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Preventive Maintenance

Information Repository (PMIR)

Functional Specification
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Technical Report

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Preventive Maintenance Information
Repository (PMIR)
Functional Specification
1000702

Final Report, November 2000

EPRI Project Manager


M. Bridges

EPRI • 3412 Hillview Avenue, Palo Alto, California 94304 • PO Box 10412, Palo Alto, California 94303 • USA
800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com

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DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES
THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN
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Applied Resource Management

ORDERING INFORMATION
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Research Institute, Inc. EPRI. ELECTRIFY THE WORLD is a service mark of the Electric Power
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Copyright © 2000 Electric Power Research Institute, Inc. All rights reserved.

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CITATIONS

This report was prepared by

Applied Resource Management


313 Nobles Lane
Corrales, NM 87048

Principal Investigator
D. Worledge

This report describes research sponsored by EPRI.

The report is a corporate document that should be cited in the literature in the following manner:

Preventive Maintenance Information Repository (PMIR): Functional Specification, EPRI, Palo


Alto, CA: 2000. 1000702.

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REPORT SUMMARY

The EPRI Preventive Maintenance (PM) Basis project has developed detailed technical basis
documents to support PM tasks and task interval selection for 38 component types. This basis
information has many practical applications in the development, optimization, and justification
of PM program activities in power plants. In order to provide the most convenient access to this
information and to enable EPRI-member utilities to continue to improve it by feeding back new
information, the database is being incorporated into a Web-enabled software product to be called
the Preventive Maintenance Information Repository (PMIR). This report describes the functions
that the electronic version of the database and Web site must embody in order to provide EPRI
members with access to the electronic version of the database over the World Wide Web.

Background
EPRI has sponsored the development of Reliability Centered Maintenance (RCM) and
Streamlined RCM for power generation and delivery systems. EPRI also introduced the concept
of the Task Selection Template, which greatly improved the quality, consistency, and efficiency
of task selection. Although streamlined RCM has proven to be a sound and cost-effective method
for maintenance task and interval selection, technical information to establish the basis for the
selected activities is not typically available to the plant maintenance professional.
In response to this need for technical basis information, EPRI sponsored the PM Basis project
beginning in 1997. The PM Basis project provides the user with the technical basis for PM tasks
and intervals by component type and gives information to adapt the intervals to plant conditions.
Task Selection Templates, a synopsis of the task content and intervals, and the reasons these
choices are technically valid have been presented for 38 major component types in a series of
report volumes. These reports, including guidelines for application of the PM Basis information,
are being widely used by EPRI-member utilities. Their use has led to requests for EPRI to
provide electronic access over the World Wide Web to a database version of the information in a
way that would enable review comments and further PM information to be submitted by utility
personnel. Such a database would develop over time to become a major repository of utility
experience relating to PM of nuclear power plants.

Objective
• To define a specification for the functions that the database and Web site would need to
provide

Approach
The investigator participated in all of the expert panels and report development for the 38
component types. He also assisted EPRI-member utilities, in collaboration with EPRI, to apply
the PM Basis information during its development. Based on this experience and continuing
communication with EPRI members who were applying the PM Basis information on their own,

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the investigator produced systematic guidelines for applications that were identified to be the
most useful by participants at an EPRI PM Optimization meeting in October 1998. Preliminary
electronic versions of the database and Application Guidelines were prepared during 1999 and
updated with further input from the EPRI Maintenance and Diagnostic Center on predictive
maintenance tasks early in 2000. This electronic version received considerable use by a few lead
utilities during this time and was presented to a sponsoring group of utilities at a workshop in
July 2000. The combined experiences and utility feedback resulted in the detailed specifications
described in this report.

Results
This report contains specific recommendations for the functional workings of a combined
computerized database and Web site. This combined product incorporates the PM Basis data, the
Application Guidelines, the Web site, and user support documentation. It describes how the
product must function from the user’s perspective, including screen design and control elements,
and functional details of related applications such as the Vulnerability Evaluation, PM
Assessment, Information Feedback, and Configuration Control.

EPRI Perspective
This work represents an important step in the full utilization of the PM Basis data developed by
EPRI in 1997 and 1998. The PMIR satisfies the continuing need for integration of these products
and preserves the content and functionality of the products while offering additional value. This
need includes 1) efficient and integrated access to all of the PM Basis information from a single
database; 2) feedback from users of important information to improve and supplement the
existing PM Basis information; and 3) periodic updates of the PM Basis information including
more component types, more basis information for existing component types, and additional
guidelines and analysis tools. Ongoing EPRI-sponsored activities are designed to accomplish
each of the above objectives. These activities are part of the PMIR project.
In addition, some potential users of the PM Basis reports believe that the primary value of the
PM Basis information is for the development and update of RCM studies. In fact, there is a
general need for the technical PM Basis information, regardless of the method selected for PM
revision and optimization. Furthermore, this information is essential for the continuing
optimization and evolution of the PM program throughout the life of the plant.

