1. A Brief History of CM in the Nuclear Industry and the CMBG
Presented By:
Sam Melton
CMBG Steering Committee
June 2, 2008 Shell Beach, California
Previous CMBG conferences - two presentations
CMBG History
CM Fundamentals (CM-101)
Try something different
Brief History of Nuclear Configuration Management in the US
CMBG’s role in that history
CM documents
CM Fundamentals Workshop

2. A Brief History of CM in the Nuclear Industry
Configuration Management in military and aerospace industry geared towards product conformance to facilitate interchangeability of parts while still satisfying the overall design requirements
MIL-STD-973 (1992), ”Configuration Management” (later replaced by ANSI/EIA )

3. A Brief History of CM in the Nuclear Industry
DOE STD “Configuration Management”
Applicable to DOE nuclear facilities in the operational phase.
DOE-STD-1073 was updated in 2003
Early model for nuclear CM

4. A Brief History of CM in the Nuclear Industry
Nuclear plants in mid 60’s to early 80’s typically designed by AEs under contract
Final design documents typically turned over to the utility at the end of construction
Little knowledge transfer of design info to utility engineering organization
Utilities struggled to deal with long term design maintenance and related document upkeep

5. A Brief History of CM in the Nuclear Industry
Early indicators that the nuclear plant design basis knowledge was becoming disconnected from the physical plant
IE Bulletin uncovered
calculation discrepancies
undocumented modifications
document discrepancies
as-built problems

6. A Brief History of CM in the Nuclear Industry
Salem ATWS event (1983)
Generic implications identified in NUREG-1000 and NRC Generic Letter 83-28
compliance with vendor recommendations
part and procurement issues
vendor manual controls
Industry initiatives by INPO, NUMARC and EPRI to provide guidance and consistency

7. A Brief History of CM in the Nuclear Industry
Davis Besse Loss of Feedwater event (1985)
Led to NRC Safety System Functional Inspections (SSFIs) and NUREG-1154
difficulties maintaining operational readiness of safety systems
lack of understanding design bases
Voluntary design basis reconstitution, DBDs and self- evaluation
NUREG-1397, NUMARC , INPO and NUREG/CR-5147

8. A Brief History of CM in the Nuclear Industry
Browns Ferry (1985)
Browns Ferry fire in Unit 1 (1975) led to changes in NRC standards for Fire Protection
All three Browns Ferry units shut down voluntarily in March 1985 due to CM related problems - containment isolation testing (Unit 1), reactor water level instrumentation (Unit 2)
Unit 1 restarted in May 2007

9. A Brief History of CM in the Nuclear Industry
NRC specialized SSFIs for safety systems
Electrical Systems (EDSFI)
Service Water Systems (SWOPI)
SECY : intent to issue generic letter to require utilities to address how they were dealing with the problems - withdrawn

10. A Brief History of CM in the Nuclear Industry
Nuclear Information and Records Management Association (NIRMA) CM Committee developed solution
control of technical information by engineering and operations personnel
mature records management and document control process
PP “Position Paper on Configuration Management Program”

11. A Brief History of CM in the Nuclear Industry
First Nuclear CM benchmarking conference hosted by PPL in Fall 1994
17 US utilities represented
Each utility made presentation about their CM program
No motivational speeches
No sales promotions by service providers

12. The CMBG Idea Grows Second conference hosted by Ontario Hydro in 1995
Drafted plans for continuing organization - approved in 1996
Adopted name: Configuration Management Benchmarking Group
Formed Steering Committee
Wrote Mission Statement “…forum for peer-level information sharing…”
Defined ground rules for holding future conferences

13. CMBG is not affiliated with any other single organization
Independent of regulatory and oversight agencies
Conference costs are paid by registration fees and supplemented by host utility
Host utility pays for web site
Activities limited to information exchange

14. CMBG accomplishments
Annual Conferences
Participation in development of industry documents
Web Site (
CMBG history
Conferences (future conferences and proceedings from previous conferences)
Steering Committee
IAEA Activities
CM Links
Papers and publications
Contact Database

15. CMBG Conferences Year Host Location 1994 PP&L Poconos, PA
1995 Ontario Hydro Ontario, Canada
1996 Houston Lighting & Power Galveston, TX
1997 Commonwealth Edison Chicago, IL
1998 NAESCO Boston, MA
1999 Duke Power Charlotte, NC
2000 Consolidated Edison Tarrytown, NY
2001 Progress Energy Raleigh, NC
2002 PSEG Nuclear Atlantic City, NJ
2003 PPL Susquehanna Hershey, PA
2004 Wolf Creek Nuclear Kansas City, KS
2005 First Energy Cleveland, OH
2006 Dominion Richmond, VA
2007 SCE&G Charleston, SC
2008 Pacific Gas and Electric Shell Beach, CA

