EQUIPMENT RELIABILITY AT KOEBERG Susan van Wyk Reliability Engineering Manager Koeberg Nuclear Power Station

Outline Setting the Scene: Koeberg Nuclear Power Station Integration of Equipment Reliability Processes – The INPO AP-913 Equipment Reliability Process Our Equipment Reliability Journey Timeline Integration of Existing Processes Equipment Reliability Tools Conclusion 2019/02/22

1. Setting the Scene: Koeberg Nuclear Power Station Unit 2 Unit 1 Turbine Hall Intake Basin Only Nuclear Power Station in Africa Two Framatome 920 MWe Units 3-loop Pressurised Water Reactors (PWR) Unit 1 began operating in 1984 Unit 2 began operating in 1985 Provides approx. 6.5% of South Africa’s electricity Sister plants: Tricastin and Blayais (EDF) 2019/02/22

1. Setting the Scene: Koeberg Nuclear Power Station Primary System: Water as moderator and coolant. Boric Acid and Control Rods for reactivity control. Secondary System: Steam / Water cycle. Steam drives Turbine-Generator sets. Ultimate Heat Sink: Cold Sea Water 2019/02/22

1. Setting the Scene: Koeberg Nuclear Power Station 3 Steam Generators Containment 3 Steam lines taking steam to the turbine Reactor Vessel 3 Reactor Coolant Pumps Basic PWR Nuclear Island Layout 2019/02/22

1. Setting the Scene: Koeberg Nuclear Power Station Systems, Components & Maintenance Number of Systems = Approx. 200 systems Number of Preventative Maintenance (PM) Tasks = Approx. 62 620 (Online and Outage) Outage 218 Duration Target ≤ 45 days Outage ALARA Dose Target ≤ 720 mSv South Africa’s Electricity Demand vs. Generating Capacity Challenges during winter and unplanned plant outage periods Equipment Reliability paramount to availability of plants Strong Demand Side Management programme to reduce wasteful use of electricity 2019/02/22

What is our common enemy? Unexpected Corrective Maintenance of Critical Equipment 2019/02/22

2. Equipment Reliability Guidelines for Nuclear: INPO AP-913 Background INPO = Institute of Nuclear Plant Operators INPO developed ER process guidelines INPO first issued AP-913 “Equipment Reliability Process” in March 2000 INPO AP-913 provides guidelines to maintain a high level of safe and reliable plant operation in an efficient manner AP-913 Guides the integration and coordination of Equipment Reliability activities into one process to: Evaluate important station equipment Monitor equipment performance and condition Make continuing adjustments to the maintenance tasks and frequencies based on equipment operating experience (OE). Develop and implement long-term equipment health plans 2019/02/22

2. Equipment Reliability Guidelines for Nuclear: INPO AP-913 Background To make sure that: We are working on the right equipment – Critical Component Determination We are doing the right maintenance – Maintenance Tasks At the right time – Maintenance Task frequency While planning ahead – Life of Plant Planning And Continually Making Improvements by: Performance and Condition Monitoring Recording “As-found” conditions and feeding back to PM programme Using feedback from the Corrective Action Programme Having a “Living” Maintenance Programme 2019/02/22

2. Equipment Reliability Guidelines for Nuclear: INPO AP-913 Top Level Diagram 2019/02/22

3. Our Equipment Reliability Journey: Timeline Mid-2007 - Development of “Equipment Reliability” group (3 ppl). Focus on improving PHC (Plant Health Committee) and System Health Reporting Oct 2008 - EPRI AP-913 Gap Analysis – Improvements identified for existing RCM Maintenance Basis EDF / Eskom Contract. EDF fully adopts AP-913, including PM Templates. 2002…. 2006 2007 2008 2009 2010 2011 2002 /3: Organisational Change - Set up for Sys Eng & Comp Eng, SHR,RCM MB, Separate ER Processes Strategy development for further partnerships with EDF and AP-913. Process Integration Maintenance Basis Optimisation Project –identification of failure modes, PM templates 2007 WANO Equipment Reliability Technical Support Mission. 2019/02/22

Existing processes require further integration: 3. Our Equipment Reliability Journey: Integration of Existing Processes Review of Component Criticality using EDF classifications as input for improved alignment of maintenance strategies Maintenance Basis Project to review plant maintenance tasks and frequencies based on Industry and plant OE. Existing processes require further integration: System Health Reporting Component Health Reporting Performance Monitoring and Trending Component Failure Assessments, Intrusive Task Assessments, Root Cause Analysis, Corrective Actions Life of Plant Plans (LOPP) Maintenance Task and Frequency Optimisation based on real plant maintenance feedback 2019/02/22

3. Our Equipment Reliability Journey: Equipment Reliability Tools Individual software systems have grown over time, e.g: system health database, component health database, Life Cycle Management system, Work management systems, Problem Reporting databases, Corrective Action management, RCM software, Maintenance Basis Database. Integration of Equipment Reliability software for: Improved processes Limiting duplication of data entries Improved monitoring and trending to become more proactive instead of reactive Avoiding gaps that may exist between processes Efficiency Ease of comparison to Industry peer stations with similar software 2019/02/22

4. Conclusion Our goal is to eliminate unexpected corrective maintenance of critical components Integration of Equipment Reliability processes for a truly LIVING MAINTENANCE PROGRAMME Koeberg is continually improving its equipment reliability using the Nuclear Industry guidelines for Equipment Reliability, Industry peer benchmarking, Operating Experience (e.g. EPRI) and partnerships with EDF. 2019/02/22

Any Questions? 2019/02/22