From the Safety Approach of a Nuclear Power Plant, to the Manufacturing and Welding of Mechanical Components in line with RCC-M Code

Transcription

1 From the Safety Approach of a Nuclear Power Plant, to the Manufacturing and Welding of Mechanical Components in line with RCC-M Code Philippe Malouines AREVA RCC-M Sub-Committee Chairman Presented by Marcello Consonni TWI Welding Engineer RCC-M UK User Group Representative Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 1 Copyright 2015 by Afcen

2 1. AFCEN Codes in Nuclear Power Plant 2. RCC-M: General overview & Quality Assurance requirements 3. Implementation for welding activities & Use of NF EN ISO 3834 Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 2 Copyright 2015 by Afcen

3 1. AFCEN Codes in Nuclear Power Plant 2. RCC-M: General overview & Quality Assurance requirements 3. Implementation for welding activities & Use of NF EN ISO 3834 Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 3 Copyright 2015 by Afcen

4 EPR Reactor Full Scope of Supply Introduction of RCC-M into the process of construction of Nuclear Power Plants for mechnical equipment concerned by nuclear safety: NI: Nuclear Island, CI:Conventional Island BOP: Balance of Plant NI CI BOP Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 4 Copyright 2015 by Afcen

5 Main Systems of a PWR Nuclear Island Conventional Island Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 5 Copyright 2015 by Afcen

6 Nuclear Island (NI): thousands of items to weld NSSS: Nuclear Steam Supply System BNI: Balance of Nuclear Island Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 6 Copyright 2015 by Afcen

7 Key Takeaways Number of valves and equipment (EPR plant) Number of valves in NI and CI - BOP o In Nuclear Island o In Conventional Island 18,000 Valves 14,000 Valves 4,000 Valves 50% RCC-M classified systems o 6 % RCC-M Class 1 In Nuclear Island o 18 % RCC-M Class 2 In Nuclear Island o 26 % RCC-M Class 3 In Nuclear Island 50% non RCC-M classified European Standard Number of other items In Nuclear Island (estimation) Exchangers, Pumps, Tanks, o 176 Heat Exchangers (68 non-classified RCC-M) o 84 Tanks: 40 non-classified RCC-M o 220 Pumps (RCC-M 2 RCC-M 3 non classified RCC-M) Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 7 Copyright 2015 by Afcen

8 AFCEN Codes in Brief AFCEN Codes privilege ISO and EN Standards AFCEN method: to continuously integrate lessons learned o The development of AFCEN Codes is a living process with regular updates and new fields being covered. o Technical studies are used as a basis to prepare or add to Code Editions. Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 8 Copyright 2015 by Afcen

9 International Use of AFCEN Codes UK: Hinkley Point C1-2 (EPR) France: ASTRID (FBR GEN IV) China: Taishan (2 EPR) Finland: OL3 (EPR) CPR 1000 (18 PWR) CNP 650 (2 PWR) CNP 1000 (2 PWR) France: 58 PWR (1977->2000) 2 FBR (shutdown) China: ACPR 1000: several ACP 1000: several France: Flamanville 3 (EPR) Jules Horowitz Reactor : ITER (Vacuum Vessel) Korea: Ulchin 9-10 (PWR) China: Daya Bay (2 PWR) India: PFBR 500MWe Ling Ao (4 PWR) Qinshan II (2 PWR) Qinshan II ext (2 PWR) South Africa: Koeberg 1-2 (PWR) : Plants in operation : Plants under construction : Future plants Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 9 Copyright 2015 by Afcen

