Configuration Management Fundamentals including Margin Management Bill Kline FirstEnergy Nuclear Operating Company (FENOC) June 2, 2008 Shell Beach, CA

PAGE 2 CM Fundamentals 2008 CM Fundamentals 1.CM Equilibrium Objective of Configuration Management 2.Margins Using CM to protect Design and Operating Margins 3.CM Process Model Restoring CM Equilibrium 4.Functional Areas Five Functional Areas of CM

PAGE 3 CM Fundamentals 2008 What is CM Equilibrium? In its simplest terms Configuration Management is what we do to assure ourselves and our regulators that we are doing everything we said we would do. The objective of Configuration Management is the conformance of the three elements represented by the CM Equilibrium Model

PAGE 4 CM Fundamentals 2008 CM Equilibrium Design Requirements technical requirements, derived from the design process, that are reflected in the final design. What Needs to be there Design characteristics and bounding parameters needed for the design to work Must be verified or monitored to confirm that design is valid Design Require- ments

PAGE 5 CM Fundamentals 2008 CM Equilibrium Facility Configuration Information (FCI) documentation that defines how the plant is designed and how we operate it. What we say is there Design Output Documents Operational Configuration Documents Other Operating, Maintenance, Training and Procurement Information Facility Config Info

PAGE 6 CM Fundamentals 2008 CM Equilibrium Physical Configuration actual physical location, arrangement and material condition of SSCs What is actually there SSCs installed (design configuration) component position (operating configuration) Physical Config

PAGE 7 CM Fundamentals 2008 CM Equilibrium Work Processes must assure that: Elements conform all the time processes in place to restore CM Equilibrium if it is lost All Changes are Authorized people are trained and qualified Conformance can be verified determine what configuration is and prove it was done correctly Design Require- ments Facility Config Info Physical Config

PAGE 8 CM Fundamentals 2008 CM Equilibrium Upsets Upsets Between Design Requirements & Facility Configuration Information errors in analysis, design inputs errors in licensing documents Operating procedure invalidates design calculation (response time) desired changes, such as power uprating Design Require- ments Facility Config Info

PAGE 9 CM Fundamentals 2008 CM Equilibrium Upsets Upsets Between Physical Configuration & Facility Configuration Information drawing / plant discrepancies components in wrong position maintenance errors that affect plant configuration desired changes: modifications, manipulating plant components Facility Config Info Physical Config

PAGE 10 CM Fundamentals 2008 CM Equilibrium Upsets Upsets Between Physical Configuration and Design Requirements failure of SSC to meet performance criteria as designed equipment out of tolerance unexpected degradation in performance of SSCs Design Require- ments Physical Config

PAGE 11 CM Fundamentals 2008 CM Equilibrium  Margins Protect the Design Basis  Design Configuration conforms to Design Basis  Operational Configuration conforms to Design Configuration Design Basis Each boundary has margins to protect these limits NSD Figure Operational Configuration Design Configuration

PAGE 12 CM Fundamentals 2008 INPO Margin Model Analyzed Design Limit Operating Limit Normal Operations Operating Margin Design Margin Unanalyzed Margin Operating Margin Range of Normal Operation Equipment /Function Failure Let’s view this cross-section

PAGE 13 CM Fundamentals 2008 Margins Range of Normal Operation Ultimate Capability Operating Margin Design Margin Analyzed Design Limit Operating Limit Analytical Margin Documented on design documents Documented in engineering calculation Failure Point Undetermined depends on many variables controlled by Operations controlled by Engineering unanalyzed region

PAGE 14 CM Fundamentals 2008 Margins Range of Normal Operation Ultimate Capability Operating Margin Design Margin Analyzed Design Limit Operating Limit Analytical Margin Documented on design documents Documented in engineering calculation Failure Point Undetermined depends on many variables controlled by Operations controlled by Engineering unanalyzed region Notes on Model describes one parameter only; different parameters may be interrelated direction may be positive or negative doesn’t represent all possible limits and setpoints gaps not intended to represent relative size of margins – may be zero

PAGE 15 CM Fundamentals 2008 Margins Range of Normal Operation Ultimate Capability Operating Margin Design Margin Analyzed Design Limit Operating Limit Analytical Margin Documented on design documents Documented in engineering calculation Failure Point Undetermined depends on many variables controlled by Operations controlled by Engineering unanalyzed region Other Limits and Setpoints Operator Alarm (HI-HI) Operator Alarm (HI) Tech Spec Limit Regulatory Limit

PAGE 16 CM Fundamentals 2008 Operating Margin Design Margin Analytical Margin Margins Range of Normal Operation Ultimate Capability Analyzed Design Limit Operating Limit Elevator Example Rated Load posted in elevator = 3500 lbs Dept of Labor - design for 25% passenger overload 4375 lbs Analyzed & tested to 4650 lbs 100 – 600 lbs Failure Point – undetermined depends on many variables

PAGE 17 CM Fundamentals 2008 Margins Normal Operation Operating Margin Design Margin Analytical Margin HVAC Example OAC Room Temperature Original analysis: Room temperature must be kept under 90° F to protect computers Note: vendor’s Operating Limit = utility’s Ultimate Capability Analyzed Design Limit = 84° F, calculated for worst case conditions Operating Limit =78° F to give operators time to take action (analysis assumption) High Alarm is set at 75° F (warning of abnormal condition) 84° F 78° F 72° F 75° F 90° F

