Suppliers Qualification to Ensure Nuclear & Radiation Safety Requirements in Newcomer Countries

Transcription

1 Suppliers Qualification to Ensure Nuclear & Radiation Safety Requirements in Newcomer Countries Dr. Thomas Lötsch International Conference Capacity Building for Nuclear Industry: New Challenges in the Era of Globalization 50 th Anniversary of the Rosatom CICE&T Obninsk, Russia, July TÜV SÜD Industrie Service GmbH, Energy and Systems (IS-ES), Westendst. 199, Munich, Germany Slide 1 Agenda 1 Introduction 2 Examples of Requirements 3 Supplier Qualification 4 Training Approach for Suppliers 5 International Cooperation TÜV SÜD - ZAES Slide 2 1

2 1. Introduction /IAEA SSG-30: Safety Classification of Structures, Systems and Components in Nuclear Power Plants/ Considering the structures, systems and components (SSC) of a nuclear facility a high level of safety has to be ensured by meeting the associated quality requirements and reliability targets. Specified in further IAEA documents as e.g. GS-R-3 as well as in national NRS regulations. The objective of ISO 9001 is to: provide a set of requirements that, if effectively implemented, will provide you with confidence that your supplier can consistently provide goods and services that: Meet your needs and expectations Comply with applicable regulations Slide 3 1. Introduction Nuclear Safety Regulations International (e.g. IAEA) & National Laws Precision of requirements increases Decrees General regulations NRS Rules, e.g. PNAEG, KTA or YVL Industrial standards, e.g. ISO, EN, DIN Technical specifications, e.g. KS D or PS Slide 4 2

3 1. Introduction Workflow - From fundamental requirements to a single component Slide 5 1. Introduction Equipment Qualification Methodology Technical Input Check of Design Requirements TÜV SÜD Services System and Component Classification Nuclear or/and conventional requirements? Nuclear Regulations and Requirements Conventional requirements covered by nuclear! Conventional Regulations and Requirements Scope of Equipment Qualification Technical Verification of relevant nuclear requirements Technical Verification of relevant conventional requirements Confirmation by Independant Inspection Body IEC Confirmation by Notified Body; PED, LVD, Slide 6 3

4 1,20 1,15 1,10 1,05 1,00 0,95 0,90 0,85 0,80 C A S M O -4 H E L IO S NESSEL Averaged value Fuel assem bly burnup [MW d/kg HM ] Measured data Calculation BIPR DYN3D + Helios DYN3D + Nessel TRAPEZ + NESSEL Agenda 1 Introduction Multiplication factor K 2 Examples of Requirements 3 Supplier Qualification Boron concentration [g/kg] Effective Full Power Days 4 Training Approach for Suppliers 5 International Cooperation TÜV SÜD - ZAES Slide 7 2. Example of Requirements Comparison of Gen III+ Reactor Designs against the HSE, UK, NRC, IAEA and STUK Safety Requirements Siemens AP 1 Textstelle / Fundort Dokument/Titel Kurzbeschreibung / / Link Inhalt AP Ready to meet Tomorrow s Power Generation AP1000 brochure by tion.com/reactor.aspx Requirements Today: AP1000 Westinghouse Ablageort AP-1000\WEG AP 'Public Report on the Generic Design Assessment of HSE's report setting out the AP-1000\HSE\ actors/reports/ap1000public.p New Nuclear Reactor Designs - Westinghouse Electric conclusions of its initial ap1000public.pdf df Company LLC AP1000, March 2008 assessment (overview of fundamental acceptability) of the AP1000 nuclear reactor. AP 'Generic design assessment of new nuclear power The Environment Agency s AP-1000\HSE\ actors/reports/ap100summar plant designs. Summary of findings following summary of findings ap100summary.p y.pdf df preliminary assessment of the submission by following its preliminary Westinghouse Electric Company LLC for their AP1000 assessment of the AP1000 design', March 2008 nuclear reactor. AP 'Generic design assessment of new nuclear power The Environment Agency's AP-1000\HSE\ actors/reports/ap1000.pdf plant designs. Statement of findings following statement of findings ap1000.pdf preliminary assessment of the submission by following its preliminary Westinghouse Electric Company LLC for their AP1000 assessment of the AP1000 design', March 2008 nuclear reactor. Compilation of data base for information on requested reactor designs (EPR, AP-1000, WWER 1000, WWER 1200, SWR-1000) Compilation of data base for internationally applied safety criteria General description of the five reactor designs Evaluation of a catalogue for safety assessment of reactor designs Overall safety assessment of the five reactor designs Scope of our work: HSE, NRC, IAEA - STUK Safety Requirement Data base on reactor designs Data base on safety criteria Plant data and safety features of different reactor types PSA western standard Safety requirements The defence in depth approach The concept of barriers Safety criteria for design of NPP Plant answers to authorities safety criterias Experiences and comparison of plant concepts Slide 8 4