Keywords
Preventive maintenance
Maintenance optimization
Component reliability
Power plant reliability

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ABSTRACT

This report contains specifications for all functions of the Preventive Maintenance Information
Repository (PMIR). The PMIR must provide the user with the technical basis for tasks and
intervals by component type and must provide information and tools to adapt the intervals to
plant conditions. Task Selection Templates, a synopsis of the task content and intervals, and the
reasons these choices are technically valid are presented for 38 major component types. The
applications detailed in the guidelines are:
• PM Task Evaluation
• Interval Evaluation
• PM Assessment
• Evaluation of As-Found Condition
• Task Deferral
• Cause Evaluation
• Predictive Maintenance Enhancement

Tools include an assessment of the vulnerability to failures of a PM program based on the EPRI
recommendations, compared to a similar evaluation of a custom-designed PM program. The
reliability implications of modifying the tasks and task intervals are automatically inferred. Other
capabilities include the feedback of utility review comments, the posting by utilities of additional
related documents, bulletin board and configuration control features, and potential interfaces for
the electronic transfer of information to utility databases.

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CONTENTS

1 INTRODUCTION.................................................................................................................. 1-1
1.1 Background and Perspective..................................................................................... 1-1
1.2 Objectives ................................................................................................................. 1-2

2 OVERVIEW OF PMIR STRUCTURE AND NAVIGATION.................................................... 2-1


2.1 Database................................................................................................................... 2-1
2.2 Application Guideline................................................................................................. 2-2
2.3 PM Assessment Forms ............................................................................................. 2-2
2.4 Supporting Documents .............................................................................................. 2-3

3 DATABASE PAGES ............................................................................................................ 3-1


3.1 The Template Page ................................................................................................... 3-1
3.2 The PM Basis Page................................................................................................... 3-1
3.3 The Definitions Page ................................................................................................. 3-2
3.4 The Degradation Page .............................................................................................. 3-2
3.5 The Vulnerability Page .............................................................................................. 3-3
3.5.1 The Vulnerability Algorithm .............................................................................. 3-3
3.6 The Default Statistics Page ....................................................................................... 3-4
3.7 The Custom Vunerability Page .................................................................................. 3-5
3.8 The Custom Statistics Page ...................................................................................... 3-5
3.9 Functional Requirements Common to All Pages........................................................ 3-5
3.10 Queries and Filters .................................................................................................... 3-6
3.11 Reports...................................................................................................................... 3-6
3.11.1 Single PM Task Report .................................................................................... 3-6
3.11.2 PM Program Report ......................................................................................... 3-6

4 PMIR WEB SITE FUNCTIONS ............................................................................................ 4-1


4.1 Security ..................................................................................................................... 4-1

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4.2 Feedback of Comments ............................................................................................ 4-2


4.3 Configuration Control................................................................................................. 4-2
4.4 Utility Template Feedback ......................................................................................... 4-3
4.5 Public Area Repository .............................................................................................. 4-3
4.6 Bulletin Board ............................................................................................................ 4-4
4.7 Home Page ............................................................................................................... 4-4

5 FUNCTIONAL SUMMARY OF PMR SCREENS .................................................................. 5-1


5.1 Web Site Access ....................................................................................................... 5-1
5.2 Database Functions................................................................................................... 5-1
5.3 Supporting Documentation ........................................................................................ 5-2
5.4 User Feedback .......................................................................................................... 5-2
5.5 Public Area................................................................................................................ 5-2
5.6 Configuration Control................................................................................................. 5-2

6 COMMAND BUTTONS ........................................................................................................ 6-1


6.1 Home Page ............................................................................................................... 6-1
6.2 Main Selection Page and Add an Additional Component Page.................................. 6-1
6.3 Template Page .......................................................................................................... 6-1
6.4 Component Source Page .......................................................................................... 6-2
6.5 Default Vulnerability Page ......................................................................................... 6-2
6.6 Custom Vulnerability Dialog Page ............................................................................. 6-3
6.7 Custom Vulnerability Page ........................................................................................ 6-3
6.8 Degradation Page ..................................................................................................... 6-3
6.9 Definitions Page ........................................................................................................ 6-4
6.10 PM Basis Page.......................................................................................................... 6-4
6.11 PM Program Report Dialog Page .............................................................................. 6-4
6.12 PM Task Report Dialog Page .................................................................................... 6-5
6.13 PM Assessment Dialog Page .................................................................................... 6-5
6.14 Feedback Dialog Page .............................................................................................. 6-5
6.15 Public Area Dialog Page............................................................................................ 6-5
6.16 Site Coordinator Page ............................................................................................... 6-5
6.17 Configuration Control Dialog Page ............................................................................ 6-5
6.18 View Data Changes Dialog Page............................................................................... 6-6
6.19 Data Changes Results Page ..................................................................................... 6-6

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1
INTRODUCTION

1.1 Background and Perspective

A power generating plant is a complex facility that is most easily represented as an assembly of
systems, each designed to perform a discrete set of well-defined functions. Such systems are
composed of a large number of components. Keeping these components at levels of reliability
and availability necessary to achieve the desired performance of system functions is inherent in
the system design and component selection and is continuously sustained through maintenance
of the components. In order to perform effective maintenance, the plant must have appropriate
tasks and intervals for all relevant components. In this way, the system functions can be achieved
and sustained with adequate reliability and availability.

EPRI has been a leader for over 10 years in the electric power industry in developing Reliability
Centered Maintenance (RCM) for power generation and delivery systems. RCM is a structured
approach to task selection that focuses on maintaining important system functions, preventing
important functional failures of critical equipment, and selecting the most appropriate
maintenance tasks and task intervals. EPRI also sponsored the development and validation of
streamlined RCM methods to reduce the cost and duration of RCM analyses. These methods
have proved successful and continue to be widely applied in the industry.

