Case Studies

Exelon Nuclear Fleet MWh Lost Due to Critical Parts Failure

Exelon Nuclear Fleet MWh Lost Due to Critical Parts Failure

In 2016, Exelon added model specific fuses, circuit cards, switches, solenoid valves and circuit breakers to the PQI program.

Prior to these models being added to the PQI program, these model specific critical part failures cost Exelon more than $5 million in MWh force loss alone.

Once these models were PQI tested before installation, critical parts failure-related SCRAMS and force loss was entirely eliminated for these models.

“Since 2017, the Exelon fleet has had zero reactor SCRAMS or MWh lost due to failed fuses, circuit cards, switches, solenoid valves, or circuit breakers as a result of implementing PQI. What is especially valuable is that the PQI program pays for itself.” 

Dan Doran, Former Engineering Director at Limerick

“The PQI program makes my life easier as a Supply Manager. We send the part straight to PowerLabs and have reasonable assurance the part will work before we put it in inventory.” 

Stanley Weglos, Limerick Site Supply Chain Manager

Limerick Nuclear Power Plant Business Case Study

From 2016 – 2018, Limerick tested almost 2,500 parts and identified a parts failure rate of 5%. Through identifying failed parts and obtaining replacements within the warranty window, warranty replacement cost savings covered a substantial portion of Limerick’s PQI program investment. These parts savings ranged from $107,000 to $191,000 annually.

Examples of failed parts included cable assemblies, valve regulators, various relay types, solenoid valves, and transducers.

Parts Quality Produces Savings at Limerick

PQI Identified Failed Parts Before They Entered Warranty

Examples of failed parts included cable assemblies, valve regulators, various relay types, solenoid valves, and transducers. In 2016, Limerick PQI tested a substantial portion of inventoried parts (as opposed to newly procured) which accounts for the lower warranty replacement savings since many of those failed parts were outside of the warranty window.

For many PQI community members, warranty replacement cost savings more than pays for the cost of implementing PQI year after year.