Foreign Material Management

Bill Corcoran,

Nuclear Safety Review Concepts

Corporaton

© 2003 Bill Corcoran , all rights reserved

Foreign Material Management

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

Foreign Material

Any material that by: Quantity or nature, and Location

Was not accommodated in the design

Programmatic Involvement In Consequential Nuclear Power Events

Reactivity management (Chernobyl, SL-1, Windscale)

Foreign material management (FMM)

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)

Famous FMM Events

Point Beach (frazile ice)

Salem (river grass) Davis-Besse (did not

find source of FM in containment)

St. Lucie (jellyfish) Columbia (foam

fragments were FM)

Other FMM Events

Concorde Titanic Surgical Items left in patients

(thousands) Trojan Horse Davis-Besse Sump Screens

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

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

FM Events

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

The Foreign Material Management Occurrence Pyramid

FMM Damage~1

FMM Near Misses~10

FMM Compromises~100

FMMInfractions/Deviations~1000

Higher seriousness points to command accountability issues

Lesser seriousness points to process issues

© 2003, William R. Corcoran, NSRC Corp., 860-285-8779, firebird.one@alum.mit.eduIntrusions are near misses

FMM Damage

FMM Damage

FM Damage FME DeviceDamage

FME Damage

FME DeviceDamage

Implosions Other Damage fromFME Devices

Cooling Lubrication Other?

Collapsed Demineralized Water Storage Tank at Calvert Cliffs

FMM Damage

Some Debris Collected From Ice Condenser at Cook Nuclear Plant

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)?

Your favorite FMM snafus...

Here Elsewhere

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

Foreign Material Management

Not just a signs and tags...

A way of doing business

Foreign Material

Exclusion Area

Foreign Material Exclusion Area

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

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

Foreign Material Exclusion (FME)

FME

An important part of FMM

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

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

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.

Response to Detected FM

Response to Detected FM

Response to Detected FM

StoppingMore FM

StoppingMore FM

Limitationof Transport

Limitationof Transport

Limitationof FM Effects

Limitationof FM Effects RemovalRemoval Assessment

of Effects

Assessmentof Effects

Documentationof FM

Configuration

Documentationof FM

Configuration

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

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

Where FMM Does Not Apply

FMM Program Organization

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

Manager (Senior technical person)

FMM Infrastructure

InvolvementInvolvement

OversightOversight

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?

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”?

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?

Find Any Pockets of FMM Program Non-participation?

Clean them out!

Questions?