Quick Opening Opening Stroke
Notes (1, 6)
Closing Stroke
Linear & Equal Percentage Opening Stroke
Notes (2, 5)
Flow Under
Notes (1, 7)
Quick Opening
Closing Stroke
Notes (2, 3, 7 )
Opening Stroke
Notes (1, 7 )
Linear & Equal Percentage
Closing Stroke
Notes (2, 3, 7 )
Opening Stroke
Notes (1, 7)
Closing Stroke
Notes (2, 3, 7)
Notes: 1. Evaluation requires multi-point model (effective area band model) 2. Evaluation using two-point method is generallly acceptable for the closing stroke. The two-point model is non-conservative at the full open position; however, the actuator output is much greater at the start of trave (at the open position) and the non-conservatism in the model does not affect margin predictions.
3. The most conservative evaluation is based on static running friction with line pressure and no DP (if this condition is applicable). 4. Acceptable evaluation method depends on normalized velocity. 5. The most conservative analysis is based on two-phase conditions. Two-phase conditions decreases the self-closing FDP just off the seat (5% to 25%). If sufficient back pressure is not present to suppress cavitation, the most conservative evaluation is based on static running friction with line pressure only unless (if this condition is applicable). 6. The most conservative analysis is based on Single-phase conditions. Single-Phase conditions increases the self-closing FDP just off the seat (5% to 25%).
7. Validation performed against test data over a range of Vp numbers
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Results – Step 3: Implementing Validated Multi-Point FDPT Model
FR FP Fwt FUS FSR FDPT For open direction, need to calculate FR at four positions
• Closed • 40% open • 55% open • Full Open
FDPT C DF C DP
4
d s2 Pv
44 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
MOV Application Guides Volume 1: Rising Stem
330 –> 187 pages Gate and globe –> Rising stem Valve requirements removed Enhanced figures QA compliant
Volume 2: Quarter Turn Valves
308 –> 65 pages Butterfly –> Quarter Turn Valve requirements removed Enhanced figures QA compliant
45 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
AOV Application Guide Objective – Provide evaluation techniques to verify the proper AOV actuator sizing and set point establishment for normal and accident conditions
Valve requirements removed Enhanced figures QA compliant
46 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
2016 Valve Products 3002008055 Evaluation Guide for Valve Thrust and Torque Requirements
3002008045
• Valve-Specific Design Information • Valve Performance Specifications • Recommended Spare/Replacement Items • Industry Performance Data
Motor-Operated Valve Application Guide Valve Vol:1
Manufacturers
3002008047 Motor-Operated Valve Application Guide Vol:2
#2
3002008056 Air-Operated Valve Application Guide
• Design/Procurement Specifications • Installation Specifications • Plant Design Parameters
• Industry Valve Performance Issues
3002007696
Users Groups
Valve Specialist Guide
• Plant-Specific Performance Experience
3002007711 Purge Valve Maintenance Guide
• Feedback on Refurbishment Specification & Requirements • Refurbished Valves 47 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Valve Specialist
• Refurbishment Work Scope Definition
Valve Specialist Guide The Need As experienced personnel leave or retire and new personnel come into the industry, it is important to plan for the transfer of knowledge to maintain reliable operation of valve systems and components. The Outcome This report provides a road map for the development of component expertise. 48 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Valve Specialist Guide Skills Chart
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Valve Specialist Guide Layout The guide uses a color coded approach (shown in the previous slide) for entry, intermediate and expert levels The format of skills, training and industry information is maintained through the guide. The Technical Advisory Group comprised of many international members
50 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
2016 Valve Products 3002008055 Evaluation Guide for Valve Thrust and Torque Requirements
3002008045 Motor-Operated Valve Application Guide Vol:1
3002008047 Motor-Operated Valve Application Guide Vol:2
3002008056 Air-Operated Valve Application Guide
#3
3002007696 Valve Specialist Guide
3002007711 Purge Valve Maintenance Guide
51 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Purge Valve Guide Purge Valves have created significant impacts to Nuclear Plant Operations Purge Valve Design and Maintenance is unique and requires specific guidance Keys to maintenance such as the graphic figures support field work
52 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Purge Valve Content The Purge Valve Guide outline: – Design Information (Section 2) – Troubleshooting (Section 3) – Condition Monitoring/Preventive Maintenance (Section 4) – References (Section 5)
