Improving Overall Performance at Palisades Nuclear Plant
A CRI Success Story
By Andrew J. Pullam, Senior Technical Instructor, Nuclear Management Company

Palisades Nuclear Plant is one of six nuclear plants operated by Nuclear Management Company (NMC). Under NMC’s business model, each plant owns and markets the power produced by its nuclear unit. However, through NMC, employees from all sites are able to collaborate to improve operational performance and sustain long-term safety and reliability levels across the six plants. Recently, NMC accepted the challenge of improving the operational performance and reliability of two installed reciprocating Instrument Air Compressors at the Palisades Nuclear Plant.

Palisades Nuclear Plant was experiencing extensive equipment downtime and rework due to poor maintenance practices. For example, in three critical areas, the plant’s performance failed to meet established criteria.

NMC conducted analysis to identify the specific trends that would need to be addressed during the next training cycle. They found that the existing maintenance and repair training for the air compressors was general in nature and did not focus on the current performance needs of the organization. They also found that many of the technicians had not completed any type of refresher training even though the availability of the two compressors fell significantly below the established performance criteria.

The results of the analysis revealed a need to enhance the existing training and focus specifically on improving the overall performance of these compressors. To do this, NMC redesigned the compressor training using the Criterion-Referenced Instruction (CRI) methodology.

During the course design and development process, NMC identified and corrected many procedural and material deficiencies. They also made significant changes to the way the training was delivered.

The previous training program consisted of an 8-hour course conducted at a training center followed by an on-site, on-the-job (OJT) evaluation that took approximately 5-6 days to complete. Scheduling the OJT to coincide with the plant’s maintenance schedule proved next to impossible. This had significant repercussions on training. For example, in one OJT session, 27 technicians needed training to learn how to perform a specific maintenance task. However, only 6 to 8 technicians (those with the most experience) actually had the opportunity to perform the task on the equipment due to the sensitivity of the equipment to plant operations. This meant that only about 25 percent of the technicians were qualified to perform the task after completing training.

After implementing the CRI methodology, training time totaled 32 hours. This included ample opportunity for learners to practice their newly learned skills on an exact replica of a compressor (purchased specifically for training purposes at a cost of $30,000). The cost of the replica compressor, however, is more than offset by the performance improvements resulting from the CRI-based training course.

CRI Training Results
After completing the new training course, all of the technicians successfully demonstrated competence in all of the areas associated with the maintenance and rebuild of the compressors. The increase in fully trained technicians has produced the following impressive results:

In addition to these performance improvements, Palisades has also:

• Saved in excess of $800,000 in air compressor replacement costs
• Reduced average repair time from 5-6 days to approximately 28 hours

Most importantly, use of the CRI methodology has provided the framework for bolstering self-confidence (or self-efficacy) of the workforce through demonstrated task performance. This boost in self-efficacy has enabled the workforce to identify and correct additional equipment deficiencies before they become significant operating liabilities.

Andrew Pullam currently serves as a Senior Technical Instructor with Nuclear Management Company. Originally from East Alton, IL, Andrew retired from the US Navy in October 2001 after serving 20 years in the Naval Nuclear Power Program as an operator and technician. While in the military, he earned a Bachelor of Science Degree in Workforce Education Training and Development from Southern Illinois University. In May 2001, he was selected by the Charleston Regional Business Journal as one of the "Top Forty Under 40" in recognition of outstanding leadership in the Charleston Business Community as a Training and Professional Development Consultant. Andrew recently completed CEP’s Expert Course Manager Workshop, which certifies him to teach the Criterion-Referenced Instruction Workshop throughout Nuclear Management Company.