Professional Documents
Culture Documents
F i l l in a defect r e p o r t / w o r k order f o r m
Review a n d registration
in the m a i n c o n t r o l r o o f n
Fill in f o r m s
for additional Approval:
permission Daily meeting; discussion of
c o n t r o l area/ all new defect reports/wvork orders
in vessels
General approval b y
p l a n t management and
maintenance management
Establish
radiation
protection
plans
Scheduling
M a i n c o n t r o l r o o m isolation,
d a i l y w o r k permission
Clearance by
w o r k supervisor
or health physics
group
Manual on Maintenance
of Systems and Components
Important to Safety
mí
\tgrj INTERNATIONAL A T O M I C ENERGY AGENCY, V I E N N A , 1 9 8 6
MANUAL ON MAINTENANCE
OF SYSTEMS AND COMPONENTS
IMPORTANT TO SAFETY
T h e f o l l o w i n g S t a t e s a r e M e m b e r s of t h e I n t e r n a t i o n a l A t o m i c E n e r g y A g e n c y :
T h e A g e n c y ' s S t a t u t e w a s a p p r o v e d o n 2 3 O c t o b e r 1 9 5 6 b y t h e C o n f e r e n c e o n t h e S t a t u t e of t h e
I A E A h e l d 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 f o r c e o n 2 9 J u l y 1 9 5 7 . T h e
H e a d q u a r t e r s of t h e A g e n c y are s i t u a t e d in V i e n n a . Its p r i n c i p a l o b j e c t i v e is " t o a c c e l e r a t e a n d enlarge t h e
contribution of atomic energy to peace, health and prosperity throughout the world".
© IAEA, 1986
P e r m i s s i o n t o r e p r o d u c e or t r a n s l a t e t h e i n f o r m a t i o n c o n t a i n e d in this p u b l i c a t i o n m a y b e o b t a i n e d
b y writing t o t h e I n t e r n a t i o n a l A t o m i c E n e r g y A g e n c y , W a g r a m e r s t r a s s e 5 , P.O. B o x 1 0 0 , A - 1 4 0 0 V i e n n a ,
Austria.
P r i n t e d b y t h e I A E A in Austria
November 1986
TECHNICAL REPORTS SERIES No. 268
MANUAL ON MAINTENANCE
OF SYSTEMS AND COMPONENTS
IMPORTANT TO SAFETY
The Agency's programme for establishing nuclear safety standards for nuclear
power plants, referred to as the N U S S 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
U s e r ' 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 N U S S 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 r o m 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. S C O P E 1
3. M A I N T E N A N C E P R O G R A M M E 2
4. I M P L E M E N T A T I O N O F M A I N T E N A N C E P R O G R A M M E 14
5. S U R V E I L L A N C E A N D V E R I F I C A T I O N ACTIVITIES 33
5.1. Surveillance 33
5.2. Administrative verification activities 33
A N N E X I. EXAMPLES OF DOCUMENTS 37
LIST O F P A R T I C I P A N T S 161
1. INTRODUCTION
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
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 r o m 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 A L A R A 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. 5 0 - S G - 0 5 .
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. 5 0 - S G - 0 7 (Section 3) and 5 0 - S G - 0 9 (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):
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
I n d u s t r y and p l a n t i n f o r m a t i o n
Failures, p o w e r loss and remedial m a i n t e n a n c e costs,
o t h e r k e y e q u i p m e n t , m a n d a t o r y m a i n t e n a n c e actions
"N C r i t i c a l items
f o r analysis
Rankings
Recycle
_L
Predictive
A preventive
y
Programme
Existing preventive maintenance programme and costs maintenance
re-evaluation improvement
analysis
O p t i o n s and p r e d i c t e d
improvement
Improvements,
Information
collection
and feedback
y benefit/cost
analysis
Predicted
net benefits
Optimization
Budget constraints analysis
Recommended
combinations
I
P r o g r a m m e approval and i m p l e m e n t a t i o n
5
TABLE I. EDUCATIONAL QUALIFICATION REQUIREMENTS
6
TABLE II. QUALITATIVE ELEMENTS OF COMPETENCE FOR POSITIONS
IN NUCLEAR POWER PLANT MAINTENANCE
Elements of competence
Positions
Manual skills Information Intellectual skills Social skills
Manager
Professional - Broad, Evaluation
descriptive/profound
Supervisor
Technician Significant Broad, Application/ Leadership
descriptive evaluation Personal authority
Persuasion
Craftsman Significant Broad, Comprehension Communication
descriptive Conciliation
Technical
Professional - Specialized, Evaluation/
profound application
7
3.3.4. 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.
