Foreign Material Management Dr. Bill Corcoran  NSRC Corporation 860-285-8779 [email_address]
This is best viewed in “Slideshow.” Click on “Slideshow.”
Foreign Material Management It’s a lot more than just foreign material exclusion (FME) “ The beginning of wisdom is to cal...
Watch Your Language <ul><li>FMM: all aspects of dealing with FM </li></ul><ul><li>FME: keeping FM out </li></ul><ul><li>FO...
Foreign Material <ul><li>Any material that by: </li></ul><ul><li>Nature, </li></ul><ul><li>Magnitude/Quantity,  </li></ul>...
Programmatic Involvement In Consequential Nuclear Power Events <ul><li>Reactivity management (Chernobyl, SL-1, Windscale) ...
Famous FMM Events <ul><li>TMI-2 ~ LOCA (water in an air system) </li></ul><ul><li>Salem-2 ~ destructive turbine overspeed ...
Famous FMM Events <ul><li>Point Beach (frazile ice) </li></ul><ul><li>Salem (river grass) </li></ul><ul><li>Davis-Besse (d...
Other FMM Events <ul><li>Concorde </li></ul><ul><li>Titanic </li></ul><ul><li>Surgical Items left in patients (thousands) ...
Other FMM Experiences
Other FM Experiences (cont.)
FM Events <ul><li>FM Damage </li></ul><ul><li>FM Near Misses (Intrusions +) </li></ul><ul><li>FMM Compromises </li></ul><u...
The Foreign Material Management Occurrence Pyramid FMM Damage~1 FMM Near Misses~10 FMM   Compromises~100 FMM  Infractions/...
FMM Damage FMM Damage FM Damage FME Device Damage
FME Damage FME Device Damage Implosions Other Damage from FME Devices Cooling Lubrication Other?
Collapsed Demineralized Water Storage Tank at Calvert Cliffs FMM Device Damage
Some Debris Collected From Ice Condenser at Cook Nuclear Plant
“ Foreign” Mat’l that talks like a “local.”
Non-nuclear FM Events <ul><li>Bhopal (water in MIC tank) </li></ul><ul><li>Herald of Free Enterprise  (water) </li></ul><u...
Your favorite FMM snafus... <ul><li>Your facility? </li></ul><ul><li>Elsewhere? </li></ul>
Foreign Material ~ A Little Bit Goes A Long Way <ul><li>Procedures can only prevent the repetition of the types of FMM eve...
Foreign Material Management <ul><li>Not just a signs and tags... </li></ul><ul><li>A way of doing business </li></ul><ul><...
Transparency; a Friend of FMM Could you tell if something was missing? (Thanks to Snap-On Tools)
FMM Includes <ul><li>Control of FM production </li></ul><ul><li>Control of FM access to buffer areas </li></ul><ul><li>In ...
FMM Includes (cont.) <ul><li>Detecting FM compromises  </li></ul><ul><li>Detecting FM intrusions </li></ul><ul><li>Control...
FMM Includes (cont.) <ul><li>Determining the factors that resulted in  </li></ul><ul><ul><li>The nature of the FM </li></u...
Foreign Material Exclusion (FME) Foreign Material Management FME An important  part of FMM
FMM Success
FM Prevention
Control of Adverse Effects of Countermeasures FMM C/M are facility changes that must be controlled.
Response to Detected FM Don't forget Root Cause Analysis! Response to Detected FM Stopping More FM Limitation of Transport...
Be sure you determine <ul><li>Where it came from </li></ul><ul><li>How it was produced </li></ul><ul><li>How it got where ...
Sad examples <ul><li>LaSalle attributed FM to a known source and delayed addressing the real problem </li></ul><ul><li>Dav...
FMM ~ Design Factors <ul><li>Good design may help filter out foreign material… or mitigate the consequences of a FMM event...
Some Places Where FMM Considerations Apply: <ul><li>Work planning </li></ul><ul><li>Purchase orders </li></ul><ul><li>Desi...
Where FMM Does Not Apply
Where FMM Does Not Apply Nowhere?
FMM Program Organization Sponsor  (Director, Site VP or Plant Manager) Owner  (Maintenance Dept. Head) Manager  (Senior te...
Where Is Our Foreign Material Management Program? <ul><li>Is it narrowly focused on FME?  </li></ul><ul><li>Is it owned by...
Where Is Our Foreign Material Management Program? (cont.) <ul><li>Does Operations support our FMM program as if the health...
Where Is Our Foreign Material Management Program? (cont.) <ul><li>Does our Plant Operations Review Committee give our FMM ...
