IAEA-TECDOC-658 Safety related maintenance in the framework of the reliability centered maintenance concept INTERNATIONAL ATOMIC ENERGY AGENCY PLEASE BE AWARE THAT ALL OF THE MISSING PAGIS IN THIS DOCUMENT WERE ORIGINALLY BLANK SAFETY RELATED MAINTENANCE IN THE FRAMEWORK OF THE RELIABILITY CENTERED MAINTENANCE CONCEPT IAEA, VIENNA, 1992 IAEA-TECDOC-658 ISSN 1011-4289 Printed by the IAEA in Austria July 1992 FOREWORD Maintenance of systems, structures and components at a nuclear power plant e mosth f t o importan e ison t programmes aimin t achievinga g safd reliablan e e power production throughout the lifetime of the plant. Historically, the maintenance of the equipment at NPPs was done in accordance to the specification of the designer. However, by analyzing experience, it was recognized that the nuclear industry could benefit significantly from optimizing maintenance. Since being adopted from the aerospace industry, the concept of Reliability Centered Maintenance (RCM) received substantial interest in the nuclear industry, primarily because of its potential benefits in plant reliabilit d safetan y y through optimizin plant'a g s maintenance programme. In order to discuss the status of RCM and other approaches for optimization of maintenance, and the safety benefits of those approaches, the IAEA convened a Technical Committee Meeting on "Safety Related Maintenance in the Framework of the Reliability Centered Maintenance Concept" in Vienna from 27 to 30 May 1991. e meetinTh attendes wa g mory b d e tha expert0 7 n s fro countrie1 m2 d an s international organizations addition I .numbea o t n f papero r s which were presented, extensive plenar d panean y l discussions took place durin e meetingth g , whera e variety of maintenance related topics were clarified. This TECDOC summarizemethods M it RC d e an e statusth th sf o s application nuclean i s Francd ran industrA e todayUS n i y , wit varietha f exampleyo s of application of RCM from several countries, as presented during the meeting. The papers presented at the meeting are reproduced in the Annex. EDITORIAL NOTE In preparing this material for the press, staff of the International Atomic Energy Agency have mounted paginatedand originalthe manuscripts submittedas authorsthe givenby and some attention to the presentation. The views expressed papers,the statementsin the general the made and style adoptedthe are responsibility namedthe of authors. necessarilyviewsnot The do reflect governmentsthosethe of of the Member States or organizations under whose auspices the manuscripts were produced. The use in this book of particular designations of countries or territories does not imply any judgement by the publisher, the IAEA, as to the legal status of such countries or territories, of their authorities and institutions or of the delimitation of their boundaries. The mention of specific companies or of their products or brand names does not imply any endorsement or recommendation on the part of the IAEA. Authors are themselves responsible for obtaining the necessary permission to reproduce copyright material from other sources. CONTENTS 1. INTRODUCTION .....................................................................................7 . 1.1. Purpose and structure of the report .......................................................... 7 1.2. Relationshinucleao t M r RC safet f po y .....................................................8 . 1.3. Terminolog f maintenancyo e .................................................................8 . 2. WHAT IS RCM ........................................................................................ 11 nuclea2.1e th . n i Overvie r M industrRC f wo y ................................................1 1 . 2.2. The limits to RCM .............................................................................. 12 2.3. History of RCM ................................................................................. 13 nuclead an M r2.4 planRC . t regulation ..........................................................6 1 . 3. ANALYTICAL METHOD ........................................................................... 17 3.1. Basic steps .......................................................................................7 1 . 3.2. The French approach ........................................................................... 18 3.3. The US approach ................................................................................ 27 3.4. Critical areas ...................................................................................... 30 4. IMPLEMENTATION .................................................................................2 3 . 4.1. Introduction ....................................................................................... 32 4.2. Project organization ............................................................................2 3 . 4.3. Task implementation ...........................................................................3 3 . livinM 4.4gRC .programm e .......................................................................5 3 . BENEFIT E ..........................................................................M TH RC . F 5 SO 7 3 . 6. STATUS OF SELECTED INDUSTRY PROGRAMMES ..................................... 39 6.1. Application of the RCM at EOF, France ................................................... 39 6.2. Applications of RCM by several utilities in the USA .................................... 41 6.3. The RCM programme of EPRI ............................................................... 42 7. STATUS OF RCM TECHNOLOGY ............................................................... 43 7.1. Demonstrated areas .............................................................................. 43 7.2. Areas under development ...................................................................... 43 analysiM 7.3RC . s workstation ....................................................................4 4 . 8. SUMMARY OF DISCUSSIONS AT THE TECHNICAL COMMITTEE MEETING ............................................................................................... 45 BIBLIOGRAPHY ............................................................................................7 4 . ANNEX. PAPERS PRESENTE TECHNICAE TH T DA L COMMITTEE MEETING Reliability centered maintenance (RCM) at Southern California Edison ........................... 51 N.B. Bloom Procedure for the arrangement of the reliability centered maintenance (RCM) activity at the Paks nuclear power plant ................................................................................9 6 . Z. Kiss, K. Timar Present status of reliability centered maintenance (RCM) in Japan ................................. 81 K. Ohta Effective maintenanc too a nuclea for elas r power plant equipmen systemand t s reliability management ................................................................................................1 9 . V. Nikolaev, GourinovichV. Development of reliability centered maintenance (RCM) methodology for the Electricite de France nuclear plants: A pilot application to the CVCS system .............................. 99 J.P. Jacquot, P. Legaud, G. Zwingelstein reliabilite Th y centered maintenance (RCM) analysis applie safete th o ydt related components of a nuclear power plant .................................................................. Ill A. Eramo, M. Pasquini Development of the Torness maintenance schedule .................................................... 125 M.L. Jenldns International maintainability standards .................................................................... 129 KrasnodebsJd,J. C.B. Wainwright, M.S. Grover Important decisions in reliability centered maintenance (RCM) program planning: Inceptio implementatioo nt n .............................................................................5 13 . L.W. Owsenek, W.D. Midgett Degradation mode analysis: An approach to establish effective predictive maintenance tasks .......................................................................................... 143 D.E. Sonnett, P.T. Douglass, D.D. Barnard Risk analysis enhancemen computea vi t r applications ................................................9 14 . D.D. Barnard, D.E. Sonnett Decision support system for effective plant maintenance .............................................. 161 S. Shimizu, S. Sakurai, T. Mori, I. Takehiro A proces r risfo sk focused maintenance .................................................................3 17 . E.V. Lofgren, S.E. Cooper, R.E. Kurlh Use of reliability data for maintenance of a fast reactor system ..................................... 193 Nakai,R. KaniY. List of Participants ............................................................................................ 201 1. INTRODUCTION 1.1. PURPOSE AND STRUCTURE OF THE REPORT Elevated safety requirements and ever increasing costs of maintenance of nuclear power plants stimulat e interesth e differenn i t t method d approachean s o t s optimize maintenance activities. Among different concepts e Reliabilitth , y Centered Maintenance (RCM) as an approach to improve Preventive Maintenance (PM) programmes is being widely discussed and applied in several IAEA Member States. In orde summarizo t r e basic principle currend an s t implementatio e RCMth e f o th ,n IAEA organized a Consultants Meeting in November 1990. The report prepared during that meeting was discussed during the Technical Committee Meeting (TCM) held in May 1991. Numerous