EPRI TR-105365, Comprehensive Low-Cost Reliability Centered Maintenance, introduced the


concept of the Task Selection Template. The template greatly improved the quality, consistency,
and efficiency of preventive maintenance (PM) task selection. Included are condition-directed,
time-directed, and failure-finding tasks including surveillance and operator-round monitoring.
When considered as a package, these tasks represent an optimized set of activities to prevent
critical failure modes, considering likely degradation mechanisms and common causes.

Although streamlined RCM has proven to be a sound and cost-effective method for maintenance
task and interval selection, technical information to establish the basis for the selected activities
is not typically available to the RCM analyst. If the analyst develops or acquires this technical
basis information, it is typically not documented as part of the RCM study. For example,
documentation usually does not include failure causes or degradation mechanisms. It almost
never documents failure locations, important degradation influences, failure timing, discovery
opportunities, or the importance of duty cycle and operating environment of the equipment.

Although this discussion has centered on a maintenance program developed using RCM, the
need for the technical PM Basis information is generally present, regardless of the method
selected for task and interval selection. Furthermore, this information is essential for the
continuing optimization and evolution of the PM program throughout the life of the plant.

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In response to this need for technical basis information, EPRI sponsored the PM Basis project
beginning in 1997. The PM Basis project provides the user with the technical basis for PM tasks
and intervals by component type and gives information to adapt the intervals to plant conditions.
A recommended PM program (the Task Selection Template), a synopsis of the task content and
intervals, and the reasons these choices are technically valid in a variety of circumstances are
presented for 38 major component types in a series of report volumes. A thorough description of
these reports and the structured way in which this information was developed, is contained in
EPRI TR-106857, PM Basis Overview Report.

These reports are widely used by EPRI-member utilities as a resource during PM Basis
development, as a part of the periodic assessment of PM program effectiveness, and during the
evolution of the PM program because of plant failure experience or other motivations.

Their use has led EPRI to provide additional related products. The first of these products was
TR-112500, Guidelines for Application of the EPRI Preventive Maintenance Basis, Final Report,
January 2000. These guidelines described the decision processes involved in six common
maintenance-planning activities: 1) PM Task Evaluation, 2) Interval Evaluation, 3) PM
Assessment, 4) Evaluation of As-Found Condition, 5) Task Deferral, and 6) Cause Evaluation.

The second product will be an electronic version of the Database and Application Guideline,
which can be accessed by utilities over the World Wide Web. This product will be known as the
Preventive Maintenance Information Repository (PMIR). In preparation for this product,
preliminary electronic versions of the Database and Application Guideline were prepared during
1999 and updated with further input from the EPRI Maintenance and Diagnostic Center on
predictive maintenance tasks early in 2000. This electronic version received considerable use by
a few lead utilities during this time and was presented to a sponsoring group of utilities at a
workshop in July 2000. The combined experiences and utility feedback resulted in the detailed
specifications described in this report.

1.2 Objectives

The PMIR must achieve the following overall objectives:


• Provide utility engineers access to the maintenance information contained in EPRI TR-
106857, PM Basis Overview Report.
• Contain a structure that would not preclude or make potential future enhancements unduly
difficult. Enhancements that can be reasonably foreseen at this stage include software tools
and calculators for the evaluation of PM task coverage, PM task ranking, more accurate
estimation of the reliability consequences of PM changes, the setting and evaluation of
component reliability and availability performance criteria, and determining the appropriate
balance between reliability and unavailability.
• Include seamless links to the state-of-the-art procedures and processes in the Applications
Guideline to address evaluation of PM Tasks, Task Intervals, As-Found Condition, Task
Deferral, and Predictive Maintenance Enhancement and to support PM Assessments and
Cause Evaluation. These guidelines will show how the database can be used in the above
processes to solve common utility maintenance problems.

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• Be able to receive and log comments and information fed back to PMIR via the Web site by
utility personnel.
• Be a read-only, multi-user, Microsoft SQL Server V7.0 or equivalent, Web-enabled
application.
• Operate ultimately as part of EPRIWEB and therefore conform to EPRIWEB standards.
• Enable all users to post informal, unreviewed utility templates and other information files.
These templates and files can be viewed by all users.
• Maintain configuration control concerning feedback from utilities, review and disposition of
the feedback comments, and modifications made to the database as a result of these and other
inputs.

The following functional specification refers to the Web-enabled SQL Server version unless
otherwise indicated. Although the screen data will be in the form of Web pages, these pages will
be designed to reproduce, to a functional degree, what would have appeared in a form or
datasheet view in the underlying database application.

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OVERVIEW OF PMIR STRUCTURE AND NAVIGATION

2.1 Database

The basic data will be arranged in (n + 4) data tables where n is the number of component types:
DegradationData (n tables), TypeData, PMTask, CommentLog, and PublicAreaRegistry tables.
• The TypeData table will consist of n records, each record pertaining to one component type
• The PMTask table will contain the PM task records for all n component types
• A CommentLog table will accumulate feedback comments from authorized users as
described in Section 4, “PMIR Web Site Functions”
• A PublicAreaRegistry table will record a list of files submitted by users and provide links to
them
• In order to keep the PMIR database as a purely read-only application, the CommentLog and
PublicAreaRegistry tables could be kept in a separate PMIRX database

Login and home pages will be the main interface to all other pages and functions. To access the
database, the user will select a component type from the Main Selection page. In addition to the
Main Selection page, there will be nine other purely database pages, referred to as the
Component Source, Definitions, Degradation, PM Basis, Template, Vulnerability, Custom
Vulnerability, Default Statistics, and Custom Statistics pages. There may be additional pages
used as subforms or dialog sheets, as required to service the pages named above. In the database,
downloaded pages should preferably be kept locally on the user’s workstation to facilitate
repeated jumping between pages by the user until the user deletes the component type. The
Vulnerability page may also be referred to as the Default Vulnerability page when there may be
confusion with the Custom Vulnerability page.