53 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Purge Valve Key Take-A-Ways A small additional pressure drop can cause tremendous additional bearing loads for large valves. A 10 psid (69 kPa) drop across a 72-in. (DN 1800) valve can result in a torque requirement of 5125 ft-lbs (6920 N-m). Testing of purge valve is direction dependent. Information Notice 88-73[4] concerning leak rate testing is addressed in this guide and ways to ensure testing is correct. Temperature is the largest contributor to seat accelerated aging, followed closely by oxidation in HVAC systems. 54 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Purge Valve Key Take-A-Ways Some plants have found that ultrasonic examination (UT) can be used effectively to detect cracking. Once an optimum point is reached that minimizes leakage, it is important to effectively lock the valve in the correct closed position. The use of a gag is very effective. If this is not possible, match marks should be used as a minimum. The valve mechanical stops should be reset if available.
55 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Product Schedule
Product ID
Title
Deliverable Date
3002008055
Evaluation Guide for Valve Thrust and Torque Requirements
August 31, 2016
3002008045
Motor-Operated Valve Application Guide Vol:1
November 15, 2016
3002008047
Motor-Operated Valve Application Guide Vol:2
November 15, 2016
3002008056
Air-Operated Valve Application Guide
November 18, 2016
3002007696
Valve Specialist Guide
October 12, 2016
3002007711
Purge Valve Maintenance Guide
November 11, 2016
56 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Potential Work for 2017/2018 Support request from PWR Owner’s Group – Quarter Turn valve testing Potentially revise diagnostic testing guide (1022954) for further guidance – Quarter Turn valve bearing COF PWROG has identified Nylon and NiResist as additional materials to be tested – Diaphragm valves Development of thrust prediction model
57 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity
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Maintenance Projects and Discussion on “Delivering the Nuclear Promise” Rick Way Principal Technical Leader NMAC-PE Integration Committee
Wednesday, August 31, 2016 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Agenda A Brief Review of “Delivering the Nuclear Promise” EPRI NMAC/ PE activities in support of DNP Discussion on PMBD and Maintenance Activities
60 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
61 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Process for review of new improvement opportunities
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EPRI NMAC and PE Activities
63 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
EPRI NMAC and PE Activities
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EPRI NMAC and PE Activities
65 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Future of PM Basis Database EPRI User Interface Vulnerability Tool
PMBD Web Services
Cost Module
Integration with:
PM Templates
Utility ER Tools 3rd Party Software
Additional EPRI Products
PMBD
Data Industry Data Work Order Information
Data Integrity
Equipment Failure Data
Regular Template Reviews Internally and with Industry Groups
Online Monitoring Data
66 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Key Take Away Points NMAC and PE a very involved in the solutions to many of the Nuclear Promise initiatives – Work Management – Preventive Maintenance – Component Classification – Supply Chain
PMBD Future: Provide a tool that integrates with other ER software tools and provide a next generation set of analysis tools which integrate cost and other aspects of reliability. 67 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
IC Meeting Summary and Discussion
68 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
IC Meeting Summary and Discussion Solicited Feedback of IC meeting Template and Input for ER APC Report Closing Thoughts
69 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Utility Success Story Applying EPRI Products for ER APC, Information for other members to consider
Company – Title Existing EPRI Products recently used to benefit your utility/plant – Including Product IDs Activities (in applying the products) – Example-Program development and implementation Benefits (from the overall application) – system vulnerability evaluations – terry turbine guide was used to better understand performance 70 © 2015 2016 Electric Power Research Institute, Inc. All rights reserved.
Maintenance Focused IC Meeting Closing Comments and Critique
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Together…Shaping the Future of Electricity
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