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Work Management and SAP NuclearDanilo SpazianiEBO NPP18th Annual Nuclear Seminar and Information MeetingČastá-Papiernička, 28-29th April 2010

Agenda1. SAP Nuclear Project2. Project implementation3. Work Management Process: on-line and outage maintenance in SE4. The IPSEC steps: corrective and recurring maintenance5. Conclusions2

Agenda1. SAP Nuclear Project2. Project implementation3. Work Management Process: on-line and outage maintenance in SE4. The IPSEC steps: corrective and recurring maintenance5. Conclusions3

SAP Nuclear Project: Need for ChangeThe long term goal for Sloveske Elektrarne Nuclear is to achieve Top DecilePerformance in Safety, Reliability, Production, and Efficiency and become theWorld’s Premier Operator Of VVER TechnologyAn international benchmarking effort to identify Nuclear Industry Best Practiceresulted 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 ProgramsSE needed to establish a model thatspecified appropriate safety andoperational standards includingmanagement, quality assurance,practices and behaviors4

SAP Nuclear Project: SNPMStandard Nuclear Performance ModelElectricity ProductionThe SAP Nuclear Project is theImplementation Phase of a 3-yearsMAJOR Process and OrganizationalRedesign of the Slovenské ElektrárneNuclear OrganizationOperate Plant(INPO)CORE PROCESSESINPO 01-002 Conduct of OperationsManage Configuration(CMBG)Work Management(INPO)Equipment Reliability(INPO)(ANSI/NIRMA CM 1.0-2000)(AP-928)(AP-913Materials and Services(NEI)(AP-908)ENABLING PROCESSESManagementProcesses andSupport 921)Nuclear Fuel(NEI)5

SAP Nuclear Project: BenefitSE Model redesign resulted in new Programs based on Nuclear Industry Best Practicein the following areas: Work Management – INPO AP 928Equipment Reliability – INPO AP 913 (project ongoing)Corrective Action – WEC functionality based on North American Best PracticeOperating ExperienceSelf Assessment&BenchmarkingHuman Performance ImprovementSAP Software System configured and customized to support Nuclear IndustryBest Practice ProgramsImplementation of the SAP Nuclear Project will act as anaccelerant to process, organizational, and behavioralchange leading to significant gains in safety, efficiency,plant performance, and organizational behavior6

Agenda1. SAP Nuclear Project2. Project implementation3. Work Management Process: on-line and outage maintenance in SE4. The IPSEC steps: corrective and recurring maintenance5. Conclusion7

SAP Nuclear – Project Objectives and StrategyImprove EBO and EMO safety and operational performanceBuild up SAP Nuclear Competence CentreRadiation and Radioactive WasteManagement Processes.ARSOZ is considered as processstandard for new implementation.Work Management, EquipmentReliability, and ContinuousImprovement Processes.INPO Guidelines are standardAP-928 (Work Management ProcessDescription)AP-913 (Equipment Reliability ProcessDescription)Strategy:Replace ARSOZ by SAP functionality.No Major Process Changes.Small changes will be made to adapt to EH&S andto align facilities on single processesCorrective Action Process - based onNuclear Industry best practices as keyinputs in process designsStrategy:New processes, new organization structure,and new software system.New Integrated systemSAP Nuclear Competence Centre8

SAP Nuclear Project – SE Approach20087 – 9/08EAMTemplate10 – 12/081 – 3/084 – 6/097 – 9/0910 – 12/091 – 3/104 – 6/10EAM ainingof TrainersDevelopmentof RICEFWTender2010Migration 1TrainingEnd Users (200)4 – 6/082009Full productionEMOLimited Production(Planning 2010)EMO/EBOARSOZ – running200-300 End UsersFull productionEBOTraining of end Users(cca. 2800)Migration 23Change ManagementSup. 1Preliminary Go-Live:Sup. 2Go-Live:9Sup. 3

Agenda1. SAP Nuclear Project2. Project implementation3. Work Management Process: on-line and outage maintenance in SE4. The IPSEC steps: corrective and recurring maintenance5. Conclusion10

Work Management in SEAs 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 ofsafe and reliable plant operation.The process encompasses the following steps:Work IdentificationPlanned Maintenance – Preventative and SurveillanceOn-lineCorrective MaintenanceModification Activities - InvestmentWork PlanningTechnician InstructionsParts, Tools, Blocking, R-Orders, etc.Work SchedulingIPSECDaily, Weekly, quarterly, cycle online schedulesOutage schedulesLong Term SchedulesWork ExecutionWork CloseOutage11

Work Management: Online ActivitiesWork management is the process by which maintenance, modifications,surveillances testing, engineering support, and any work activities that requireplant coordination or schedule integration are implementedProcesses are simple, efficient, incorporate human factors considerations,and ensure effective performance during all phases of plant operationPlanning and scheduling are applied to activities that impact plant operation orrequire detailed work instructions.The duration of the scheduled work activities are reviewed against technicalspecifications and Probabilistic Risk Assessment (PRA). Work is scheduled tooptimize safety system availability and to ensure maintenance can be performedwithin allowed regulatory or administrative time limits13 Weeks Cycle12

E-6E-5Scope CoolingE-4Cycle ManagerE-3E-2Schedule CoolingE-1Work ManagerPlanningEngineeringParts - Materials – External ResourcesSchedulingOperation - PRAOperation - ClearanceWork Groups13E-0Review - FeedbacksE-7Work ExecutionE-8Work Package ReadyE-9Schedule FreezingE-10Schedule E-4E-11Scope FreezeE-12Schedule E-10E-28Scope E-12Scope E-28Post WorkWeek CritiqueMeetingPlan of the DayMeetingWork WeekTurnoverTechnical RigorReviewScheduleFreeze MeetingCycle Mg /Work Week MgTurnoverScope tingRight WorkMeetingLong aheadscope meetingWork Management: On-line 13 Week CycleE 1