The user should be able to select additional component types that will each open in a new
browser window unless the user chooses to use an existing window, in which case the existing
component type using that window will be deleted. The use of additional browser windows will
provide access to any page from any other page regardless of component type. Closing the
browser window for a component type will delete all pages associated with that component. The
Main Selection page, in particular, must be accessible from every page so that the user is never
more than one click from selecting a new component type.

The user will select a component type by scrolling in a list box on the Main Selection page. The
Component Source is the default page that will open as soon as a component type has been
selected. Its purpose is to display the selection buttons or links for the other pages, as they will
appear on all the pages, and to display brief guidance on the contents and use of each.

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Overview of PMIR Structure and Navigation

Command buttons on each page will enable the user to move to any other page for the same
component type. The nine pages, plus the n + 4 data tables, make up the permanent objects
stored in the PMIR database. An auxiliary PMIRX database may contain the CommentLog and
PublicAreaRegistry tables, and some copies may be made of the n data tables to serve as data
sources for subforms.
With the structure described above, two main queries will normally be executed, one on each of
the TypeData and PMTask tables to select records for a selected component. Other queries will
correspond to specific user needs, such as a query on the PMTask table (if and when PM
Assessment pages are selected) or queries to list unique values of certain fields in the
Degradation table.

2.2 Application Guideline

The Application Guideline will be a single .pdf file linked from the Component Source page in
the database and from the PMIR Web site home page. The Application Guideline will open in a
new window.

A Contents page in the Application Guideline will directly link to the following sections:
• Overview - A one page section to facilitate “Getting Started Quick”
• PM Task Evaluation
• Task Interval Evaluation
• As-Found Condition Evaluation
• Task Deferral Evaluation
• PM Audits
• Cause Evaluation
• Predictive Maintenance Enhancement–A new section of the Application Guideline to be
added for PMIR

2.3 PM Assessment Forms

PM Assessment forms are designed to be filled out by the user during an assessment of the user’s
plant’s PM program. The forms must contain current data drawn from the PMTask table
comprising PM task names and task intervals for one of the eight sets of plant conditions under
which the component is operated. The forms will be created on demand, one page at a time, in a
convenient location on the user’s workstation, for example as a set of Excel worksheets or Word
pages in a single workbook or document, so that the assessment results are accessible in an
electronic, editable format.

A PM Assessment button will be on the home page. Code attached to the PM Assessment button
will create a dialog box in which the user will enter the plant name (with a feature to remember
the name), the system name, and the relevant criticality, duty cycle, and service conditions.
When the user selects a “Create Form” button in the dialog box, a query from the PMTask table

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is created containing the PM Task Name and relevant category task intervals from the selected
category column. The procedure will create a new but empty PM Assessment document (if one
has not already been created) and will export the query results to this document. As long as
subsequent PM Assessment queries are exported to the same document, they will appear in it as
new pages. Each page should be labeled with the plant name, component type, the system name,
and an index that counts the number of pages inserted for the same system name and component
type.

The software implementation for the PM Assessment will probably operate via XML pages. The
result should functionally approximate the above process from the user’s perspective.

2.4 Supporting Documents

Other supporting documents such as the User Manual and the Project Overview report will exist
in .pdf format. They should be linked from the Component Source page in the database and from
the PMIR Web site home page. Where the supporting documents are lengthy (Overview Report),
the user must be able to go directly to the relevant parts, either by linking directly to a bookmark
or by clicking on a page number in a table of contents. Because of the .pdf format, no hyperlinks
can operate between the supporting .pdf files and exterior files, such as the database.
Consequently, the Application Guideline will refer to Web pages by name but will not link to
them directly.

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3
DATABASE PAGES

3.1 The Template Page

The Template page shows all tasks and recommended task intervals for a variety of service
parameters. The page for displaying this information should closely match the format of the
Template in Section 2.1 of each published database report. Specific fields to be displayed from
the PMTask table include the Task Name plus the Task Interval for all eight combinations of
Critical/Non-Critical, High/Low Duty Cycle, and Severe/Mild Service Conditions.

Clicking a task name in this page will display a pop-up page for the user to select the Task
Objective or the Task Content (fields from the PM Basis page). The Criticality, Service
Conditions, and Duty Cycle labels on the Template page header will also activate a pop-up page
to display the Definitions field contents from the TypeData table when the labels are clicked.

A Program Report button will produce a report on the whole set of PM tasks as described in
Section 3.11.

3.2 The PM Basis Page

The PM Basis page shows information for each task, with text sections showing the most
significant failure locations and causes, the timing aspects of these that drive the task interval,
and the listing of task scope and content. This information is contained in Section 2.3 of the
published database reports. Specific fields to be displayed are:
• Task Name
• Failure Location and Cause
• Progression of Degradation to Failure
• Fault Discovery and Intervention
• Task Content
• Task Objective
• Task Type
• Last Changed In Version

The Template, PM Basis, and Degradation tables and pages contain references to other
component types that the user can consult to obtain further information, usually about PM tasks

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that are also relevant to the current component. It should be designed to allow the user to follow
the references by going to the PM Basis page, selecting the task record that contains the
reference as a PM task name, and clicking a LinkToReference button on the page. In each case,
the link will activate the new component selection from the Main Selection page and open its
Template page.

