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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• Average of 20% of installed plant equipment is obsolete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• Documented Configuration:– Do you know what in your plant is obsolete?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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