Elective Maintenance Backlog Reduction at Ontario Power Generation Darlington Nuclear

Abstract

Elective Maintenance (EM) work orders document deficiencies in nuclear power plant equipment which is degraded, but still functioning. The detailed definition of EM is found in the Institute of Nuclear Power Operations (INPO) Document AP928, Work Management Process Description. Industry experience shows that there is a direct correlation between low EM backlogs and a low Forced Loss Rate at nuclear power plants. Since 2005, Darlington Nuclear has reduced its EM backlog from a total of 3100 work orders (775 per unit) to 1600 by year end 2007. Darlington reached a backlog of 1400 (350 per unit) in August, 2008. This level of backlog is considered ‘live zero” or sustaining level for a highly reliable four unit Candu nuclear power plant and is in line with Industry Best Practice. Improvement in plant reliability has been evident and consistent throughout Darlington’s Backlog Reduction Program. This paper documents the history of backlog reduction at Darlington Nuclear and the specific methodologies used to achieve this success. It is structured around four phases. Details of each phase are provided and lessons learned discussed. The four phases are: 1) Data Review and Cleanup/Fix-It-Now (FIN) Team Focus; 2) Improve FIN Performance/Increase EM Work Orders Scheduled; 3) Improve Schedule Rigor/Rapid EM Work Order Turnaround/Increase Resource Utilization; 4) Engineer Solutions for “Hardened”/Aged Backlog. The role of FIN team is also discussed in detail in terms of their mandate, organization and work methods.