Find Any Pockets of FMM Program Non-participation? <ul><li>Clean them out! </li></ul>
Questions? Dr. Bill Corcoran  NSRC Corporation 860-285-8779 [email_address]
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Foreign Material Mgt 2010 02 27 0901

  1. 1. Foreign Material Management Dr. Bill Corcoran NSRC Corporation 860-285-8779 [email_address]
  2. 2. This is best viewed in “Slideshow.” Click on “Slideshow.”
  3. 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
  4. 4. Watch Your Language <ul><li>FMM: all aspects of dealing with FM </li></ul><ul><li>FME: keeping FM out </li></ul><ul><li>FOD: “Foreign Object Damage” or “Foreign Object Debris”-a term used in aviation </li></ul>
  5. 5. Foreign Material <ul><li>Any material that by: </li></ul><ul><li>Nature, </li></ul><ul><li>Magnitude/Quantity, </li></ul><ul><li>Location, and/or </li></ul><ul><li>Timing: was not accommodated in the design </li></ul>
  6. 6. Programmatic Involvement In Consequential Nuclear Power Events <ul><li>Reactivity management (Chernobyl, SL-1, Windscale) </li></ul><ul><li>Foreign material management (FMM) </li></ul>
  7. 7. Famous FMM Events <ul><li>TMI-2 ~ LOCA (water in an air system) </li></ul><ul><li>Salem-2 ~ destructive turbine overspeed (particulates in control oil) </li></ul><ul><li>Salem-2 ~ anticipated transient without scram (wrong lubricant hardened and froze RTB) </li></ul><ul><li>Cook ~ regulatory shutdown (fibrous material in containment) </li></ul><ul><li>LaSalle service water (injection of sealant in service water tunnel) </li></ul><ul><li>Fermi-1 ~ core damage (component adrift in reactor) </li></ul>
  8. 8. Famous FMM Events <ul><li>Point Beach (frazile ice) </li></ul><ul><li>Salem (river grass) </li></ul><ul><li>Davis-Besse (did not find source of FM in containment) </li></ul><ul><li>Mischaracterized silt at Watts Bar </li></ul><ul><li>St. Lucie (jellyfish) </li></ul><ul><li>Columbia (foam fragments were FM) </li></ul><ul><li>2002 Northeast Blackout (vegetation is FM!) </li></ul><ul><li>Cooling Tower Drift caused scram at River Bend </li></ul>
  9. 9. Other FMM Events <ul><li>Concorde </li></ul><ul><li>Titanic </li></ul><ul><li>Surgical Items left in patients (thousands) </li></ul><ul><li>Trojan Horse </li></ul><ul><li>Davis-Besse Sump Screens </li></ul>
  10. 10. Other FMM Experiences
  11. 11. Other FM Experiences (cont.)
  12. 12. FM Events <ul><li>FM Damage </li></ul><ul><li>FM Near Misses (Intrusions +) </li></ul><ul><li>FMM Compromises </li></ul><ul><li>FMM Infractions and Deviations </li></ul>
  13. 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, firebird.one@alum.mit.edu Intrusions are near misses
  14. 14. FMM Damage FMM Damage FM Damage FME Device Damage
  15. 15. FME Damage FME Device Damage Implosions Other Damage from FME Devices Cooling Lubrication Other?
  16. 16. Collapsed Demineralized Water Storage Tank at Calvert Cliffs FMM Device Damage
  17. 17. Some Debris Collected From Ice Condenser at Cook Nuclear Plant
  18. 18. “ Foreign” Mat’l that talks like a “local.”
  19. 19. Non-nuclear FM Events <ul><li>Bhopal (water in MIC tank) </li></ul><ul><li>Herald of Free Enterprise (water) </li></ul><ul><li>ValuJet 592 (oxygen generators) </li></ul><ul><li>“ Chunnel” Fire (burning cargo) </li></ul><ul><li>“ Concorde” (loss of aircraft) </li></ul><ul><li>9-11-01 (box cutters)? </li></ul><ul><li>2010 Kleen Energy Explosion </li></ul>
  20. 20. Your favorite FMM snafus... <ul><li>Your facility? </li></ul><ul><li>Elsewhere? </li></ul>
  21. 21. Foreign Material ~ A Little Bit Goes A Long Way <ul><li>Procedures can only prevent the repetition of the types of FMM events that have occurred </li></ul><ul><li>FMM education is necessary to prevent new types of FMM events </li></ul>
  22. 22. Foreign Material Management <ul><li>Not just a signs and tags... </li></ul><ul><li>A way of doing business </li></ul><ul><li>Part of the Culture of Safety </li></ul>Foreign Material Exclusion Area Foreign Material Exclusion Area
  23. 23. Transparency; a Friend of FMM Could you tell if something was missing? (Thanks to Snap-On Tools)
  24. 24. FMM Includes <ul><li>Control of FM production </li></ul><ul><li>Control of FM access to buffer areas </li></ul><ul><li>In FM buffer areas and danger areas: </li></ul><ul><ul><li>FM inventory control </li></ul></ul><ul><ul><li>FM physical control </li></ul></ul><ul><li>FM removal before closeout </li></ul><ul><li>FM exclusion </li></ul><ul><li>Controlling the adverse side effects of FME measures </li></ul>
  25. 25. FMM Includes (cont.) <ul><li>Detecting FM compromises </li></ul><ul><li>Detecting FM intrusions </li></ul><ul><li>Control of intruded FM </li></ul><ul><li>Removal of intruded FM </li></ul><ul><li>Analyzing potential future effects of intruded FM </li></ul><ul><li>Disposition of intruded FM </li></ul><ul><li>Configuration tracking of intruded FM </li></ul>
  26. 26. FMM Includes (cont.) <ul><li>Determining the factors that resulted in </li></ul><ul><ul><li>The nature of the FM </li></ul></ul><ul><ul><li>The magnitude of the FFM </li></ul></ul><ul><ul><li>The location of the FM </li></ul></ul><ul><ul><li>The timing of the FM </li></ul></ul><ul><li>Addressing the above factors </li></ul><ul><li>Addressing the factors that resulted in those factors </li></ul>
  27. 27. Foreign Material Exclusion (FME) Foreign Material Management FME An important part of FMM
  28. 28. FMM Success
  29. 29. FM Prevention
  30. 30. Control of Adverse Effects of Countermeasures FMM C/M are facility changes that must be controlled.
