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Maintenance programme
International Atomic Energy Agency, May 2015
v1.0
Background
In 1991, the General Conference (GC) in its resolution RES/552 requested the Director General to prepare 'a
comprehensive proposal for education and training in both radiation protection and in nuclear safety' for
consideration by the following GC in 1992. In 1992, the proposal was made by the Secretariat and after
considering this proposal the General Conference requested the Director General to prepare a report on a
possible programme of activities on education and training in radiological protection and nuclear safety in its
resolution RES1584.
In response to this request and as a first step, the Secretariat prepared a Standard Syllabus for the Post-
graduate Educational Course in Radiation Protection. Subsequently, planning of specialised training courses
and workshops in different areas of Standard Syllabus were also made. A similar approach was taken to develop
basic professional training in nuclear safety. In January 1997, Programme Performance Assessment System
(PPAS) recommended the preparation of a standard syllabus for nuclear safety based on Agency Safely
Standard Series Documents and any other internationally accepted practices. A draft Standard Syllabus for
Basic Professional Training Course in Nuclear Safety (BPTC) was prepared by a group of consultants in
November 1997 and the syllabus was finalised in July 1998 in the second consultants meeting.
The Basic Professional Training Course on Nuclear Safety was offered for the first time at the end of 1999, in
English, in Saclay, France, in cooperation with Institut National des Sciences et Techniques
Nucleaires/Commissariat a l'Energie Atomique (INSTN/CEA). In 2000, the course was offered in Spanish, in
Brazil to Latin American countries and, in English, as a national training course in Romania, with six and four
weeks duration, respectively. In 2001, the course was offered at Argonne National Laboratory in the USA for
participants from Asian countries. In 2001 and 2002, the course was offered in Saclay, France for participants
from Europe. Since then the BPTC has been used all over the world and part of it has been translated into
various languages. In particular, it is held on a regular basis in Korea for the Asian region and in Argentina for
the Latin American region.
In 2015 the Basic Professional Training Course was updated to the current IAEA nuclear safety standards. The
update includes a BPTC text book, BPTC e-book and 2 “train the trainers” packages, one package for a three
month course and one package is for a one month course. The” train the trainers” packages include
transparencies, questions and case studies to complement the BPTC.
This material was prepared by the IAEA and co-funded by the European Union.
Editorial Note
The update and the review of the BPTC was completed with the collaboration of the ICJT Nuclear Training
Centre, Jožef Stefan Institute, Slovenia and IAEA technical experts.
Module XIII: Maintenance programme
CONTENTS
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Module XIII: Maintenance programme
Learning objectives
After completing this chapter, the trainee will be able to:
1. Explain the purpose of maintenance and maintenance
programmes.
2. List elements of the maintenance programme.
3. List IAEA Safety standards relevant to maintenance.
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work permit procedure, for example) of all work in the nuclear power
plant. Following maintenance, the equipment is returned to service
after a test if necessary and a documented check of its configuration.
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2 TYPES OF MAINTENANCE
Learning objectives
After completing this chapter, the trainee will be able to:
1. Explain the purpose of preventive maintenance.
2. List the different types of preventive maintenance.
3. List some of the tools for predictive maintenance.
4. Describe the purpose of corrective maintenance activities.
When you drive a car, you depend a lot on the sounds, the feel of the
steering wheel and the instruments to determine if the car is running
correctly; similarly with the operating equipment at a power plant - if
sounds or vibration of the equipment or the instruments and test
equipment indicate a problem or degradation, actions are taken to
correct the deficiency. If the equipment fails to start or run, more
immediate actions are taken. In some cases, regulations called
technical specifications require the plant to be shut down if the
equipment is not corrected within a certain period of time. The length
of time depends on the safety significance of the equipment.
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Vibration analysis
Vibration analysis is used to determine the operating condition of
rotating equipment (e.g. turbines, motors, pumps), identifying
developing problems before they cause serious failures and unplanned
shutdown. Problems can include deteriorating or defective bearings,
mechanical looseness, worn or broken gears, misalignment or
imbalance. Vibration monitoring can be periodic, utilising portable
vibration probes and data collectors, and may also be done with a
permanently installed system. A continuous vibration monitoring
system has the capability to assist the vibration specialist in not only
tracking but also diagnosing vibration-related problems.
