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

2. 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

3. 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

4. 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

5. 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

6. 1. Setting the Scene: Koeberg Nuclear Power Station
Systems, Components & Maintenance
Number of Systems = Approx. 200 systems
Number of Preventative Maintenance (PM) Tasks = Approx (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

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

8. 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

9. 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

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

11. 3. Our Equipment Reliability Journey: Timeline
Mid Development
of “Equipment Reliability”
group (3 ppl). Focus on
improving PHC (Plant
Health Committee) and
System Health Reporting
Oct EPRI AP-913 Gap Analysis – Improvements identified for existing RCM Maintenance Basis
EDF / Eskom Contract. EDF fully adopts AP-913, including PM Templates.
2002…
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

12. 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

13. 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

14. 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

15. Any Questions?
2019/02/22