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Obsolescence Impact on Configuration Management

Presented By:Rob Santoro

PKMJ Technical Services, Inc.

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Definition of Obsolescence

• Obsolete Equipment - “An item in plant service that is no longer manufactured or are otherwise difficult to procure and qualify.”

Source: INPO NX-1037 Revision 1, Obsolescence Program Guideline

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Obsolescence in Nuclear

• What does that mean to Nuclear Power?– Manufacturers are no longer making components required to

maintain Plant– Plants are built with technologies from the 60’s and 70’s

• License Renewal: How will obsolescence impact the plant for the next 20 years?

• Average of 20% of installed plant equipment is obsolete

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Obsolescence Challenges

• Existing station workloads make it difficult to allocate resources to support proactive solution development– Daily challenges of operating the plant take precedence

over Proactive Obsolescence Management

• Obsolescence Is Not Going Away:– Obsolescence is growing by an average of 12,000 models

per year

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• It Impacts All Pillars of the Configuration Triangle!

DesignRequirements

PhysicalConfiguration

DocumentedConfiguration

How does Obsolescence Affect Configuration?

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How does Obsolescence Affect Configuration?

• Documented Configuration:– Do you know what in your plant is obsolete?

• Design Requirements– When replacing obsolete components/parts with new

ones, will you change the design requirements?

• Physical Configuration– The plant may change when replacing an obsolete item

with a new item

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Tackling Obsolescence• Understand Its Impact

– Industry Tools Available:• Proactive Obsolescence Management System (POMS)• RAPID/OIRD

• Prioritize Challenges– Industry Tools Available:

• Preventive Maintenance Forecaster (PM Forecaster)• Obsolescence Manager (OM)

• Solve Challenges– Several Solution Options:

• Surplus• Equivalency Evaluations• Design Changes• Reverse Engineer

– Industry Tools Available• CMIS

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Tackling Obsolescence• Understand Its Impact

– The Industry has adopted POMS to identify obsolescence• POMS collects all installed equipment information from each

site• Every year, all manufacturers of equipment is contacted to

identify obsolescence

– All U.S. Utilities are members of POMS

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Understanding Obsolescence Impact

• POMS Identified: – 19% of Data Collected Un-Usable

• Cannot contact a manufacturer called “%^&:”

– 15% of Results Incomplete• Model number insufficient to determine obsolescence

– 11% of Results Unidentifiable• Manufacturer could not recognize Model Number

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Understanding Obsolescence Impact

• What does this mean to Configuration Management?

• Incorrect/Missing information in Enterprise Management systems could indicate a gap in Configuration Management

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Configuration Challenges• Configuration Challenges discovered when trying

to understand impact of obsolescence to plant– Master Equipment List’s Incomplete/Inaccurate

• Missing Information– Manufacturer– Model Number– Equipment Details

• Incomplete– Model Number Incomplete– Series Number listed– Site specific number scheme/code

• OEM Not Identified– AE’s listed as OEM– Utility listed as OEM

• Bill of Materials Incomplete

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Addressing Configuration Data

• Data Clean-Up– Review Design Requirements and Physical Configuration

to identify what is installed and update Configuration Management Databases

– Look at:• Purchase Orders• Work Order History• Drawings• Vendor Manuals• Design Changes• Equivalency Evaluations

– Walk-Down: Review Nameplate data

– Large Effort• Attack in phases: Critical Components first

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Data Clean-Up

• Results:– Better data available to identify obsolescence

challenges– Provides for better planning

– Some Utilities require Configuration Change Management to modify this information

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Configuration Changes

• Be Cognizant of Obsolescence When Performing Configuration Changes– Do not “design-in” obsolescence

• Digital Equipment– Does the OEM have a long term replacement plan?

• Does my new design implement an obsolete item?

– Consider Adding a Check in your design process to check for obsolescence before completing design changes

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Configuration Changes

• Post Implementation: Update Data Systems– Does your Configuration Change Process require

Enterprise Database Updates before Change is complete?

• Have you updated the Master Equipment List?• Have you updated the Bill of Materials?

– Avoid future obsolescence challenges by clearly documenting current design changes

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Configuration Changes

• When Performing activities that impact configuration due to Obsolescence:– Consider a “design once, install many” approach

• Replace all affected component locations with the same item (when possible)

– Identify and satisfy “worst case” characteristics when

replacing obsolete items across multiple systems

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Questions

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