A Task Report button will produce a report on the current task as described in Section 3.11.

3.3 The Definitions Page

The Definitions page will define key items, such as the terms critical and duty cycle used in the
Template. Also included must be the text description of common failure causes, items that
contribute to the risk of performing the task, and general notes that were attached to the
Template in the published database reports. Most of this material appeared in Section 2.5 of
those reports. Specific fields to be displayed are:
• Component Boundary
• Definitions of Critical and Non-Critical Components, High and Low Duty Cycle, and Severe
and Mild Service Conditions
• Common Failure Causes
• Items that contribute to the Risk of Performing Maintenance
• Template Notes
• References To Industry Reports
• Anecdotal Information
• Last Changed In Version

The Anecdotal Information field will be a memo field, which will initially be empty. Reviewers
such as EPRI database maintenance and update contractors may add comments to this field when
preparing update versions of the database. Comments can indicate feedback received from users
that should be brought to users’ attention even though it does not merit being directly
incorporated into the other database fields at the time.

3.4 The Degradation Page

The Degradation page shows records from Table 3.1 of the published reports, using the
DegradationData table as the record source. Specific fields to be displayed in the page are:
• Counter
• Failure Location
• Degradation Mechanism
• Degradation Influence

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• Graphics
• Degradation Progression
• Failure Timing
• Time Code
• Discovery or Prevention Opportunities
• Common Degradation
• Last Changed In Version
• PM Strategies

The graphics field will initially be blank, but can accept a reference to external files, for
example, graphics files.

3.5 The Vulnerability Page

The EPRI PM Basis task and interval recommendations do not provide uniform defenses for all
failure mechanisms. In particular, when a utility elects to perform only a subset of the
recommended tasks, significant gaps in coverage of failure modes may arise. The main variables
involved in estimating the weaknesses in coverage will be included in a semiquantitative
Vulnerability Evaluation.

This evaluation will occur automatically when the Vulnerability page is displayed. This page will
use the Degradation table as a record source for its subform and will clearly display the header,
“Vulnerability of the Complete Set of Recommended Tasks.” The Vulnerability page will
therefore mimic the Degradation table but will show only Failure Location, Degradation
Mechanism, Degradation Influence, Time Code, Common Degradation, and the duplicate set of
PM Strategy fields. Whenever the Degradation tables are opened, as in the Vulnerability
subform, there needs to be an alphabetic sort on the fields of FailureLocation,
DegradationMechanism, and DegradationInfluence in combination to ensure that all records are
grouped appropriately.

3.5.1 The Vulnerability Algorithm

The intrinsic task effectiveness (high (H), medium (M), or low (L)) is that originally entered in
the PM Strategy fields of the Degradation table. The overall task effectiveness (also H, M, or L)
is a product of the Vulnerability evaluation. It is either stored in array variables or in a duplicate
set of PM Strategy fields. It is the overall task effectiveness values that are displayed in the PM
Strategy fields on the Vulnerability page.

In executing the following algorithm, the time intervals will be taken from the first column of
interval data in the Template page unless that column is technically inappropriate (for example,
all intervals are NR or AR). The code must sense this condition and default to the next available
data column. The default category selected must be displayed on the Vulnerability page.

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Database Pages

The Open event of the Vulnerability page will contain code to place an M in the PM Strategy
field when the intrinsic task effectiveness is H and an L when the intrinsic task effectiveness is
M:
• Whenever any random (*R* in TimeCode field) failure mechanism is addressed by a PM
task with an interval longer than six months
• Whenever a wearout (*W*) failure mechanism has a range of failure-free intervals (ffi) that
spans the CHS task interval
• Whenever a wearout failure mechanism has a single ffi such that ffi < task interval ≤ 1.5 x ffi

The algorithm will make the overall task effectiveness an L whenever a wearout mechanism has
a range of ffi with the upper end of the range less than the task interval or has a single ffi such
that the task interval is less than 1.5 x ffi.

The task Operator Rounds is often entered with AR for the interval, which will be interpreted as
one day for this task in this algorithm only. Otherwise, the entries AR and NA will be assumed to
be blank. Any ambiguity arising from this necessary assumption can be removed by entering
specific intervals for these tasks in the Custom Vulnerability page.

When the Vulnerability page opens, the following algorithm will be executed using the newly
calculated Overall Task Effectiveness entries:
• Color red any record that has no tasks addressing it and any record that has no task more
effective overall than L. Red records have zero or low protection that may not be acceptable.
• Color orange any record that is not red and has no task more effective overall than M. The
orange records have a medium level of protection, which may not be acceptable.
• Color yellow any record containing just one H. These failure modes are well protected.
• Color green any record that has at least two tasks with H. Green records have a high level of
protection.

A standard Access filter function is highly desirable for manipulating data in the Vunerability
pages. Nevertheless, limitations of the Web page format may prevent the use of filter functions.
If a filter function cannot be provided, more information may need to be added to the Statistics
page in the future.