PAGE 18 CM Fundamentals 2008 Margins HVAC Example Over time margin is lost due to one or more of these causes: heat loads added to room lake temperature higher than analyzed poor heat exchanger performance due to fouling OAC Room Temperature Normal Operation Operating Margin Analytical Margin 88° F 82° F 74° F 78° F 90° F Design Margin New Analyzed Design Limit (88°F) reduces Analytical Margin and affects Operating Limit (78° F to 82°F) affects Operating Margin affects Alarm Setpoint (75° F to 78°F)

PAGE 19 CM Fundamentals 2008 Normal Operation Operating Margin Design Margin Analytical Margin OAC Room Temperature 84° F 78° F 72° F 75° F 90° F Larger air conditioning unit can restore room temperature margin but will require more electrical power increase weight on Aux Bldg roof Margins HVAC Example Voltage AnalysisRoof Structural Analysis Normal Operation Operating Margin Design Margin Analytical Margin Normal Operation Operating Margin Design Margin Analytical Margin …resulting in other margin losses

PAGE 20 CM Fundamentals 2008 CM Process Model high level model integrated processes used to return CM Equilibrium developed in early 2002 by CMBG task force. included in INPO Ap-929, Revision 1 in 2005

PAGE 21 CM Fundamentals 2008 CM Process Model Evaluate Identified Problem or Desired Change apparent discrepancy (discovered error) desired change (modification, manipulating plant components) Evaluate Identified Problem or Desired Change Change Facility Configuration Information ? Change Design Requirements ? Change Physical Configuration ? Do Nothing More CM Equilibrium Physical Configuration Change Authorization Process Design Requirements Change Process Facility Configuration Information Change Process No Yes No CM001

PAGE 22 CM Fundamentals 2008 CM Process Model Change Design Requirements? What are Design Requirements? Does change affect Design Requirements?  Use Design Requirements change process Evaluate Identified Problem or Desired Change Change Facility Configuration Information ? Change Design Requirements ? Change Physical Configuration ? Do Nothing More CM Equilibrium Physical Configuration Change Authorization Process Design Requirements Change Process Facility Configuration Information Change Process No Yes No CM002

PAGE 23 CM Fundamentals 2008 CM Process Model Change Physical Configuration? Modify components or change position of components?  Use mod process to change design Configuration  Use operating procedures to change component position Evaluate Identified Problem or Desired Change Change Facility Configuration Information ? Change Design Requirements ? Change Physical Configuration ? Do Nothing More CM Equilibrium Physical Configuration Change Authorization Process Design Requirements Change Process Facility Configuration Information Change Process No Yes No CM003

PAGE 24 CM Fundamentals 2008 CM Process Model Change Facility Configuration Information? Design Output documents (drawings & specs) Operational Configuration Documents Other operating, maintenance, training, etc. Evaluate Identified Problem or Desired Change Change Facility Configuration Information ? Change Design Requirements ? Change Physical Configuration ? Do Nothing More CM Equilibrium Physical Configuration Change Authorization Process Design Requirements Change Process Facility Configuration Information Change Process No Yes No CM004

PAGE 25 CM Fundamentals 2008 CM Process Model Do Nothing More If cost effective, do nothing more…except Document your conclusion Evaluate Identified Problem or Desired Change Change Facility Configuration Information ? Change Design Requirements ? Change Physical Configuration ? Do Nothing More CM Equilibrium Physical Configuration Change Authorization Process Design Requirements Change Process Facility Configuration Information Change Process No Yes No

PAGE 26 CM Fundamentals 2008 Functional Areas of CM #1Protect the Design Basis Design Basis Configuration #2Modify the Plant Engineering Change Control #3Operate the Plant Operational Configuration Control #4Maintain the Plant Configuration of SSCs not in service #5Test the Plant Plant Design Validation

PAGE 27 CM Fundamentals 2008 Functional Areas of CM Protect the Design Basis Objective: Understand and maintain design basis consistent with licensing basis design Major processes control of licensing and design basis documents (such as & UFSAR) engineering calculations Causes for upsets in CM Equilibrium new or revised Design Requirements inadequate original review

PAGE 28 CM Fundamentals 2008 Functional Areas of CM Modify the Plant Objective: Assure that changes to design configuration conform to Design Requirements and are accurately reflected on Facility Configuration Information Major processes modification process Causes for upsets in CM Equilibrium desired change (modification) undocumented plant changes

PAGE 29 CM Fundamentals 2008 Functional Areas of CM Operate the Plant Objective: Assure that alignment of in-service equipment is consistent with approved design through use of approved technical procedures. Major processes operating procedures tag out process Causes for upsets in CM Equilibrium failure to follow operating procedures human errors due to workarounds, abandoned equipment, temp mods, etc.

PAGE 30 CM Fundamentals 2008 Functional Areas of CM Maintain the Plant Objective: Assure that SSCs are procured and maintained in accordance with approved design Major processes maintenance procedures procurement procedures Causes for upsets in CM Equilibrium failure to follow procedures inadequate procurement QA

PAGE 31 CM Fundamentals 2008 Functional Areas of CM Test the Plant Objective: Assure the performance of SSCs meets Design Requirements Major processes performance testing plant walkdowns Causes for upsets in CM Equilibrium inadequate performance testing programs inadequate plant aging programs

PAGE 32 CM Fundamentals 2008 “It’s what you do now When you don’t have to do anything That lets you be What you want to be When it’s too late to do anything about it.” Warren Owen, former Exec. VP Duke Power