5 2. Example of Requirements Pressure Equipment Directive (97/23/EC, 2014/68/EU) PED Competence Need of qualified PED nuclear and conventional inspectors Area of Competence: Design/ Inspection/ Material/ NDT/ Welding/ QA-Auditor Qualification: Theoretical and practical training Exchange of experience Global concept, English language Slide 9 2. Example of Requirements Step 1 Step 2 Step 3 Step 4 Road map equipment qualification accord. to YVL E.7 TT TA Final Suitability Analysis Scope of Activities Preliminary Sutability Analysis (PSAR) Concept including site specific requirements for I&C Step 1b: Selection of supplier and products/systems Type Testing Testing of the components in the testing laboratories accreditated according to ISO 17025, goal: evidence of certain features Type Approval Manufacturing assessment for the site equipment, confirmation: TT-specimen = site equipment Final technical verification and assesment of declaration of conformity by Inspection Agency IEC 61226, ISO 17020, 17025, etc. Approval READY for STUK / Regulator s Approval Slide 10 5

6 2. Example of Requirements Construction inspection Planning vs. Real Life Constr. Plan Rev. 1 approved Insp. Plan Manufacturing Corrective actions (2 weeks) Manufacturer Manufacturer Schedule acc. expierence to plan Time needed acc. to Pre inspection (1 week) Licensee Manufacturer 3 rd party * Construction insp. (1 week) STUK / AIO Licensee Manufacturer (Approved Testing Organisation) Insp. Plan STUK/AI O Deviations Inspection time with out additional loop: 4 weeks vs. Review time with 1 additional loop: 10 weeks * Invitation 2 weeks in advance acc. to YVL TÜV SÜD Industrie Service GmbH Slide Example of Requirements I & C Qualification & Licensing acc. to YVL safety guides Preliminary Suitability Analysis Concept including site specific requirements Final Suitability Analysis 3rd Party accredited certification E.7 / 572 Type Inspection (TT, TA) TT 3rd Party Design Manufacturing Test Specification Practical Testing 5.5 / 5.6 / 5.7 TA - 3rd Party Check TT aux 575 QM Check 576 Prod. batch 577 SW!!! Theoretic Practic al al Product Evaluation 5.4 / 527 TA Reps Certificates EC 762 / Tests 517, 518 TT Reps Certificates Design Docs FAT Reps Design HW-Qualification SW-Qualification E.7 / 6 (SW) E.7 / 5 (HW) Production of Equipment 5.3 / FAT On-site Receiving Inspection 7.2 Install 7.3 Commiss. 7.4 Final 523 Tests 522 Vendor AIO/Notif.Body Regulator Slide 12 6

7 Agenda 1 Introduction 2 Examples of Requirements 3 Supplier Qualification 4 Training Approach for Suppliers 5 International Cooperation TÜV SÜD - ZAES Slide 13 / Supplier Qualification PROVIDING RELIABLE ENERGY QUALITY «RIGHT FIRST TIME» DEVELOP A NATIONAL SUPPLY CHAIN GLOBAL RECOGNITION The complete set of relevant requirements is compiled in the Five Pillars of Quality Slide 14 7

8 Five Pillars of Quality Management System ISO 9001 adopted to nuclear safety aspects, see actual activities of ISO TC85 and EN TC 435, GS-R-3 Design & Manufacturing Quality Adequate tools, methods, number of staff, staff qualifications, flow of material, equipment, testing equipment Delivery Reliability Resources (Personal, Financial, Hardware), risk assessment of manufacturing processes (fire, delivery of essential working materials or starting materials, labor disputes, replacement deliveries, spare part delivery Communication Project management and -structure, operational organization, organizational structure, operation of interfaces, communication and documentation, network/it management Training, Culture Experienced staff, experience with similar tasks, knowledge of interfaces, safety culture, experience in new build projects, knowledge management, qualification program, experience sharing, intercultural competence Milestones and Services Weak-point analysis Systematic overview, observations, recommendation - Identification of action points and gaps Grading and planning Prioritization of recommendations and planning of implementation together with the customer Coaching / training / monitoring Supporting the customer with implementation activities to fulfill the intended level of quality Validation Assessments and Certificate 8