3.6 The Default Statistics Page

The Default Statistics page will be activated by a button on the Vulnerability page and will
calculate and display the percentage of all mechanisms that are green, yellow, orange, and red. In
addition, counts of many other records need to be performed and the results displayed on the
Statistics page. These results are at a minimum: 1) the number of records with an R in the
TimeCode field, 2) those with a W contained in the TimeCode field, and 3) those with C in the
CommonDegradation field, and a repeat of these statistics for records colored red.

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3.7 The Custom Vunerability Page

The Custom Vunerability page, also reached by a button on the Vulnerability page, will invite
the user to select task intervals for a subset of the PM Strategy tasks. The task intervals selected
would normally correspond to the subset the user believes will be implemented at the user’s
plant. The above Vulnerability analysis and record-coloring algorithm will be reapplied to the
selected subset of tasks when the user selects OK. The new display must be clearly labeled as
“Vulnerability of the Custom Set of Tasks.” Columns for tasks, which were not selected, will be
grayed or dimmed out in the display. These fields will be excluded from the rest of the algorithm
and record counts.

3.8 The Custom Statistics Page

A Custom Statistics page will display results similar to those displayed on the Default Statistics
page but for the custom set of PMIR recommendations. In addition, there will be indications of
how much the unreliability or numbers of failures would be changed by adopting the custom set
of tasks and intervals.

Calculation of all these results and statistics will require weighting of common failure
mechanisms with respect to the failure modes that are not common. The weight used and the
effectiveness assumed for high, medium, and low effectiveness tasks will be displayed on both
statistics pages.

3.9 Functional Requirements Common to All Pages

All pages will have the following functional requirements:


• Each component type the user selects must be able to display each of the component pages
using buttons on the pages themselves. Buttons are strongly preferred to menu items because
they are more visible and accessible. However, hyperlinks may be used in place of buttons
when necessary to create an agreeable page layout.
• Each page should be labeled with the component type name at least in one place.
• Each page will be labeled with the type of page (for example, Template) in the header of the
page window.
• Each page will include the ability to scroll tables vertically and/or horizontally when
necessary.
• Each component page that displays a single record (for example, PM Basis) must contain a
field for EPRI to show the version in which the last change was made to the data.
• Each page that displays a single record should contain a mechanism similar to standard
access record counters, and selectors should be used to navigate between records.

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Database Pages

3.10 Queries and Filters

PMIR will include additional query and filter capabilities to provide filtering functions for the
Vulnerability page. These must include the ability to filter on blanks, non-blanks, and custom
entries. The filters must be capable of being applied successively (that is, cumulatively) to any
number of data fields.

Additional queries will be executed by clicking control buttons on the Degradation page. These
control buttons, Unique Failure Locations, Unique Degradation Mechanisms, and Unique
Degradation Influences, will list unique values of the respective field entries in a pop-up
window.

Double-clicking on a label showing Unique Causes will produce a pop-up listing the unique
combinations of Failure Location, Degradation Mechanism, and Degradation Influence. This
query is mainly used in Cause Evaluation.

3.11 Reports

All tables and pages will be able to be printed using the standard print and print preview
capabilities. However, this capability will be extended by providing two types of reports. The
simple report will document the basis for a single PM task for the component type. The more
complete report will document the whole PM program for the component type. Reports will not
be available to restricted users.

3.11.1 Single PM Task Report

Items to be documented include: component type name, PM task name, set of eight task intervals
for the defined conditions, the three-section basis text, task scope if it exists, task objective, code
version, and report date.

The single task report would be selected by a Task Report button on the PM Basis page (that
addresses a single task). Pressing this button will enable the following choices to be made:
• Print
• Save As Text File
• Save As Excel/Word File

3.11.2 PM Program Report

Items to be documented include: component type name, template, objective for each task,
definition of duty cycle and service condition, common failure modes for the component type,
maintenance risk items, code version, and the report date.

This report would be selected by a Program Report button on the Template and on the PM Basis
pages. Pressing this button would bring up a dialog box offering the following choices:

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• Template Only (the report would contain just the Template)


• Full Program (all the above items)
• Print
• Save As Text File
• Save As Excel/Word File

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4
PMIR WEB SITE FUNCTIONS

4.1 Security

The Web site and database will conform to EPRI standards regarding login, user identification,
and security levels. User access to the database itself will be read-only for all users except PMIR
Administrators. Site coordinators must be able to provide security information and feedback, and
users must be able to provide feedback comments. These are Web site functions rather than
database functions.

The following permissions should be provided: EPRI PMIR Administrator, Utility Site
Coordinator, Feedback, Read-Only, and Restricted. Designated contractors will need to use the
Administrator level for database update and maintenance. If this is not permitted by EPRI
regulations, then a separate Update level will be required.

The Site Coordinator is a single individual at each sponsoring site who authorizes Read-Only or
Feedback levels of access for users at the site and communicates the information to the EPRI
PMIR Administrator. The PMIR Administrator will maintain a register of Feedback permitted
users with utility, site, name, e-mail address, phone number, and component type(s) for which
they are authorized. This register is not part of the database or Web site software but exists
within the security structure for the EPRI Web site to be used for this product. The site
coordinator does not provide any other administrative functions.

Feedback permission is for users who are entrusted by the utility to provide authoritative
comments on specified component types for EPRI to review and consider as updates in future
versions.

At any time, the Site Coordinator must be able to contact the Web site and enter/change the user
names, passwords, and access levels and to designate/change the authorized component type(s)
for the Feedback level users for the coordinator’s site.