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.
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.
3.5.1. Facilities
(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
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.
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:
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.
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
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;
17
(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.
4.3.1. Applicability
18
— information from all groups in the plant related to the system or component
— documentation of all work done on the plant.
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.
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:
19
N)
O
Initiation:
Fill in a defect r e p o r t / w o r k order f o r m
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.
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.
22
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:
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.
23
Scheduled maintenance or modification work
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.
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
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
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.
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.
4.4.1. Modifications
4.4.2. Replacement
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.
29
u> -SECTION- - Introduction
o
SECTION- - S a f e t y precautions
- Pump
Instructions - Preventive maintenance • Cleaning the cooling and flushing water filter
CW (circulating - - SECTION
water) pumps - c
1
7.1 - List of work specifications — — — — — — - Valves
• Inspecting glands
- Motor — corrective maintenance
— SECTION
-C1
8.1 - List of work specifications
- Instruments -
• Functional checks
„
• Inspecting and repairing
I 11.1 • Instruments — corrective maintenance
SECTION • Assembling
- C " 12.1
1 • List of work specifications
• Replacing
- Instruments — calibration
• Overhauling the cooling and flushing water filter
-SECTION
' 13.1— List of work specifications • Fault finding
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.)
4.6. Records
32
5. SURVEILLANCE AND VERIFICATION ACTIVITIES
5.1. Surveillance
5.1.2. Inspections
(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.
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.
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)
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.
3.3.2.1. Introduction
3.3.2.2. Organization
The Station Manager shall have the final responsibility for the implementation
of the requirements of this Section 3.3.
41
3.3.2.2.3. Mechanical Maintenance Engineer
The Instrument and Electrical Engineer shall be responsible for directing the
performance of station maintenance activities affecting instrumentation and electrical
equipment.
(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.
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.
42
3.3.2.6. Replacement materials and components
3.3.3. PROCEDURES
43
Temporary Maintenance Procedures may be used, where appropriate, for
maintenance activities which are of a non-recurring nature. Examples of such uses
are:
(a) Title
(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
44
(e) Safety considerations
45
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.
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.
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.
46
(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.
47
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) 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.
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.
(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
49
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
(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.
(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.
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.
51
(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.
3.3.5. DOCUMENTATION
52
EXAMPLE 2
TRAINING FACILITY FOR MAINTENANCE PERSONNEL
(Section 3.3.4.3)
53
MAJOR TRAINING COURSES
•COMMON
#MECHANICAL
DISASSEMBLY,ASSEMBLY AND
REACTOR VESSEL 0 REACTOR VESSEL HEAD 1 UNIT INSPECTION OF THE VESSEL
HEAD AND ITS ATTACHMENT
0 PRIMARY SIDE CHANNEL HEAD 1 UNIT
WORK INSIDE STEAM GENERATOR
0 TUBE EXAMINATION 1 SET
STEAM PRIMARY SIDE CHANNEL HEAD
EQUIPMENT.
GENERATOR (MAINLY EDDY CURRENT TEST)
0 STEAM CENERATOR 1 SET
MANIPULATOR
* Non-fuel-bearing components.