Work Management: Refueling OutagesThe Outage Management process defines a structured approach for thepreparation, the execution and the assessment of refuelling outages byfollowing the Work Management principles through the IPSEC stepsimplementation over a period of 21 monthsM-19Identifylong leadmaterialM-18M-11M-10Identify pre- ng forWosIdentification PhaseSet outagegolasM-5M-2WCDpreparationM-1M-0M ution EvaluationphasephasePreparation PhaseIssueScheduleRev. AIssueScheduleRev. BIssueScheduleRev. 0PerformALARAevaluationIssueScheduleRev. 1Each phase is characterized by set of predefined milestonesaccurately scheduled in order to optimize the wholeOutage Management process14WorkscheduletrackingFeedback &lessonslearned

Agenda1. SAP Nuclear Project2. Project implementation3. Work Management Process: on-line and outage maintenance in SE4. The IPSEC steps: corrective and recurring maintenance5. Conclusions15

The IPSEC Steps: Why SAPWhy 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 industry16

The IPSEC Steps: Why SAPSDModules MPMHREH&SISWFIMPSAMCOFIPSSales and DistributionMaterials ManagementProduction Planning and ControlQuality ManagementPlant MaintenanceHuman ResourcesEnvironmental Health and SafetyIndustrial SolutionsWork flowInvestment managementAsset ManagementControllingFinancialProject systemEH&SImplementedModulesin SE, a. s.

The IPSEC steps: Corrective MaintenanceSAP / WEBMaintenancework isIdentifiedMaintenancenotification iscreated in SAPSAPNotification isreviewed andconverted into awork orderWork is Planned and Scheduledand the work order is releasedSAPEndAccounting settles thework order and businessclose.Work order is “Technically Work progress work andClosed” by the Planner status(TECO)Maintenancework is assigned andExecuted18

The IPSEC steps: Recurring MaintenanceSAPCreate/ Update Task List/Maint.PlanIdentifychanges tothe PlanWork order is autogenerated(Identified) in SAPfrom MaintenanceplansWork is Planned and Scheduledand the work order is releasedSAPEndAccounting settles thework order and businessclose.Work order is “Technically Work progress work andClosed” by the Planner status(TECO)Maintenancework is assigned andExecuted19

The IPSEC steps: reate Notif.Plan-Object-When-What steps-Resources-Internal -When-What steps-Avail. Res.-Avail. Eqpmt-CapacityClose-Shop papers-Use resources-Parts-Materials-Tools-Purchasing-Work complete-Time recorded-What was done-Labor used-Parts used-Materials used-Return toolsSchedule WOPrint Work OrderAssign WOPerform WorkCreate WORelease WOContinuousImprovementExecuteComplete WOComplete Notif.Analyze-Usage history-Performance-KPIsAP-91320

The IPSEC steps: Identification1. Initial problem discoveryOperator identifies problem during normal rounds / personal identifies issuesCaptures dataTags equipment2. Problem entered in SAP as a NotificationWHAT3. Initial Review – Shift SupervisorOperability review (task generation)Approval4. Work Control Team Review – daily SOC meetingCreate work orderCode work order to online or outageSet priority and preliminary schedule target (5 priorities)5. Work Order CodingAssign WO to main Work Management Cycle (online – outage)Code WO out of Work Management Cycle (FIN team – minor maintenance – recurring activities)21

The IPSEC steps: PlanningAP-928Identify-Object-Symptoms-WhenCreate Notif.Plan-Object-When-What steps-Resources-Internal -When-What steps-Avail. Res.-Avail. Eqpmt-CapacityClose-Shop papers-Use resources-Parts-Materials-Tools-Purchasing-Work complete-Time recorded-What was done-Labor used-Parts used-Materials used-Return toolsSchedule WOPrint Work OrderAssign WOPerform WorkCreate WORelease WOContinuousImprovementExecuteComplete WOComplete Notif.Analyze-Usage history-Performance-KPIsAP-91322

The IPSEC steps: Planning1. Review – check history – equipment data2. Preliminary requirementsCheck for duplicitySafety ClassificationApproach grade3. Define Work ScopeWork Steps / operations relationshipsTimingResourcesSupport and permitsWork Clearance requirement4. Materials/Services5. Documents/Tools6. Costs – Plan/ActualHOW7. Statusing for WOs23

The IPSEC steps: e Notif.Plan-Object-When-What steps-Resources-Internal -When-What steps-Avail. Res.-Avail. Eqpmt-CapacityClose-Shop papers-Use resources-Parts-Materials-Tools-Purchasing-Work complete-Time recorded-What was done-Labor used-Parts used-Materials used-Return toolsSchedule WOPrint Work OrderAssign WOPerform WorkCreate WORelease WOContinuousImprovementExecuteComplete WOComplete Notif.Analyze-Usage history-Performance-KPIsAP-91324

The IPSEC steps: SchedulingThe scheduling is the process necessary to prepare a database containingall the information needed to model the sequence of work tasks required toaccomplish the approved online/outage scope, minimizing the plant riskand optimizing duration, cost and resources mobilizationSystem WindowThe main scheduling technique isbased on “System window”principle where all plannedmaintenance, in service inspectionand testing activities on a piece ofequipment or a train of a systemare planned to be performed duringa pre-defined time periodSystem 1FEG 1WCDFEG 2WCDWO 1WO 2WO 3CDF minimizationWOoperationsWHENFunctionalEquipment GroupWO 4Work ClearanceDocumenttime25