Restricted access is provided by the EPRI PMIR Administrator to prospective sponsors for a
limited number of sessions. Prospective members will be given a provisional password from the
EPRI PMIR Administrator to access to the database for a limited period or for a limited number
of sessions as a restricted member. This access will not enable report generators and will not
permit feedback of comments to the Web site.

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4.2 Feedback of Comments

The Feedback level of access is for people trusted to give authoritative feedback on certain
equipment, for example equipment engineers, MOV, or check valve program managers. They
will often be authorized to provide feedback on more than one component type. Respondents at
each site are thereby limited in number and possess a certain pedigree, avoiding the need to
verify respondents’ qualifications and experience in the EPRI feedback review protocol.

Any user logging on to the PMIR Web site can select the Feedback button on the home page to
view the Feedback Dialog. The options will be: Provide Comments and View Comments. If the
user has Feedback permission and selects Provide Comments, a query based on the
CommentLog table is opened for viewing and adding new records, but not for editing the
previous records. The query will select only records pertaining to the component types for which
the user has Feedback permission.

A new record in the CommentLog table will be automatically filled with the following: utility
name and site name, user name, user e-mail address, user phone number, date sent, CommentLog
record ID number, and the current code version. Feedback comments go into a memo field. The
PMIR will not accept a feedback record that lacks the component type and a feedback comment.

Any user could view the CommentLog table using the View Comments option on a read-only
basis for any component types, in order to view feedback made by other users and to check the
review status and the review dispositions. Initially, a query function will not be provided for the
read-only user to select a subset of the records, for example, for a particular component type. If
the volume of feedback causes the table to expand significantly, this feature could be added later.
Any user should be able to print selected entire records from the CommentLog table for internal
review.

4.3 Configuration Control

The Configuration Control button on the home page provides the following options: View Data
Changes and Edit (visible only with Administrative level permission). Periodically, EPRI
contractors will review the comments that have been submitted to the CommentLog table, using
the Edit option. After EPRI contractors have viewed a feedback comment posted in the
CommentLog table, they will exercise the review protocol (to be developed) and document the
review status in the following fields of the CommentLog table: Reviewed With Source, Other
Review, Review Notes/Disposition, and Code Version In Which To Incorporate. These fields
will be editable only with Administrator level permission, so the review contractors will need the
PMIR Administrator permission or have an additional permission level created for them.

The View Data Changes button will be selected by users desiring to update plant databases. It
will provide a view of changes made to the data tables since a specific version of the database
was released. The version is chosen by the user in the View Data Changes dialog box, along with
selecting the data table(s) (usually to specify the component types of interest) from a list.
Selecting OK will display the results of queries on the relevant tables to list records changed
since the release of the selected version. These queries must address the PMTask and TypeData
tables as well as the component tables. In the future, users will probably want to access these

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queries electronically in order to update plant databases. The current data export capability will
be limited to saving the query results as Word or Excel files.

The View Data Changes capability, the CommentLog table together with the contractor review
protocol, and a procedure for contractors to follow when updating the database to a new version
will constitute the configuration control process for the PMIR. The functions described above are
consistent with more formal steps that could be implemented to control updates. These further
steps may be added in the future, but will not be part of PMIR Version 1.0. Additional
configuration control is exerted at the level of individual records in each data table where the
LastChangedInVersion field tracks the series of database versions where changes were made, for
example, 3.0/3.2/5.0. Contractors updating the database will make these entries.

4.4 Utility Template Feedback

Users may want to use the EPRI Templates as a starting point for their own plant-specific
templates and then submit their own version as part of their feedback comments. For this
purpose, a user would create a Template Report as an electronic file, for example, a Word file.
After modifying it to the plant-specific situation, the user should be able to feed it back to PMIR
using a Template feedback page that would be autoloaded into the memo field of the
CommentLog table. This memo would constitute a feedback of utility experience for EPRI
consideration for inclusion in future updates of PMIR. The use of a Template feedback page may
be avoided if equivalent functionality is preserved.

4.5 Public Area Repository

Feedback of comments and information to EPRI via the CommentLog table is for information to
be subject to EPRI review and potential inclusion in the database. In contrast, the Public Area
Repository is a place to accumulate plant Templates or other files, and for users to view files
submitted by any other user. These files would not be reviewed by EPRI, would not be a part of
the PM Basis database, and would not be considered candidates for updates to the database. The
Public Area Repository would simply be a collection of files in a Public Area Repository folder
on an auxiliary server, organized into folders named for each component type.

The file formats accepted by the Public Area Repository would be .pdf or any file convertible to
.pdf format. The .pdf format will make it possible for users to download selected documents. The
easiest way to communicate the files to EPRI would be via e-mail attachments sent to the EPRI
PMIR Administrator. No configuration control is involved, but to ensure that complete contact
information is transmitted along with the file, the Post to Public Area button on the Web site
would show a Post A File dialog box for the user to complete. The dialog box will request the
file name and a component type from a drop down box. On completion of the dialog box, the
upload process would be initiated via e-mail to the EPRI PMIR Administrator, including
standard information specifying the sender’s identity (user’s name, phone number, e-mail
address, and date).

The full contact information, file name, and date would be transferred automatically to a data
table (PublicAreaRegistry) held in the same auxiliary database (PMIRX) as the CommentLog

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table. Files not already in .pdf format would be periodically converted by the EPRI PMIR
Administrator and added to the appropriate folder on the server. The PMIR Administrator would
flag in the PublicAreaRegistry that a file is now available to view.

