© 2010 NSRC Corporation1 Foreign Material Management Dr. Bill Corcoran NSRC Corporation 860-285-8779 [email protected].

© 2010 NSRC Corporation

1

Foreign Material Management

Dr. Bill Corcoran NSRC Corporation

[email protected]

mailto:[email protected]


2

This is best viewed in “Slideshow.”

Click on “Slideshow.”


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It’s a lot more than just foreign material exclusion (FME)

“The beginning of wisdom is to call things by their right names.” A Chinese Proverb


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Watch Your Language

FMM: all aspects of dealing with FM FME: keeping FM out FOD: “Foreign Object Damage” or

“Foreign Object Debris”-a term used in aviation


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Foreign MaterialAny material that by: Nature, Magnitude/Quantity, Location, and/or Timing: was not accommodated in the design


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Programmatic Involvement In Consequential Nuclear Power Events

Reactivity management (Chernobyl, SL-1, Windscale)

Foreign material management (FMM)


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Famous FMM Events TMI-2 ~ LOCA (water in

an air system) Salem-2 ~ destructive

turbine overspeed (particulates in control oil)

Salem-2 ~ anticipated transient without scram (wrong lubricant hardened and froze RTB)

Cook ~ regulatory shutdown (fibrous material in containment)

LaSalle service water (injection of sealant in service water tunnel)

Fermi-1 ~ core damage (component adrift in reactor)


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Famous FMM Events Point Beach (frazile

ice) Salem (river grass) Davis-Besse (did not

find source of FM in containment)

Mischaracterized silt at Watts Bar

St. Lucie (jellyfish) Columbia (foam

fragments were FM) 2002 Northeast

Blackout (vegetation is FM!)

Cooling Tower Drift caused scram at River Bend


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Other FMM Events

Concorde Titanic Surgical Items left in patients

(thousands) Trojan Horse Davis-Besse Sump Screens


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Other FMM ExperiencesStation FM Event Consequences

Beaver Valley Leak sealant injected into aprimary system

Inoperable ReactorHead Vent System

Turkey Point Rag in a lube oil sump triggered asearch for generic implications

Delayed start-up

Cook Snow and ice plugged a tankgoose neck vent

Tank implosion

Doel,Haddam Neck

Debris created by machiningoperations

Widespread coredamage

Peach Bottom Rigging in Core Spray System(Trojan Horse FM event!)

Core Spray inop,major cleanup andtest


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Other FM Experiences (cont.)

Station FM Event ConsequencesMaine Yankee Machine oil contained a forbidden

substanceDelayed sleevingproject

Salem Management of a foreign materialintrusion

$500,000 civilpenalty

Susquehanna Sand blast grit ingested by a dieselengine

Unavailability andre-overhaul ofdiesel

Calvert Cliffs Uncontrolled FMM measures Imploded a largetank

Cook Assorted FM in Ice Condenser Part of $500, 000civil penalty


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FM Events

FM Damage FM Near Misses (Intrusions +) FMM Compromises FMM Infractions and Deviations


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The Foreign Material Management Occurrence Pyramid

FMM Damage~1

FMM Near Misses~10

FMM Compromises~100

FMM Infractions/Deviations~1000

Higher seriousness points to command accountability issues

Lesser seriousness points to process issues

© 2003, William R. Corcoran, NSRC Corp., 860-285-8779, [email protected]

Intrusions are near misses


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FMM Damage

FMM Damage

FM Damage FME DeviceDamage


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FME Damage

FME DeviceDamage

Implosions Other Damage fromFME Devices

Cooling Lubrication Other?


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Collapsed Demineralized Water Storage Tank at Calvert Cliffs

FMM Device Damage


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Some Debris Collected From Ice Condenser at Cook Nuclear Plant


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“Foreign” Mat’l that talks like a “local.”


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Non-nuclear FM Events

Bhopal (water in MIC tank) Herald of Free Enterprise (water) ValuJet 592 (oxygen generators) “Chunnel” Fire (burning cargo) “Concorde” (loss of aircraft) 9-11-01 (box cutters)? 2010 Kleen Energy Explosion


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Your favorite FMM snafus...

Your facility? Elsewhere?


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Foreign Material ~ A Little Bit Goes A Long Way

Procedures can only prevent the repetition of the types of FMM events that have occurred

FMM education is necessary to prevent new types of FMM events


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Not just a signs and tags... A way of doing business Part of the Culture of Safety

Foreign Material

Exclusion Area

Foreign Material Exclusion Area


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Transparency; a Friend of FMMCould you tell if something was missing?

