KOREA HYDRO & NUCLEAR POWER CO., LTD

Transcription

1 Engineering Department Made by cheon se bin in Shinkori 1 plant

2 Contents I. Plant operation status II. Analysis of environment to KHNP III. Analysis of Outage extension trend IV. Method of outage optimization

3 Introduce my country, the Republic of Korea Korean-style architecture Korean Map The National flag of Korea (Teageukgi) Divided country Nuclear power : energy market share (30%) in Korea Korean cloth and classic music 1

4 I. Operation status in KHNP 24 units are in commercial operation Hanul Hanbit Wolsong Kori Pressurized light water reactor (20 units), Pressurized heavy water reactor (4 units) [Total 24] 1200 (MWe) PHWR unit1 unit2 unit3 unit4 400 unit5 unit6 0 Kori Wolsong Hanbit Hanul 2

5 II. Analysis of Environment to KHNP NSSC & KINS ERPC & Residents Residents (Nuclear Safety Residents conference) NSSC (Nuclear Safety and Security Commission) Reinforce Regulation and Monitoring Safety, Transparence, Integrity (rise) Outage (extend) Rate of operation (reduce) ERPSC (Environment Radiation Private Supervisory Center) KHN P KINS (Korea Institute of Nuclear Safety) We have to communicate with regulator and the public regularly, continuously to accumulate trust! 3

6 II. Analysis of Environment to KHNP Outside Environment Reach to the stage to recover the trust in public Try to keep the safety operation continuously without scram Government & Regulator focus on the reinforcement of the safety for nuclear power plants The public has more concerns and anxieties about the Nuclear Power Plant after Fukushima accident or domestic issues The media tend to exaggerate grossly to NPP even if small issues Must get the permission of critical state in reactor by regulator (Nuclear Safety and Security Commission)` 4

7 II. Analysis of Environment to KHNP Trend of Regulation Requirement of preventive measure not to occur same incident Specialized regulation in consideration of character to incident In-depth and extensive regulation to the management of organization, training, qualification 5

8 II. Analysis of Environment to KHNP Inside Environment Try to nurture experts in engineering for Safety and Reliability New employees have been on the increase and engineers of wide knowledge are in shortage Difficult to supply the qualification class materials (obsolescence of materials, verify qualification document, shortage in supplier) Improve the procurement and material management system (under establishing Supply Chase Management ) Try to recover the pride of KHNP by establishing the 5 core values (Technology, Respect, Ultimate Safety, Social Responsibility, Timeless Integrity) 6

9 III. Analysis of Outage trend Trend of outage Extension Fukushima accident ( 11.03) Kori unit1 SBO event ( 12.02) General plan for Improving plants Safety by Government ( 12.02) QVD issue displacing the parts( 12~ 15) (Safety related Electrical cable) Huge improvement of facilities Reinforce the nuclear plants safety after Fukushima event and Kori#1 SBO event Outage duration was extended for improving safety General plan for improving plants safety by Government ( 12.02) Main reason of the outage extension huge improvement of facilities, resolve last problem(qvd) Estimate to reaching the goal for 30~35days average outage duration in the near future 7

10 III. Analysis of Outage trend Trend of outage Extension Action to the reinforcement of nuclear plants safety after Kori#1 Station Black Out event and Fukushima accident Outage duration was extended for improving safety General plan for improving plants safety by Government ( 12.02) Main reason of the extension of outage in 2 nd stage huge improvement of facility, resolving last problem (QVD, S-PWHT) and SG foreign object retrieval, tube sleeving Estimate to reaching the goal for 30~35days average outage duration in the near future 8

11 Preparation for Outage and Prevent Time Loss Outage Optimization Respond to Regulator and Residents Outage duration Optimization Manage the Safety (FME, LOV, Industrial Safety, Fire protection ) Management of Outage experience and Feedback Maintenance Items Optimization Prevent Rework & Retest 9