55
ELECTRICAL & INSTRUMENTATION
PUMP MOTOR OOIL COOLER TUBING 1 UNIT OF THE BEARING AND NON-
ASSEMBLY
INSTRUMENTATION
56
EDUCATION AND TRAINING PROGRAM AT THIS CENTRE
SERVICE
YEARS No. OF DAYS
1 2 3 A 5 6 7 8 9 10 n 12 13 14 15 16 17 18 19-
EOUCATION*^^
BASIC EOUCATION
18
II)
BASIC EDUCATION
30
(III
1
SYSTEMATIC EDUCATION
BASIC EDUCATION
20
(Ml
I
PROCRAM
SfECIAllY EDUCATION
to
(MATURITY)
1
APPUEO EDUCATION
5
(MASTERY)
I
TECHNIC Al MANACt-
MfNT m m m m . 3
EDUCATION
i m 8ASIC CLASS 2
QC EOUCATION
/BASIC,MIDDU. \ (W MIDDLE CLASS 3
UENIOK CLASSES/
m SENIOR CLASS 2
SMCIAITY EDUCATON
57
M A J O R M A I N T E N A N C E W O R K SCHEDULE I N ANNUAL
PROGRAM A N D PRACTICAL T R A I N I N G 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
BASIC
EDUCATION
EDUCATION 3 89 1513 2 64 1152 1 40 720
(II
BASIC
EDUCATION 1 35 1050 2 40 1200 2 42 1260
(ID
SYSTEMATIC EDUCATION PROGRAM
BASIC
EDUCATION 3 45 900 3 73 1460
(III)
TECHNICAL
MANAGEMENT 1 20 60 1 25 75
EDUCATION
QC 2 38 93 3 60 140
EDUCATION 2 38 99
ELECT- 20 70
2 10 45 4 17 64 4
RICAL
ON VARIOUS
INSTRU-
MENTA- 3 14 70 5 25 102 5 26 106
TION
59
EXAMPLE 3
WORK ORDER/DEFECT REPORT
(Section 4.3.4)
61
W O R K ORDER No.
Determined noted
Dale. Time. Signature Shift supervisor. Operations management
P e r f o r m e d by
W o r k t o be p e r f o r m e d
N u m b e r of persons Man-hours
Requirements Yes No
Urgency« © (ÏÏ) (Ñ) (Ô)
Isolation
Cost i t e m
W o r k f l o w chart
Repair r e p o r t
A d j u s t m e n t / T e s t i n g required Isolation r e q u i r e m e n t No.
Ye
Collective dose > 5 man- rem sQ NoQ Individual d o s e > 1 r e m Yes • No Q
R a d i a t i o n p r o t e c t i o n at w o r k p o s i t i o n :
continuous/not continuous R a d i a t i o n p r o t e c t i o n w o r k f l o w chart required
I Othßr
o Measures d e t e r m i n e d W o r k p o s i t i o n i n d o c t r i n a t i o n and cleared Work completed
Clearance f r o m .
Date/Signature
Maintenance Radiation S e c u r i t y and Operations
supervisor protection industrial safety management
extended u n t i l
P e r f o r m a n c e tested and
isolated state restored W o r k clearance f o r r e m a i n i n g w o r k
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
EXAMPLE 5(e)
® ©
Tag ordered by
Tag put on by
Date Time.
Placement
verified by
Tag removed by
Date . Time .
DANGER
Ordered removed by
TO #
Tag # .
THIS EQUIPMENT
WR#
EQUIP _
MUST NOT BE
TAGGED. OPERATED
REASON. UNTIL THIS TAG
POS T A G G E D .
HAS BEEN
SUPERVISOR
RES W O R K
PROPERLY
REMOVED
TO # _
Tag # -
WR # .—
Remarks
EQUIP _
TAGGED.
LOC
Completed
date — . Time .
Signed
No.-
No..
No..
67
EXAMPLE 5(e)
RETURNED
TAGS TO
DESIRED PLACED VERIFIED NORMAL NORMAL VERIFIED
LOCATION POSITION BY BY POSITION BY BY
REMARKS:
68
EXAMPLE 4(c)
Isolation
Mechanical circuit
Isolation book No
Component No
I s o l a t i o n status:
Reason
Date Signature
EXAMPLE 5(e)
Isolation No.
Sheet No. — Serial No.
Control room
Comp. No. -
actuator
Name
Shift_sugeryisor_
Do not operate
Isolation No.
Sheet No . Serial N o . -
Comp. No. -
Circuit No. -
Process
I n s t r u m e n t rack operational Q
control
system non-operational O
earthed O
simulated Q
Name
S h i f t supervisor
D o not operate
Isolation No
A d d i t i o n a l use
Sheet No Serial No—
such as fuse,
Comp. No.
c i r c u i t - b r e a k e r , or
Activity
local a c t u a t o r
Name
S h i f t supervisor
D o not operate
Isolation No
Sheet No Serial N o . .