(Thanks to Snap-On Tools)


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FMM Includes Control of FM production Control of FM access to buffer areas In FM buffer areas and danger areas:

FM inventory control FM physical control

FM removal before closeout FM exclusion Controlling the adverse side effects of FME

measures


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FMM Includes (cont.)

Detecting FM compromises Detecting FM intrusions Control of intruded FM Removal of intruded FM Analyzing potential future effects of

intruded FM Disposition of intruded FM Configuration tracking of intruded FM


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FMM Includes (cont.) Determining the factors that resulted in

The nature of the FM The magnitude of the FFM The location of the FM The timing of the FM

Addressing the above factors Addressing the factors that resulted in

those factors


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Foreign Material Exclusion (FME)

FME

An important part of FMM


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FMM Success

P reven tion C on tro lo f A d verseE ffec ts o f

C ou n term easu res

D etec tion L im ita tion

R em ova l M itig a tion

F M MS u ccess


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FM Prevention

B u ffe rA reas

D an g erA reas

C on tro l o fF M

P rod u c tion

B u ffe rA reas

D an g erA reas

In ven to ryC on tro l

F MC on tro l

B u ffe rA reas

D an g erA reas

D etec tin gC om p rom ises

B u ffe rA reas

D an g erA reas

F MC lean u p

F M Efrom D an g er

A reas

F MP reven tion


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Control of Adverse Effectsof Countermeasures

A ssessm en to f

P o ten tia lE ffec ts

C on tro l o fC on d it ion s

D u rin gU se

A ssu ran ceo f

R em ova l

C on tro l o f A d verse E ffec tso f C ou n te rm easu res

FMM C/M are facility changes that must be controlled.


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Response to Detected FM



StoppingMore FM

StoppingMore FM Limitation

of Transport

Limitationof Transport Limitation

of FM Effects

Limitationof FM Effects Removal

Removal Assessmentof Effects

Assessmentof Effects

Documentationof FM

Configuration

Documentationof FM

Configuration


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Be sure you determine

Where it came from How it was produced How it got where you found it


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Sad examples

LaSalle attributed FM to a known source and delayed addressing the real problem

Davis-Besse did above for RV head FM and stopped the investigation of atmospheric FM

Calvert Cliffs treated FM as a causal factor when it was a symptom and delayed addressing the real problem


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FMM ~ Design Factors Good design may

help filter out foreign material… or mitigate the consequences of a FMM event

But, don’t rely on design factors alone to identify & prevent FMM problems


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Some Places Where FMM Considerations Apply:

Work planning Purchase orders Design engineering Chemistry controls Radiation protection ALARA Pre-job briefings Post-job walkdowns Performance indicators

QC inspections Receipt inspections Alarm response

instructions Operator training Management & tech.

staff training QA audit program Severe weather

walkdowns


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Where FMM Does Not Apply


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Where FMM Does Not Apply


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FMM Program Organization

Sponsor (Director, Site VP or Plant Manager)Owner (Maintenance Dept. Head)

Manager (Senior technical person)

FMM Infrastructure

InvolvementInvolvement

OversightOversight


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Where Is Our Foreign Material Management Program?

Is it narrowly focused on FME? Is it owned by a senior

“FMM Zealot”? Does it include

education as well as procedures? Do key managers support our FMM

program as if their careers depend on it?


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Where Is Our Foreign Material Management Program? (cont.)

Does Operations support our FMM program as if the health and safety of the public depends on it?

Can our corrective action database give a good picture of the status and adequacy of our FMM program performance?

Are our senior managers good FMM role models? Do they “walk the talk”?


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Where Is Our Foreign Material Management Program? (cont.)

Does our Plant Operations Review Committee give our FMM program the attention it deserves?

Has our executive level nuclear safety committee held a review of our FMM program performance?

Has our independent oversight organization audited the status and adequacy of our FMM program performance?


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Find Any Pockets of FMM Program Non-participation?

Clean them out!


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Questions?

Dr. Bill Corcoran NSRC Corporation

[email protected]

mailto:[email protected]

© 2010 NSRC Corporation1 Foreign Material Management Dr. Bill Corcoran NSRC Corporation 860-285-8779 [email protected].

Documents

foreign material intrusion

foreign material managementits

foreign material managementdr

fmm infractionsdeviations

foreign object damage

fm outfod

source of fm

foreign object debris