12 Preparation for Outage Outage work flow chart Master Plan (D-12~10M) Master plan (maintenance item, main schedule, material etc) Execution Plan (D-8~6M) Fixed maint. Items for requesting parts (D-6M~5M) Preparation Meeting (4 times) (D-4M~15D) Operation of HIT Team (D- 4M~7D) Organize OCC and Training(D-15D) Meeting prior to Inspection(D-2D) Execution plan (Confirm maintenance item & scope, detailed schedule, modification lists workers &tools, separated construction & service) Fixed maintenance items (PM item, weak facility, shut down item, IST, tech spec, OH feedback, other plant experience etc) Outage preparation meeting once a month focus on the status of securing spare part conclusion of separate contract, Design change list, manpower, tool inspection etc Select session item potential outage period extension(polar crane, LOV, EDG test etc) Consist of 10 organization in OCC(schedule team, work order, FME, Safety & Fire etc) Meeting prior to Inspection with regulator 10

13 Prevent Time Loss during Outage OCC OCC Meeting (Treat the delay point) Adjust the schedule (Break down, keep precedence) Analyze the risk (ORION) Work management (Grouping, Tagging, Punch item) Focus management of ISI, IST Concentrate on Test Input the proficient engineer & skilled worker Prepare spare part Follow the procedure Communicate with regulator Prevent Time Loss Report & Analyze Issue & Report immediately (to manager, Headquarter, regulator) Collect & analyze Data (compare last data, review by expert) Analyze & summary bases Manage Configuration Follow the design change Procedure Return to normal state (Valve Line up, Design change, Difference drawing and field) Manage extraordinary facility (filter, power supply, hose, air etc) 11

14 Outage duration standardization & optimization Reference outage schedule (Critical path based on 20 hours, reference plant is Shinkori 1) 7.3D RCS Cooling & Drainage Disassemble Reactor Head 5D Fuel withdrawal Reactor MUT Full drainage Valve Maint MCR HVAC Maintenance 7D 3D 7D 6D 3D 8D Reload Fuel Assemble Head RCS Fill & Vent RCS Heat up Test for critical 3D 4D Approve Critical Rx Test TBN test Synchronization 36.3D TRN B Maint TRN A Maint EDG A Test EDG B Test Reduce main activity by inputting More manpower and Crane 3.5D 30D 4.6D 4D RCS Cooling & Drainage SG Lancing/ FOSAR/ ECT (100% per OH) Reinforced Test by Regulator Reduce main activity by developing advanced Tool and skilled worker in using new system RCS Fill & Vent RCS Heat up Test for critical Approve Critical Rx Test TBN test Synchronization 42.1D 12

15 Outage period standardization & optimization Assignment need to be improved 1) Standardization : nonstandard activity to standardization [Initial install, reinforced inspection SG FOSAR/ECT, ESF Train maintenance, Switch Yard maintenance etc] 2) Optimization activity : Review activity result, optimize schedule 3) Input more manpower & tools : More installing Crane, Tools Input more skilled workers, Produce more advanced device 4) Revise the Outage index : Challengeable(prize and penalty) 5) Critical path based on 24hours : negotiate with Government & Regulator 6) Approval On-Line Maintenance : Under reviewing it by regulator 13

16 Experience and Feedback Experience is the best teacher Experiences and outage feedback must be reflected to the system (Revise procedure, educate) Outage Feedback List Category : OH schedule, procedure, design change, education, FME, Safety, operation Share the experience and feedback immediately by video conference once a week (leading by VP) All employees should draw up valuable experience from their note or memo and make documents immediately by using program (Event & Issue report, CAP, SOER, OH preparation report) Engineers and contractors must have time to hold workshop, seminar for advancing technology Feedback should be managed by system and reviewed by manager for being habituated 14

17 Maintenance Items Optimization Maintenance order master file Recognize that excessive maintenance could lead to rework Trying to select the must to maintenance item (weakness facility, experienced item from other plant or last outage, shut down item, post action for indication by regulator etc) Preventive Maintenance Templet Standardization (Problem) In sufficiency of technical background to PM (Need) (Strategy) excessive maintenance rather than other excellent plants Requirement for optimization by respecting the standardization of preventive maintenance 1st Stage(2014) Action to PM duty standardization 2nd Stage(2015) Reflection of the standardization PM by Plant type 3rd Stage(2016) Reflection to General plant in KHNP Select target items Make the Task List Decision for PM period Make up for Equip. Master Identify procedure and regulation Make the Maint. Item 2,235 Grouping the Same Equip. Review Application for PM Task Make up for Maint. Plan Enrollment to Program 15

