1. Presented By: John Gierlach, Senior Advisor Ontario Power Generation
Vendor Manual
Program Implementation
Presented By:
John Gierlach, Senior Advisor
Ontario Power Generation
8th Configuration Management Benchmarking Conference
October 29 – 31, Raleigh, NC

2. Agenda Background Vendor Manual Reconstitution Program Summary
Principles
Baseline scope and results
Re-contact scope and results
Analysis of changes
Update of plant documentation
Summary

3. Background Ontario Power Generation (OPG) nuclear assets History
Darlington (4 units) & Pickering (8 units)
Bruce (8 units) leased to Bruce Power in 2001
History
1970’s ’s: Construction
1990’s: Deteriorating performance
1997: Start of Nuclear Recovery & Configuration Management Restoration Project (CMRP)
Vendor Manual Reconstitution Program for 12 of 20 nuclear units

4. Principles Use only original approved copies from Records
Minimize paper - electronic image with text
Not done in house - contracted to Data Repro Com
4,329 Vendor Manuals on intranet, fully text searchable
Satisfy plant personnel
Focused on installation/operation/maintenance (IOM)
Focused on essential systems
Reduce risk of baseline and re-contact effort
Not done in house - contracted to VIS
Included evaluation of changes - minimize OPG workload

5. Baseline Scope and Results
1,943 Vendor Manuals
1,448 for essential systems
495 for non-essential systems
Above Vendor Manuals contained 23,438 Publications
18,761 for essential systems
4,677 for non-essential systems
1,221 vendors
12% consisted of multiple copies of same publication
Over 50% of the Publications in Vendor Manuals were immediately classified as insignificant - unlikely that evaluation or vendor contact would yield substantive plant operations and maintenance benefit

6. Baseline Results (2) Largest populations: Honeywell 232
Klockner Moeller 222
Johnson Controls 185
Solar Turbines 179
Envirex 152
ITE
Rotork 128
Fisher Controls 114

7. Baseline Results (3) Insignificant Publication types:
Catalog (may contain performance specifications) 804
Correspondence (OPG or vendor) 185
Product data sheet, specification 1,492
Drawing (stand alone) 6,644
Seismic, EQ test results
Plant cataloging information 1,640
OPG plant procedure 10
Purchase requirements, warranties 111
Sales / price list (no performance specifications) 44
Parts lists ( No IOM or technical information) 1,017
Total ,348

8. Baseline Results (4) Significant Publication types: IOM manuals 9,308
Product bulletins 972
SALs, errata, addenda 259
Recommended spare parts 551
Total 11,090

9. Re-contact Scope Focus on essential systems: 8,705 Publications
Eliminate duplicates: - 1,460 Publications
Staticon, Velan, Crompton Instruments, Honeywell
Eliminate vendors: - 1,001 Publications
Ontario Power Generation, Ontario Hydro Technologies, AECL, General Electric, Westinghouse
Final Re-contact scope: 6,244 Publications
956 vendor contacts

10. Re-contact Results 95.8% vendor contact success rate Uncooperative:
Vendors Publications Reason
Many calls – no response
Combative
Other priorities
Expensive subscription
Unresponsive:
Vendors Publications
9 85

11. Re-contact Results (2)
Future contact not necessary:
Description Publications
Vendor out of business 341
Catalog
Out of scope
Information not available 33
Not subject to revision
Obsolete equipment 1,347
Use original publication 2,648
Total ,737

12. Re-contact Results (3) Future contact necessary:
Description Publications
Current, but may be revised later 503
Out-of-date, new revision sent 703
Not enough info to verify 37
Unresponsive
Uncooperative
Total ,507

13. Re-contact Results (4) Analysis of changes - changes not of concern:
205 Publications contained administrative or non-technical changes
Trivial, editorial change
Not expected to impact plant configuration or procedures.
Addition of background information
Addition of specifications
General guidance, such as troubleshooting
33 Publications contained configuration changes:
Change that does not apply to OPG installation

14. Re-contact Results (5) Analysis of changes - changes of concern:
28 additional Publications provided:
Publication provides information not previously found in OPG system and cannot be compared to anything
363 Publications contained technical changes:
Expected to impact plant configuration or procedures
Changes to specifications
Changes in order of task performance
Addition of, or changes to, maintenance
Addition of acceptance criteria

15. Update of Plant Documentation
Routed through Engineering Change Control
No changes - no review
Changes not of concern - minimum review
Changes of concern - full review
PassPort database updated
Vendor Manual image file embedded (Acrobat format)
Review cycle timeframe entered to indicate when future contact is necessary (3 years or 99 years)
Vendor Manual linked to equipment record
Minimize paper copies and distribution

16. Summary 4,329 Vendor Manuals placed on intranet
1,943 Vendor Manuals subject to baseline efforts
18,761 Publications in 1,448 Vendor Manuals for essential systems analyzed in detail:
67% (12,517 Publications) not significant
25% (4,737 Publications) significant but do not require future contact
8% (1,507 Publications) significant and require future contact
2% (363 Publications) significant and had substantial technical changes