10 At the level of a country, grouping of all the local companies interested in working with AFCEN Codes o To adapt the codes to an international context o o o To develop a culture of cooperation and feedback between AFCEN and international members To help set up training sessions and special events To contribute to evolution of codes RCC-M UK User Group is Chaired by TWI (Technical Welding Institute) for 3 years o 6 th meeting in June 2015 o o 35 members Working on An International Scale: User Groups Numerous presentations by RCC-M experts; exchanges with UK companies and expression of needs; structuring of training offers and funding TWI / AFCEN MOU - UK 8 Chinese User groups (all codes, 2 for RCC-M) One European Workshop Agreement (CWA 064 Phase 2) o 3 Groups: RCC-M, RCC-MRx, ETC-C for identification of R&D needs CGN / AFCEN MOU - China Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 10 Copyright 2015 by Afcen

11 1. AFCEN Codes in Nuclear Power Plant 2. RCC-M: General overview & Quality Assurance requirements 3. Implementation for welding activities & Use of NF EN ISO 3834 Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 11 Copyright 2015 by Afcen

12 RCC-M Content and Structure Safety Report Subsection A : General requirements A 3000 Documents Section I A4000 RCC-M Quality Levels A 5000 Quality Management System Subsec.B Subsec.C Subsec.D Subsec.E Subsec.G Subsec.H Subsec. J Subsec.P Subsec. Z Section VI RPP* Applicability Section II Materials Section III Examination Section IV Welding Section V Manufacturing * RPP: Probationary Phase Rule B: Level 1 C: Leve l2 D: Level 3 E: Small equipment G: Reactor internals H: Supports J: Low pressure equip.. P: Penetrations Z: Appendix Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 12 Copyright 2015 by Afcen

13 RCC-M Content and Structure Safety Report Subsection A : General requirements Section I A4000 RCC-M Quality Levels A 5000 Quality Management System Subsec.B Subsec.C Subsec.D Subsec.E Subsec.G Subsec.H Subsec. J Subsec.P Subsec. Z Section VI RPP* Applicability Section II Materials Section III Examination Section IV Welding ISO 3834 Section V Manufacturing * RPP: Probationary Phase Rule B: Level 1 C: Leve l2 D: Level 3 E: Small equipment G: Reactor internals H: Supports J: Low pressure equip.. P: Penetrations Z: Appendix Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 13 Copyright 2015 by Afcen

14 A 5000 Quality Management System A 5000 Quality Management System (QMS) This chapter specifies the basic rules for the preparation and implementation of QMS of the parties involved in the supply chain of RCC-M safety classified components A 5110 Responsibilities of the Contractor, Manufacturer or Supplier Preparation and implementation of a QMS in accordance with the requirements of A Notifying each of its manufacturers and suppliers of the applicable quality assurance requirements. Verification that Contractors, Manufacturers and Suppliers meet the requirements specified Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 14 Copyright 2015 by Afcen

15 A 5000 Quality Management System A 5200 Quality Management System Requirements A 5210 Safety Culture Safety culture: overall characteristics and attitudes in organisations and individuals which establishes that, as an overriding priority, protection and safety issues receive the attention warranted by their significance. A 5220 Graded Approach Focus on Activities Important for Safety Important For Safety: item or activity which contribute to the quality and functionality of the product. Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 15 Copyright 2015 by Afcen

16 A 5000 Quality Management System A 5230 QMS Requirements (in additions to ISO ) General QMS requirements (responsibles, change management) Documents & Data Control (verificator different) Suitably Qualified & Experienced Personnel (SQEP in the UK) Design & Development Verification (verificator different) Procurement Specifications (cascade the requirements) Identification & Traceability of Product Monitoring & Measurement of Products Control of Non-Conforming Product Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 16 Copyright 2015 by Afcen

17 1. AFCEN Codes in Nuclear Power Plant 2. RCC-M: General overview & Quality Assurance requirements 3. Implementation for welding activities & Use of NF EN ISO 3834 Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 17 Copyright 2015 by Afcen

