© 2010 NSRC Corporation
1
Foreign Material Management
Dr. Bill Corcoran NSRC Corporation
© 2010 NSRC Corporation
3
Foreign Material Management
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
© 2010 NSRC Corporation
4
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
© 2010 NSRC Corporation
5
Foreign MaterialAny material that by: Nature, Magnitude/Quantity, Location, and/or Timing: was not accommodated in the design
© 2010 NSRC Corporation
6
Programmatic Involvement In Consequential Nuclear Power Events
Reactivity management (Chernobyl, SL-1, Windscale)
Foreign material management (FMM)
© 2010 NSRC Corporation
7
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)
© 2010 NSRC Corporation
8
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
© 2010 NSRC Corporation
9
Other FMM Events
Concorde Titanic Surgical Items left in patients
(thousands) Trojan Horse Davis-Besse Sump Screens
© 2010 NSRC Corporation
10
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
© 2010 NSRC Corporation
11
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
© 2010 NSRC Corporation
12
FM Events
FM Damage FM Near Misses (Intrusions +) FMM Compromises FMM Infractions and Deviations
© 2010 NSRC Corporation
13
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
© 2010 NSRC Corporation
15
FME Damage
FME DeviceDamage
Implosions Other Damage fromFME Devices
Cooling Lubrication Other?
© 2010 NSRC Corporation
16
Collapsed Demineralized Water Storage Tank at Calvert Cliffs
FMM Device Damage
© 2010 NSRC Corporation
19
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
© 2010 NSRC Corporation
21
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
© 2010 NSRC Corporation
22
Foreign Material Management
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
© 2010 NSRC Corporation
23
Transparency; a Friend of FMMCould you tell if something was missing?
(Thanks to Snap-On Tools)
© 2010 NSRC Corporation
24
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
© 2010 NSRC Corporation
25
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
© 2010 NSRC Corporation
26
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
© 2010 NSRC Corporation
28
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
© 2010 NSRC Corporation
29
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
© 2010 NSRC Corporation
30
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.
© 2010 NSRC Corporation
31
Response to Detected FM
Response to Detected FM
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
© 2010 NSRC Corporation
32
Be sure you determine
Where it came from How it was produced How it got where you found it
© 2010 NSRC Corporation
33
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
© 2010 NSRC Corporation
34
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
© 2010 NSRC Corporation
35
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
© 2010 NSRC Corporation
38
FMM Program Organization
Sponsor (Director, Site VP or Plant Manager)Owner (Maintenance Dept. Head)
Manager (Senior technical person)
FMM Infrastructure
InvolvementInvolvement
OversightOversight
© 2010 NSRC Corporation
39
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?
© 2010 NSRC Corporation
40
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”?
© 2010 NSRC Corporation
41
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?
© 2010 NSRC Corporation
43
Questions?
Dr. Bill Corcoran NSRC Corporation