A user would select the View Public Area button on the Web site to view (and be able to print)
the registry to view who has submitted files and on which dates for various component types.
Clicking on a file points the user’s browser to the .pdf file stored in the PublicAreaRepository
folder. The client’s workstation would have to have the capability to open .pdf files. Standard
print capabilities should be available.

Software implementation for the Public Area facility may be simpler and involve fewer
automatic features than described above if the essential functionality is preserved.

4.6 Bulletin Board

A Bulletin Board feature could be provided, depending on the level of utility interest and support
at the time the Web site is available to users. If the level of support is sufficient, the Bulletin
Board would provide the capabilities for users to post comments and ask questions, which could
be viewed and responded to by any user.

4.7 Home Page

Buttons on appropriate EPRI Web site screens will activate the PMIR login screen. The home
page displayed after a successful login will display 1) a welcome header, 2) buttons and labels
for database operation, 3) an announcement area with an attention-gathering banner where the
PMIR Administrator can post information on forthcoming events and requests to the User Group,
and 4) links to other sites (to be decided). The following buttons will provide access to PMIR
operation:
• PM Basis Database
• Application Guideline
• Feedback
• Public Area
• Site Coordinator
• User Manual
• Project Overview Report
• Configuration Control
• Bulletin Board

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5
FUNCTIONAL SUMMARY OF PMR SCREENS

An overview of the most important screens (pages, dialog boxes, or windows) is presented in this
section. Pages are grouped according to functions. However, not all pages in a functional group
are linked together (linked from each other).

5.1 Web Site Access


• Home Page
• Database Access/Security
• Site Coordinator: Register Site Users
• Bulletin Board

5.2 Database Functions


• Main Selection
• Component Source
• Degradation
• PM Basis
• Definitions
• Template
• Default Vulnerability
• Default Statistics
• Custom Dialog
• Custom Vulnerability
• Custom Statistics
• PM Program Report Dialog
• PM Task Report Dialog
• PM Assessment Dialog

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5.3 Supporting Documentation


• Application Guideline
• User Manual
• Overview Report

5.4 User Feedback


• Feedback Dialog
• Provide Comments
• View Comments
• Template Feedback

5.5 Public Area


• Post A File Dialog
• View of Registry

5.6 Configuration Control


• Edit
• View Data Changes Dialog
• Data Changes Results

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6
COMMAND BUTTONS

PMIR Web pages will contain many controls. Command buttons for each page are listed below.

6.1 Home Page

Command Buttons:
• Application Guideline
• User Manual
• Overview Report
• Site Coordinator
• Database
• Feedback
• Public Area
• Configuration Control
• Bulletin Board
• PM Assessment

6.2 Main Selection Page and Add an Additional Component Page

Command Button:
• Go

6.3 Template Page

Command Buttons:
• PM Basis
• Definitions
• Degradation
• Vulnerability

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Command Buttons

• Component Source
• Main Selection
• Select an Additional Component
• PM Program Report

6.4 Component Source Page

Command Buttons:
• Application Guideline
• User Manual
• Project Overview Report
• PM Basis
• Template
• Definitions
• Degradation
• Vulnerability
• Main Selection
• Select an Additional Component

6.5 Default Vulnerability Page

Command Buttons:
• Custom Vulnerability
• Statistics
• Template
• PM Basis
• Definitions
• Degradation
• Component Source
• Main Selection
• Select an Additional Component

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Command Buttons

6.6 Custom Vulnerability Dialog Page

Command Button:
• OK

6.7 Custom Vulnerability Page

Command Buttons:
• Default Vulnerability
• Statistics
• Template
• PM Basis
• Definitions
• Degradation
• Component Source
• Main Selection
• Select an Additional Component

6.8 Degradation Page

Command Buttons:
• Template
• PM Basis
• Definitions
• Vulnerability
• Component Source
• Main Selection
• Select an Additional Component
• Unique Failure Locations
• Unique Degradation Mechanisms
• Unique Degradation Influences
• Unique Causes

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6.9 Definitions Page

Command Buttons:
• Template
• PM Basis
• Degradation
• Vulnerability
• Component Source
• Main Selection
• Select an Additional Component

6.10 PM Basis Page

Command Buttons:
• Template
• Definitions
• Degradation
• Vulnerability
• Component Source
• Main Selection
• Select an Additional Component
• Link To Reference
• PM Task Report
• PM Program Report

6.11 PM Program Report Dialog Page

Command Buttons:
• Template Only
• Program Report
• Print
• Save As Text File
• Save As Word/Excel File

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Command Buttons

6.12 PM Task Report Dialog Page

Command Buttons:
• Print
• Save As Text File
• Save As Word/Excel File

6.13 PM Assessment Dialog Page

Command Button:
• Create Form

6.14 Feedback Dialog Page

Command Buttons:
• Provide Comments
• View Comments

6.15 Public Area Dialog Page

Command Buttons:
• Post File
• View Registry

6.16 Site Coordinator Page

Command Button:
• Submit

6.17 Configuration Control Dialog Page

Command Buttons:
• Edit
• View Data Changes

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Command Buttons

6.18 View Data Changes Dialog Page

Command Button:
• Submit

6.19 Data Changes Results Page

Command Button:
• Save As Word/Excel File

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