Oil analysis
Oil analysis can be used on machines that have a circulating oil
system (e.g. turbines, generators, hydraulic systems, diesel engines) to
identify the condition of fluids and lubricants, and determine if they
are suitable for continued use or should be changed. It usually consists
of periodically sampling selected oil streams for detection of
particulates or contaminants that can indicate bearing failure,
overheating, or other machine problems. Analysis of oil samples is
usually done off-site, and following the data trend over time will
indicate the component condition, and can be used to predict the
optimum time and mode of corrective actions.
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Thermography
Thermographic analysis using infrared scanners provides a non-
contact temperature indication for components such as bearings,
motors, electrical connections, or conductors. This information can be
particularly important in electrical equipment where circuits and
connections may show no visible signs of deterioration until moments
before a complete failure. Thermography can also detect cracks or
deterioration in roof or wall insulation as well as in concrete
structures, faults which can increase heat loss. A thermographic
programme usually utilises a walk-around survey procedure.
Visual inspection
Visual observation, listening and touching are the oldest and most
common condition monitoring techniques. In many cases human
observation helps to identify a problem that is undetected by other
predictive techniques or maintenance inspections. This can include
loose, visibly worn or broken parts, oil leaks, chattering gears or hot
bearing housings.
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2.3 Questions
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3 MAINTENANCE PROGRAMMES
Learning objectives
After completing this chapter, the trainee will be able to:
1. Explain the purpose of maintenance programmes.
2. Describe the difference between predictive, preventive and
corrective maintenance programmes.
3. Explain the purpose of in-service inspection and plant ageing
programmes.
4. Explain the interrelationship between maintenance, surveillance
and in-service inspection.
3.1 Introduction
The maintenance programme for a nuclear power plant covers all the
preventive and remedial measures, both administrative and technical,
necessary to identify, prevent and/or mitigate degradation of a
functioning structure, system or component (SSC), or to restore the
design functions of a failed SSC to an acceptable level. The range of
maintenance activities includes servicing, overhaul, repair and
replacement of parts and may include, as appropriate, testing,
calibration and in-service inspection. Typical relationships among
these basic components and types of maintenance are shown in Figure
3.1.
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and records are kept, and maintenance history records are updated on
the basis of PM activities.
Ageing management
The power plant also has an ageing programme that takes into account
the plant equipment ageing process through the various activities of
operation, surveillance and maintenance. The importance of ageing
processes, addressing physical degradation of plant systems, structures
and components as well as their obsolescence, for the safety and
availability of a nuclear power plant is recognized in order to maintain
and enhance the plant’s long term operating characteristics.
Assessments are made of whether and how the ageing of SSCs would
increase the potential for common mode failures and for varying
levels of incipient, degraded and catastrophic failures, in order to
provide assurance of the availability of aged SSCs important to safety
until the end of their service life. The programme to manage the
ageing process contains elements such as:
Identification of components that are susceptible to ageing
degradation that could affect plant safety;
Adequacy of current methods for inspection, surveillance,
maintenance and testing for the detection of ageing problems;
Appropriate records to enable the ageing process to be tracked.
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3.4 Questions
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Learning objectives
After completing this chapter, the trainee will be able to:
1. Describe the organization of the maintenance department and its
purpose.
2. Explain the purpose of training and qualification programmes.
3. List the factors which affect the organization of maintenance.
4. Identify what provides a representative view of maintenance
performance.
5. Describe the functions of managers.
6. Explain why maintenance training and qualification programs
are developed.
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of the plant, the outage work to be performed by the plant's staff, and
supervision of contractor's work during an outage. Contractor
personnel are subject to the same criteria as plant personnel. Good
initial and continuing training is implemented.
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4.3 Questions
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Learning objectives
After completing this chapter, the trainee will be able to:
1. Explain the purpose of working facilities.
2. Explain the purpose of facilities for maintenance of radioactive
items, decontamination facilities and mock-ups.
3. Explain the purpose of special equipment and tools.
Workshop facilities
On-site workshops are provided for mechanical, electrical, control and
instrumentation equipment.