9 3. Supplier Qualification From Duty to Excellence and Success Full Integration of NRS Requirements Quality And Understanding Agility to different Nuclear projects in different countries Certification according ISO9001 Efficiency Slide 17 Agenda 1 Introduction 2 Examples of Requirements 3 Supplier Qualification 4 Training Approach for Suppliers 5 International Cooperation TÜV SÜD - ZAES Slide 18 / 45 9

10 4. Training Approach for Suppliers NPP stakeholders need to develop the necessary competencies for new-build, maintain competencies for current NPPs in operation, and build up competencies for decommissioning and dismantling of NPPs and other nuclear facilities. Nuclear safety culture training has to take in to consideration specific requirements stipulated, e.g. in international guidelines such as IAEA INSAG 4, WANO and INPO. TÜV SÜD adopts the concept of the own developed TÜV SÜD Nuclear Academy for its customers. The main principle behind is that every customer is totally flexible regarding this concept and is free to select the suitable components of this TÜV SÜD Nuclear Academy for its conditions and environment. Slide Training Approach for Suppliers TÜV SÜD Nuclear Academy Leadership & Expert Development-House Technology Safety Management (project, quality, ) Public acceptance Leadership Development & Expert Development Executive Program Supply chain & Technical review and Inspection services Technology Leader Program Advanced Leadership Program Emerging Leaders Program Project management & Management competencies & Behavioral skills Human factors & Quality management and assurance & Safety management Senior Expert Program Expert Program TÜV SÜD Technical & Engineering School Base point International energy framework & Fundamentals of nuclear power reactor technology & Radiation protection & Safety standards, security guidelines, requirements & Public acceptance Planning and Preparation Design Component Manufacturing Construction Operation Commissioning Decommissioning Slide 20 10

11 Agenda 1 Introduction 2 Examples of Requirements 3 Supplier Qualification 4 Training Approach for Suppliers 5 International Cooperation TÜV SÜD - ZAES Slide 21 / International Cooperation Results Example Specific regulation for Nuclear Pressure Equipment Nuclear Pressure Equipment Categorization Nuclear Third Party definition Link between Safety Authority and Third Party Conformity assessment Cost German Finish Russian Yes (Atomic Energy Act, BMUB Safety Requirements, KTA guides) Yes (4 components classes K1, K2, K3, K4 (K4a and K4b) depending on possible radioactive emissions in case of failure + PED) The State Regulatory Body (each Federal State) has designated some Expert Organisation e.g. TÜV SÜD acc. 20 AtG; Federation Level: Federation Expert Organisation GRS Strong (work groups, regular meetings) Yes (Nuclear Energy Decree, Decree on Safety, YVL guides) Yes (3 safety classes SC1, SC2, SC3, depending on possible radioactive emissions in case of failure + EYT) The Nuclear Safety Authority (STUK) accredits Third Party Inspection Organization (IO) (ISO 1020 and 17025) For SC3 & SC4: delegation of design review and inspection to IO For SC1and SC2: STUK assesses the conformity but can delegate inspection to IO Basic (follow up meetings) Yes (Atomic Energy Act, Gov. Resolution, FNP guides) Yes (4 safety classes SC1, SC2, SC3, SC 4 depending on possible radioactive emissions in case of failure + GOST) The Federal Nuclear Safety Authority Rostechnadzor (with regional Departments accredits Independent Third Party and has own Third Party and Scientific, Engineering and Training Centre Assesses the conformity but can delegate design review inspection to Independent Third Party Strong (work groups, regular meetings) Paid by the manufacturer Paid by the manufacturer Paid by the manufacturer Slide 22 11

12 5. International Cooperation. Slide International Cooperation Results Comparison of safety standards relevant for inspections work and the respective approaches and methods Comparison and analysis of the practical methods of organisation, performance and documentation of the results of the inspection of manufacturing equipment taking into account regulatory requirements Slide 24 12

13 Thank you for your attention! Slide 25 13