18 RCC-M Content and Structure Safety Report Subsection A : General requirements Section I A4000 RCC-M Quality Levels A 5000 Quality Management System Subsec.B Subsec.C Subsec.D Subsec.E Subsec.G Subsec.H Subsec. J Subsec.P Subsec. Z Section VI RPP* Applicability Section II Materials Section III Examination Section IV Welding Section V Manufacturing B: Level 1 C: Leve l2 D: Level 3 E: Small equipment G: Reactor internals H: Supports J: Low pressure equip.. P: Penetrations Z: Appendix Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 18 Copyright 2015 by Afcen

19 Section IV Section IV: Welding Scope o This section provides requirements for welding, which should be applied in conjunction with Subsections B, C, D according to equipment classification level (respectively 1, 2 and 3) and E, G, J, H, P for the other equipment. o RCC-M integrates technical requirements coming from European regulations on pressure equipment (PED 97/23/CE or soon 2014/68/UE) through harmonized European standards, in addition to specific requirements for components of large thickness which are used in Pressurized Water Reactor (PWR) designs. Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 19 Copyright 2015 by Afcen

20 Self-contained section covering every aspect of welding: Section IV: Welding Scope Base material Section II Welder/operator s qualification S4000 NF EN 287-1, ISO Filler metals qualification S5000 Workshop qualification S6000 Filler metals acceptance welds S2000 Production welds S7000 Production test coupon S7800 Non destructive exminations S7700 Hardfacing S8000 NF EN ISO Refers to Section IV Welding o S 1000 GENERAL o S 2000 ACCEPTANCE OF FILLER MATERIALS o S 3000 QUALIFICATION OF WELDING PROCEDURE o S 4000 QUALIFICATION OF WELDERS AND OPERATORS Welding procedure qualification S3000 o o o o NF EN ISO EN 473, EN IS S 5000 QUALIFICATION OF FILLER MATERIALS S 6000 QUALIFICATIONS OF PRODUCTION WORKSHOPS S 7000 PRODUCTION WELDS S 8000 HARDFACING Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 20 Copyright 2015 by Afcen

21 Workshop qualification Section IV, chapter S6000 lays out the requirements for workshop qualification. o Adequate means of production: Welding equipment shall be suitable for welding procedures Welding Requirements Working areas well equipped (including handling systems), adequate cleanliness level shall be maintained, according to the material to be produced Heat treatment installations shall be in good condition, with appropriate capacities for the works to be carried out o Staff and management: Welding and examination staff (including management) must be sufficiently skilled and competent. o Experience: The workshop must demonstrate adequate experience in the performance of products using comparable welding processes. The RCC-M sub-committee is currently adapting the implementation of NF EN ISO 3834 Quality requirement for welding» with requirements laid out in chapters A 5000 and S 6000 Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 21 Copyright 2015 by Afcen

22 Working methodology: NF EN ISO & are considered A cross matrix allowed to check if RCC-M requirements satisfy also NF ISO 3834 requirements Identification of differences Welding process qualification, welders/operators qualification, of RCC-M (Chapters S 3000, S 4000, ) are already compliant with ISO 3834 Most of the quality and organizational requirements for welding are in Chapters A 5000 and S 6000 and A 3500 ( Welding documents), Welding coordinator skill and authorization, has to be defined and integrate in RCC-M. It will be in Chapter S Chapter S 6000 will be also modified to deal with: Reception of new equipment, or equipment after maintenance, Follow up of manufacturing equipment in workshop Chapters S6000 and A 3000 must be consistent for document records and traceability Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 22 Copyright 2015 by Afcen

23 ISO 3834 certification alone does not imply compliance with the RCC-M requirements: RCC-M will publish a guidance document to assist welding workshops with upgrading their welding quality system for the production of welds for nuclear equipment The document will provide guidance on the additional requirements that manufacturers certified or working in compliance with ISO 3834 need to fulfil to meet RCC-M Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 23 Copyright 2015 by Afcen

24 Aberdeen, 8 th October, 2015 malouines.afcen@gmail.com 24 Copyright 2015 by Afcen