Workshops are designed to take into account some specific rules for
the use and storage of and work with special products; e.g. separation
of carbon steel and stainless steel storage and work areas (welding,
grinding…), use of halogen-free products, etc. These rules aim to
avoid potential corrosion or stress-corrosion problems in the
medium/long term.
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Decontamination facilities
Adequate decontamination facilities for removing radioactive
contamination from plant items, tools and equipment prior to their
maintenance are available and used to minimize radiation doses and
exposure to contamination. They include the following features:
access control and changing rooms;
ventilation with discharge filters;
handling, storage and disposal of liquid radioactive waste;
handling, storage and disposal of solid radioactive waste;
equipment for radiation monitoring and radiation protection;
decontamination tanks and special equipment capable of
decontaminating the largest plant items likely to require
decontamination;
an adequate electric power supply and adequate supplies of
steam, hot water, compressed air and appropriate chemical
decontaminating agents;
other decontamination systems, such as those for glass blasting
or ultrasonic techniques.
Mock-ups
In some cases, there are advantages for maintenance in designing and
constructing simulations, mock-ups or models of particular sections of
the plant, in areas remote from the section of the plant concerned.
Mock-ups are considered in particular for:
rehearsing work to be carried out in high radiation areas or on
highly contaminated plant items, particularly for personnel not
familiar with the plant or for an unusual or specialized task;
preparation and validation of procedures, to avoid errors and
reduce exposure;
gathering of experience with tools and protective equipment;
development and improvement of tools and equipment;
training and qualification of personnel for specific work, and
confirmation of estimates for work durations.
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5.3 Questions
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Learning objectives
After completing this chapter, the trainee will be able to:
1. Explain why procedures and work instructions are used.
2. Explain the purpose of using a maintenance history.
6.1 Introduction
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The last two items are operating functions and are included either in
the maintenance procedure or in a special interfacing operating
procedure.
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6.4 Questions
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Learning objectives
After completing this chapter, the trainee will be able to:
1. Describe the conduct of maintenance work.
2. Explain the purpose of the work planning and control system.
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The work control system ensures that plant equipment is released from
service for maintenance, testing, surveillance and in-service inspection
only upon authorization of designated operating personnel and in
compliance with the operational limits and conditions. It also ensures
that, following maintenance, testing, surveillance and in-service
inspection, the plant is returned to service only upon completion of a
documented check of its configuration and, where appropriate, of a
functional test.
7.3 Questions
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system?
4. What has to be done before equipment is returned back to
service?
5. What does the work control system provide for management?
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8 MATERIAL CONDITIONS
Learning objectives
After completing this chapter, the trainee will be able to:
1. Explain the purpose of maintaining good material conditions.
2. List some examples of good material conditions.
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8.2 Questions
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Learning objectives
After completing this chapter, the trainee will be able to:
1. Explain what materials management ensures.
2. Describe the procurement, storage and control of spare parts.
3. Understand the importance of preventing counterfeit, fraudulent
and suspect items (CFSI) from entering the facility, and in
identifying and disposing of CFSI that already exist.
9.1 Procurement
Materials and parts needed for outages are ordered well in advance, so
that the material is available on site and in time to support the outage
schedule.
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9.3 Questions
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10 OUTAGE MANAGEMENT
Learning objectives
After completing this chapter, the trainee will be able to:
1. Describe what ensures effective outage management.
2. Describe outage organization.
3. Explain the purpose of planning and scheduling of outages.
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Outage planning and scheduling activities provide for safe, timely and
orderly completion of outage work. The following aspects are
considered:
Freeze dates are scheduled to limit growth of the scope of
outage work. Adequate reviews are conducted to include work
after freeze dates;
System and equipment outages are scheduled to provide
sufficient defence in depth for cooling the reactor core and to
meet the operating limiting conditions;
Personnel are trained for special outage work including the use
of mock-ups where appropriate;
Adequate provision of resources is allotted for operational
testing at optimal points in the schedule.
Coordination between operations, maintenance and other groups
involved with outage work.
Advance preparation and approval of maintenance and
modification work packages, including work procedures, post
maintenance and modification test procedures.
Procurement of parts and materials.
Scheduling and provision of manpower, equipment and services
to support the work quality and the outage schedule.
10.3 Questions
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11 REFERENCES
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