  31. 31. Response to Detected FM Don't forget Root Cause Analysis! Response to Detected FM Stopping More FM Limitation of Transport Limitation of FM Effects Removal Assessment of Effects Documentation of FM Configuration
  32. 32. Be sure you determine <ul><li>Where it came from </li></ul><ul><li>How it was produced </li></ul><ul><li>How it got where you found it </li></ul>[ Examples on next slide ]
  33. 33. Sad examples <ul><li>LaSalle attributed FM to a known source and delayed addressing the real problem </li></ul><ul><li>Davis-Besse did above for RV head FM and stopped the investigation of atmospheric FM </li></ul><ul><li>Calvert Cliffs treated FM as a causal factor when it was a symptom and delayed addressing the real problem </li></ul>
  34. 34. FMM ~ Design Factors <ul><li>Good design may help filter out foreign material… or mitigate the consequences of a FMM event </li></ul><ul><li>But, don’t rely on design factors alone to identify & prevent FMM problems </li></ul>
  35. 35. Some Places Where FMM Considerations Apply: <ul><li>Work planning </li></ul><ul><li>Purchase orders </li></ul><ul><li>Design engineering </li></ul><ul><li>Chemistry controls </li></ul><ul><li>Radiation protection </li></ul><ul><li>ALARA </li></ul><ul><li>Pre-job briefings </li></ul><ul><li>Post-job walkdowns </li></ul><ul><li>Performance indicators </li></ul><ul><li>QC inspections </li></ul><ul><li>Receipt inspections </li></ul><ul><li>Alarm response instructions </li></ul><ul><li>Operator training </li></ul><ul><li>Management & tech. staff training </li></ul><ul><li>QA audit program </li></ul><ul><li>Severe weather walkdowns </li></ul>
  36. 36. Where FMM Does Not Apply
  37. 37. Where FMM Does Not Apply Nowhere?
  38. 38. FMM Program Organization Sponsor (Director, Site VP or Plant Manager) Owner (Maintenance Dept. Head) Manager (Senior technical person) Effective FMM Program FMM Infrastructure Involvement Oversight
  39. 39. Where Is Our Foreign Material Management Program? <ul><li>Is it narrowly focused on FME? </li></ul><ul><li>Is it owned by a senior “FMM Zealot”? </li></ul><ul><li>Does it include education as well as procedures? </li></ul><ul><li>Do key managers support our FMM program as if their careers depend on it? </li></ul>
  40. 40. Where Is Our Foreign Material Management Program? (cont.) <ul><li>Does Operations support our FMM program as if the health and safety of the public depends on it? </li></ul><ul><li>Can our corrective action database give a good picture of the status and adequacy of our FMM program performance? </li></ul><ul><li>Are our senior managers good FMM role models? Do they “walk the talk”? </li></ul>
  41. 41. Where Is Our Foreign Material Management Program? (cont.) <ul><li>Does our Plant Operations Review Committee give our FMM program the attention it deserves? </li></ul><ul><li>Has our executive level nuclear safety committee held a review of our FMM program performance? </li></ul><ul><li>Has our independent oversight organization audited the status and adequacy of our FMM program performance? </li></ul>
  42. 42. Find Any Pockets of FMM Program Non-participation? <ul><li>Clean them out! </li></ul>
  43. 43. Questions? Dr. Bill Corcoran NSRC Corporation 860-285-8779 [email_address]
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