Comp. No.
open closed
Component
Maintenance p o s i t i o n Q Q
Normal position Q Q
Name
_Shift sugeryisor_
Isolation No. .
Sheet No . Serial N o .
Comp. No. —-
Process /^n
control operational l _ ; o p e n
closed
Tag control book sys,em
non-operational O O
earthed Q
simulated Q
Name
S h i f t supervisor
70
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
EXAMPLE 5(e)
flrrtpr Nn
Safety Precaution Form System No. .
ACCESS PERMISSION Isolation No.
Unit: Isolation must be suitable for access
Text:
Building Component
A B C 0 E F G H 1 Other
Unventilated room
^ Media, vessels, rooms
Revolving parts
Acid/Alkali
Shafts/pits
Solvent
Safety precautions
Steam
Water
Gases
o
v
!
Cleaning X X X
Rinsing w i t h X
entering/accessing during work
-toxic (mpc)
Air analysis
Safety precautions when
Other/Remarks/Special measures
74
E X A M P L E 5(e)
75
-J
Os
NO W E L D I N G !
during power operation in the f o l l o w i n g rooms:
UNIT A UNIT B
Switchgear building + 8 m switch distributor 3423 Switchgear building + 8.80 m all switchgear rooms 0401-
Switchgear building + 12 m switch r o o m 3521 (except offices) 0435
Switchgear building + 12 m computer r o o m 3523 Switchgear b u i l d i n g + 12.95 m all switchgear rooms 0501-
Switchgear building + 12 m neutron f l u x measurement 3527 (except offices) 0535
Reactor building 21 m p l a t f o r m
Notes:
1. The f o l l o w i n g precautions must be taken whenever 2. I n the case of electric welding the welding earth should be
w o r k involving naked flames is carried o u t : connected t o the part being welded at a point as close by
as possible (max. 3 m).
1.1. Clear space
(Possible interference w i t h measurement lines and sensors
1.2. Cover
by electromagnetic fields.)
1.3. Insulate
3. In the case of inert-gas shielded arc welding, the actual w o r k
1.4. M o u n t fire watch should be preceded by a brief trial during which contact should
1.5. Check repeatedly be maintained w i t h the c o n t r o l r o o m by telephone.
E X A M P L E 5(e)
System/Component
Safety Precaution Form
RADIATION PROTECTION PERMISSION
Unit: Svstem No.
Radiation protection Date
Executing
Dept. Order No. Room No. clearance required rrom: y[mB
G Mask • Compressed air breathing apparatus • Plastic suit • Complete protection suit
• Shielding Thickness
' ~
Remarks
D Lead mats
• Lead bricks
• Concrete bricks
S ? • Partitions
o 'z:
c =j
• Dose rate - max. expected value • Component closed approx. m-rem/h
•S-o
O Component open appro*. mrem/h
O Decontamination: O before • during • after w o r k
Radiation protection
officer: Date Name ( p r i m in capitals) Signature
Deviations
Work commenced:
time ~ Signature (Work leai.ier at w o r k position)
Work ended:
Signature (Work leader at w o r k position)
77
Daily clearance for w o r k by radiation protection group
Commencement of w o r k
Radiation protection group
Date Time Work leader at w o r k position
Signature
Signature
V4N1322
78
E X A M P L E 5(e)
ORDER "R" No:
Time
Gamma exposure
Neutron exposure
79
Additional precautions of rad. safety
Individual doses
80
EXAMPLE 6
SUMMARY OF A PROCEDURE FOR THE CONTROL
OF MODIFICATIONS
(Section 4.4.6)
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.
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.
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
2.1.2. 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.
87
3. PREREQUISITES
None.
4. DEFINITIONS
None.