18 II. Method of Outage optimization Prevent Rework (by improving maintenance quality) Revise the maintenance procedure near perfect and follow Maintenance procedure the procedure thoroughly (Reflect experience, design change etc) Check and sign the procedure and then proceed the next step Learn and study professional knowledge continuously (Manual, code, procedure, system, law & regulation etc) Put into skilled worker and educate them systematically Follow the modification and configuration procedure with double check Root cause analysis for the incident to prevent reoccur Check the qualification document and use qualified materials Have to do final check meeting before synchronization with all manager and contractor 16

19 Management (FME) Management system Education Procedure Reinforce the requirement of supervision for FME Area (FME petrol team, watchman) Enrich the operation of FME Area Reinforce the requirement of action for FME to contractor Build up empathy or increase of awareness for FME Educate FME procedure to all em ployees until being habituated Operate education system with different level separately Simplify and make clear procedure (reviewed by experts periodically) Supervise employees whether or not to follow the procedure Incoming from outside classification part Tools total remark Metal non metal Reactor internal (including Fuel) % Steam Generator % Primary or Spent Fuel Pool % Secondary (GEN,, Feed % WTR) Excitor Control Pannel etc % 9 2(11% Total (ratio) 4 (22%) 3 (17%) 18 (100%) (50%) ) Foreign Materials from outside (small metal, bolt, wire, chip etc) have been decreased by reinforcing the management, system, procedure and education Try to prevent incoming of foreign object (fragment due to damaged facility) from system by improving maintenance quality and keeping the stable operating condition 17

20 Management (FME) Follow the Basic Follow FME Process Recognition importance of FME Impact 18

21 Design change Malfunction Management (LOV) Work management Human error Improve the Procedure Prevent Human Error Advance reliability of LOV induced equipment Attention sticker for LOV Analysis of LOV Event (2008~2012 : 12) LOV Occurrence : 60% during O/H Period Reason of Loss Of Voltage - Poor Work management : 42% - Human error : 37% - Design Change : 11% - Malfunction etc : 10% Physical Barrier for LOV Arrange the maintenance schedule in order to supply the power to safety load at least 1 Off-site Power and 1 Diesel generator Block Diagram for Preventing LOV 19

22 Management (Industrial Safety) Operate the Industrial Safety Guidance Team inspection (3 experts issue the indication and coach contractor everyday) presentation the result of Industrial Safety inspection in the morning meeting to head manager (Share with employees good practice and poor practice) Everyone who will come to the plant must finish the safety education in the safety experience center Access the industrial safety to all maintenance work Share summary of the Safety procedure to learn safety process easily Select the high risk work orders and manage them intensively Daily report of Safety inspection Best Practice Best Practice 4M-Risk Assessment table 20

23 Management (Industrial Safety) Summary of the key Safety procedure Treat the heavy load and management of tools Select the work of high risk for Industrial safety Heavy load High ground Air Tight weld Electric shock Final report by Safety guidance Team Management of air tight(low oxygen) area maintenance work 21

24 Management (Fire Protection) 1) Reinforce the education of preventing fire to all managers, workers and supplemental personnel dealing combustible material, procedure of welding, how to use fire extinguisher, how to report occurred fire, how to take shelter 2) Reinforce the field inspection for fire protection by Fire Protection Team (3 divided team inspect everyday) Action to prevention measure for work inducing fire Inspection to the temporary installation (container, blower, authorized heater/air conditioner etc) 3) Plan of reinforced system coping with the fire how to report the assigned fire station Action drill with initial fire fighting team and outer fire company preparation for fire in Reactor Building Poor Practice Fire suppression drill Best Practice 22

25 Dealing with regulator and the public 1) Follow the basic and procedure thoroughly 2) Communicate with regulator continuously 3) Understand regulation s position 4) Management of regulator s indication and recommendation systematically 5) Intensive management of the requirements from regulator with readiness 5) If conflict on issue, negotiate with regulator by using apparent base and appropriate logic 6) As to Important issues, must communicate with residents sincerely and continuously Nuclear Safety conference with residents representatives Explanatory Meeting with residents for nuclear power plants issue 23

26 Conclusion All person in plant do their best for successful outage and outage optimization with safety mind, by the full use of method Experts Source Outage Optimization Process Relationship Recognition Management 24

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