16. A Brief History of CM in the Nuclear Industry
NIRMA TG
“ Configuration Management of Nuclear Facilities”
Built on the NIRMA PP-02 document
Presented elements and attributes that facilities needed to establish of a good CM program.
Later became basis for ANSI/NIRMA CM
Criteria
Program management
Design requirements
Information Control
Change control
Assessment
Training

17. A Brief History of CM in the Nuclear Industry
Millstone Spent Fuel Pool Cooling (1996)
NRC had lost confidence in utility’s ability to know and maintain its design basis and to implement design and licensing requirements
10CFR50.54(f) letter in October 1996 to all licensees that required a response on how design basis information was controlled and maintained.
More far-reaching implications than letter that NRC was persuaded not to issue in 1993

18. A Brief History of CM in the Nuclear Industry
Millstone Spent Fuel Pool Cooling (1996)
10CFR50.54(f) letter helped to solidify CMBG as a viable resource for the industry and demonstrated how the CMBG "network" could be used to find and distribute valuable CM information between utilities, including good practices and lessons learned

19. A Brief History of CM in the Nuclear Industry
DC Cook Design issues (1997)
Extended shutdown due to inability to respond to design basis event and other configuration issues
Contributed to INPO decision to modify the evaluation performance objectives and criteria to include configuration management and to the formation of a new CM evaluation department.

20. A Brief History of CM in the Nuclear Industry
INPO AP-929 (1998)
“Configuration Control Process Description”
Focused on changes to plant configuration

21. CMBG Contributions to Industry CM Guidance Documents
ANS/NIRMA CM
“ Configuration Management of Nuclear Facilities”
Based on NIRMA TG-19
CMBG members participated in development, review and issuance.
Drafts reviewed at CMBG conferences
Criteria
Program management
Design requirements
Information Control
Change control
Assessment
Training

22. CMBG Contributions to Industry CM Guidance Documents
IAEA TECDOC-1335 (2003)
"Configuration Management in Nuclear Power Plants“
Contained elements of INPO AP-929 and ANSI/NIRMA CM-1.0
Criteria
Program management
Design requirements
Information Control
Change control
Assessment
Training

23. CMBG Contributions to Industry CM Guidance Documents
2002 CMBG Conference - initiative to reach agreement between INPO and NEI documents
NEI CM Community of Practice (2002)
CM Process and PI’s included in NEI Standard Nuclear Performance Model (2003)

24. A Brief History of CM in the Nuclear Industry
INPO - Margin Management (2003)
INPO reorganization emphasized, “Evaluating Configuration and Margin Management”
Greater than design basis range
Operating Point Limit
Normal Operating Point
Design or Tech Spec Basis Limit
Functional/Design Failure
Allowed operating range
Analyzed transient range
Operating margin
Design margin
( Design allows operation in the transient range. However operating restrictions consistent with the design, such as the magnitude and frequency of excursions into this range apply)
( The allowed operating range provides the normal margins operators use without violating setpoints )
( This is a prohibited range of operation and represents the additional conservative margin to account for uncertainties in design and construction )

25. A Brief History of CM in the Nuclear Industry
INPO (November 2003)
“Performance Objectives and Criteria”
Configuration Management
CM.1 Maintaining Margins Consistent with Design Requirements
CM.2 Operational Configuration Control
CM.3 Design Change Processes
CM.4 Conduct of Engineering
CM.5 Reactor Engineering and Fuel Management

26. A Brief History of CM in the Nuclear Industry
INPO (May 2005)
“Performance Objectives and Criteria”
Configuration Management
CM.1 Maintaining Margins Consistent with Design Requirements
CM.2 Operational Configuration Control
CM.3 Design Change Processes
CM.4 Reactor Engineering and Fuel Management

27. CMBG Contributions to Industry CM Guidance Documents
INPO AP-929, Rev 1 (2005) “Configuration Management Process Description”
“Three-Ball model became “CM Equilibrium Model”
Return to CM Equilibrium (new)
Margin Model (new)

28. CMBG Contributions to Industry CM Guidance Documents
IAEA Draft Safety Report. “Application of Configuration Management in Nuclear Power Plants” (to be issued in 2007)
Elements of AP-929 (Rev 1)

29. CMBG Contributions to Industry CM Guidance Documents
ANSI/NIRMA Standard-CM-1.0, Rev 1 “Configuration Management of Nuclear Facilities”

30. 2008 CMBG Conference Changes
First ever West Coast site
“Café” style breakouts
Wednesday IT forum
Dreaded “vendor” participation

31. CMBG Contributions to Industry
What’s next?