5. PROCEDURE
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
88
N-XXX-YYY (PROCEDURE TITLE)
1. PURPOSE
2. RELATED MAINTENANCE
3. REFERENCES
4. PREREQUISITES
5. PRECAUTIONS
6. SPECIAL T O O L S A N D SUPPORT S E R V I C E S
7. PROCEDURE
8. RETURN TO NORMAL
A N E X A M P L E OF S U B P A R A G R A P H S IS AS FOLLOWS:
7. PROCEDURE
7.1. XXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
7.2. XXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
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) XXXXXXXXXXXXXXXXXXXXXXX
(2) XXXXXXXXXXXXXXXXXXXXXXX
(A) XXXXXXXXXXXXXXXXXXX
(B) XXXXXXXXXXXXXXXXXXX
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
(3) References
(4) Prerequisites
89
(5) Precautions
(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.
91
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.
5.3.2. 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.
92
5.3.5. The preparer shall:
(3) Provide the procedure and Safety Evaluation (if needed) to the
Engineer-Maintenance for review.
5.3.7. The preparer shall resolve any comments and return the procedure and
Safety Evaluation (if needed) to the Engineer-Maintenance.
(1) Submit the procedure and Safety Evaluation (if needed) for P O R C
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 Q C supervisor (or designee).
5.5. Approval
93
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.
5.6. Issuance
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.
94
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.
5.8. Cancellation
95
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 F o r m (see
Administrative Procedure A - l ) in other cases.
(1) Update the Maintenance Procedures Index to reflect the date of the
periodic review (see paragraph 5.9.1).
6. REFERENCES
96
INSTRUCTIONS FOR PREPARING
MAINTENANCE MANUALS
1. INTRODUCTION
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.
Manuals are written as a permanent record and guide for correct, safe and
economic performance of maintenance works on the station equipment.
97
1.2.2. Reference 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.
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
98
2. ORGANIZATION OF THE MANUAL
2.1. General
99
Example 2: 32400 Moderator auxiliary cooling system:
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.
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.
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.
100
3.1.5. Technical data
3.1.6. References
3.1.8. Sub-assembly
3.2.1. General
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
101
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.
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 b e prepared for smaller equipment
such as D G sets, M G sets, compressors, different pumps, etc. if it is not covered
by the P . M . checks.
A small chapter may be included. Under this, the techniques like signature
analysis, partial discharge tests, etc., appropriate to the equipment, can be included.
3.4.1. 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.
102
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
j o b will be listed out in this section.
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.
103
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
3.7.1. General
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.
4.1. General
104
4.2. Manual set up
Manuals will be identified by the title from the station system USI.
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
105
manufacturers' published articles of special interests, improved maintenance
techniques, general m a i n t e n a n c e instructions, design data, etc.
Such information can be added in t h e appropriate sub-sections of the
maintenance manual.
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
106
Appendix A [to Example 7(b)]
TECHNICAL DATA - ELECTRICAL EQUIPMENT
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
Rated amp
2.18. Max. rated hp/kW
2.19. Brush Type maker No.
2.20. Bearing Type maker No.
2.21. Temperature detector
2.22. Bearing temperature running max.
2.23. Lubrication type No. Maker
2.24. Space heater Resistance
Resis Connection
No. of heaters
2.25. Any other special features
3. Transformer
3.1. Type
3.2. SI. No.
3.3. Phase Frequency
3.4. Temperature
3.5. Cooling
3.6. Temperature rise (°C)
3.7. kVA
3.8. Voltage nominal/max. HV LV
3.9. Current HV LV
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:
108
Appendix B [to Example 7(b)]
TECHNICAL DATA - MECHANICAL EQUIPMENT
1. System USI
2. Plant equipment USI & No
3. No. o f o f f s
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
109
Appendix C [to Example 7(b)]
TECHNICAL DATA — INSTRUMENTATION
110
EXAMPLE 8
MAINTENANCE INSTRUCTIONS AND CHECKLISTS
(Section 4.5)
Ill
MAINTENANCE MANUAL FOR STANDBY COOLING PUMPS
1.3.2. Makes:
113
1.3.8. Inlet press: 85 atm
1.3.13. Pump bearings numbers: NU314 DE side (drive end) 7314 BG-NDE side
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).
114
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).
1.6.1. Give due regard to cleanliness in all equipments of nuclear system, which
is of utmost importance.
1.6.6. Don't be conservative. Renew all the gaskets, O rings, lock washers, lock
wires, etc.
1.6.9. The seal faces should be handled very carefully and no impressions to be
left on the seal faces.
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.
115
1.6.13. Not the least! Follow the assembly and disassembly of the components
strictly as per the approved procedure.
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.
1.7.5. 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.
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 p u m p s predictive maintenance
techniques, namely (i) vibration and noise trend analysis, (ii) vibration signature
analysis, (iii) p u m p motor unit r u n d o w n time and (iv) seal leak rate will b e under-
taken at regular intervals, analysed and corrective steps taken at the earliest
opportunity.
Engineer 1
Supervisor 1
Maintainers 3
3.3. Consumables
117
PVC sheets
Turbine oil 11
Masking tape
Lint free cloth
Set of O rings, gaskets and lock washers.
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
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.
118
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).
3.4.3.8. 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.
3.4.4.2. Disconnect the process water connections to the bearing housing, drain
and collect the process water.
119
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).
3.4.5.1. 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 N D E 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).
3.4.5.8. 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 N D E bearings (49) bearing cover (52)
can be removed.
120
3.4.5.11. Loosen and remove the cap screws (70) and separate the bearing cover (52)
from the assembly (43). Now the N D E 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 D E and N D E 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).
3.4.6.5. 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 N D E 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).
3.4.7.4. 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).
121
3.4.7.7. Remove the sleeve key (28).
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.
3.4.8.1. 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 N D E 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).
3.4.8.10. 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.
3.5.1. 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 m m .
122
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.
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.
123
PREVENTIVE MAINTENANCE PROCEDURE FOR THE
SAFETY RELATED STANDBY LIQUID CONTROL PUMP
PLUNGER PACKING REPLACEMENT
1. PURPOSE
3. REFERENCES
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.
4.4. 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.
6.3. Consumables
6.3.3. Solvent
125
6.5. Sign and date Section 6.0 of the M D R F , Appendix C, to indicate awareness
of the need for these special tools, consumables and spare parts.
7. PROCEDURE
CAUTION
NOTE
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.
126
NOTE
For a detailed drawing of the stuffing box and internais see Appendix B.
NOTE
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 M D R F ,
Appendix C.
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.
7.2.3. 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 M D R F , Appendix C.
7.2.6. Screw the stuffing box gland (338) into the stuffing box to hold all the parts
in place. Do not tighten.
NOTE
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.
7.2.11. Install new cylinder head gasket. Record cylinder head gasket replacement
on the M D R F , 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
128
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.
7.2.14. 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 M D R F , 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
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 M D R F , Appendix C.
8. R E T U R N TO N O R M A L
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 M D R F , Appendix C.
129
Appendix A [to Example 8(b)]
370 317 617 622 341 338 623 6 3 2 634 116 112 113 649 620
LIST OF PARTS
130
Appendix B [to Example 8(b)]
STUFFING B O X A S S E M B L Y
131
Appendix C [to Example 8(b)]
EQUIP. NO.
SIGN DATE
4.0. PREREQUISITES VERIFIED
SIGN DATE
SIGN DATE
* Explain all unsatisfactory conditions and corrective actions taken in the Remarks Section.
132
MAINTENANCE DATA RECORD FORM
7.2. PACKING
INSTALLATION
AND EQUIPMENT
RUN IN
* Explain all unsatisfactory conditions and corrective actions taken in the Remarks Section.
133
MAINTENANCE DATA RECORD FORM
PMQ-048-001
REMARKS:
134
EXAMPLE 8(c)
135
ELECTRICAL 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 R O D A C T U A T O R SERVICE TEST SHEET SHEET 2 OF 2 SHEETS
136
Annex II
DESCRIPTIONS OF PRACTICES
137
PRACTICE 1
THE PLANNING PROCESS
(Section 4.2)
139
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
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
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.
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.
144
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".
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)
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:
149
3. MATERIAL INVENTORY SYSTEM
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 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
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.
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.
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)
155
OUTAGE PLANNING AND MANAGEMENT
1. O U T A G E PLANNING
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.
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
(1) Communications
(2) Co-ordination
(3) Feedback and analysis
(4) Control.
2.1. Communications
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.
2.2. Co-ordination
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
161
Novak, S. Division of Nuclear Safety,
(Scientific Secretary) International Atomic Energy Agency,
(IAEA) P.O. Box 100, A-1400 Vienna, Austria
162
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