Engineering Department KOREA HYDRO & NUCLEAR POWER CO., LTD Made by cheon se bin in Shinkori 1 plant KOREAHYDRO& NUCLEARPOWERCO.,LTD
Engineering Department
KOREA HYDRO & NUCLEAR POWER CO., LTD
Made by cheon se bin in Shinkori 1 plant
KOREA HYDRO & NUCLEAR POWER CO., LTD
Contents
II. Analysis of environment to KHNP
III. Analysis of Outage extension trend
IV. Method of outage optimization
I. Plant operation status
KOREA HYDRO & NUCLEAR POWER CO., LTD
Introduce my country, the Republic of Korea
1
Nuclear power : energy market share (30%) in Korea
Korean-style architecture
The National flag of Korea (Teageukgi) Divided country
Korean cloth and classic music
Korean Map
KOREA HYDRO & NUCLEAR POWER CO., LTD
I. Operation status in KHNP
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24 units are in commercial operation
Kori
Wolsong
Hanul
Hanbit
0
400
800
1200
Kori Wolsong Hanbit Hanul
587
679
950 950
650 700
950 1000 1000 1000 1000
unit1
unit2
unit3
unit4
unit5
unit6
Pressurized light water reactor (20 units), Pressurized heavy water reactor (4 units) [Total 24]
PHWR
(MWe)
KOREA HYDRO & NUCLEAR POWER CO., LTD
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KHNP
NSSC & KINS ERPC & Residents
ERPSC (Environment Radiation
Private Supervisory Center)
NSSC (Nuclear Safety and
Security Commission)
KINS (Korea Institute of
Nuclear Safety)
Residents (Nuclear Safety
Residents conference)
Reinforce Regulation and Monitoring
Safety, Transparence, Integrity (rise)
Outage (extend)
Rate of operation (reduce) We have to communicate with regulator and the public regularly , continuously to accumulate trust !
II. Analysis of Environment to KHNP
KOREA HYDRO & NUCLEAR POWER CO., LTD
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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)`
Outside Environment
II. Analysis of Environment to KHNP
KOREA HYDRO & NUCLEAR POWER CO., LTD
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
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Trend of Regulation
II. Analysis of Environment to KHNP
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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)
Inside Environment
II. Analysis of Environment to KHNP
KOREA HYDRO & NUCLEAR POWER CO., LTD
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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
Trend of outage Extension
III. Analysis of Outage trend
KOREA HYDRO & NUCLEAR POWER CO., LTD
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
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 2nd 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
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Trend of outage Extension
III. Analysis of Outage trend
KOREA HYDRO & NUCLEAR POWER CO., LTD
IV. Method of Outage optimization
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Outage
Optimization
Maintenance
Items
Optimization
Outage duration
Optimization
Management of
Outage experience
and Feedback
Preparation for
Outage and
Prevent Time Loss
Prevent
Rework & Retest
Respond to
Regulator and
Residents
Manage the Safety
(FME, LOV, Industrial
Safety, Fire protection )
KOREA HYDRO & NUCLEAR POWER CO., LTD
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• Master plan (maintenance item, main schedule, material etc)
Master Plan (D-12~10M)
• Execution plan (Confirm maintenance item & scope, detailed schedule, modification lists workers &tools, separated construction & service)
Execution Plan
(D-8~6M)
• Fixed maintenance items (PM item, weak facility, shut down item, IST, tech spec, OH feedback, other plant experience etc)
Fixed maint. Items for requesting parts (D-6M~5M)
• 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
Preparation Meeting (4 times)
(D-4M~15D)
• Select session item potential outage period
extension(Polar crane, LOV, EDG test etc)
Operation of HIT Team (D-4M~7D)
• Consist of 10 organization in OCC(schedule team,
work order, FME, Safety & Fire etc)
• Meeting prior to Inspection with regulator
Organize OCC and Training(D-15D) Meeting prior to Inspection(D-2D)
Preparation for Outage
IV. Method of Outage optimization
Outage work flow chart
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Prevent Time Loss during Outage
Prevent
Time Loss
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
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)
IV. Method of Outage optimization
KOREA HYDRO & NUCLEAR POWER CO., LTD
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Reference outage schedule (Critical path based on 20 hours, reference plant is Shinkori 1)
Outage duration standardization & optimization
5D
IV. Method of Outage optimization
36.3D 4D
RCS Cooling
& Drainage
Disassemble
Reactor Head
7.3D
7D 3D 7D
Fuel withdrawal
Reactor MUT Reload
Fuel
Full drainage Valve Maint MCR HVAC Maintenance
6D 3D 8D
Assemble Head RCS Fill & Vent
RCS Heat up Test for critical
Approve Critical Rx Test
TBN test Synchronization
TRN B Maint TRN A Maint EDG A Test EDG B Test
Reduce main activity by inputting More manpower and Crane
30D
RCS Cooling
& Drainage
3.5D 4D 4.6D
RCS Fill & Vent RCS Heat up
Test for critical
42.1D
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
Approve Critical Rx Test
TBN test Synchronization
3D
KOREA HYDRO & NUCLEAR POWER CO., LTD
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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
Outage period standardization & optimization
IV. Method of Outage optimization
KOREA HYDRO & NUCLEAR POWER CO., LTD
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Experiences and outage feedback must be
reflected to the system (Revise procedure, educate)
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
Experience is the best teacher
Experience and Feedback
IV. Method of Outage optimization
Outage Feedback List
Category : OH schedule, procedure, design change, education, FME, Safety, operation
KOREA HYDRO & NUCLEAR POWER CO., LTD
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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
excessive maintenance rather than other excellent plants
(Need) Requirement for optimization by respecting the
standardization of preventive maintenance
(Strategy)
1st Stage(2014)
Action to PM duty standardization
Select target
items
Make up for
Equip. Master
Grouping the
Same Equip.
2nd Stage(2015)
Reflection of the standardization PM by Plant type
3rd Stage(2016)
Reflection to General plant in KHNP
Review Application for PM Task
Identify procedure and regulation
Make the
Task List
Decision for
PM period
Make the
Maint. Item
Make up for
Maint. Plan
Enrollment to
Program
Maintenance Items Optimization
IV. Method of Outage optimization
Maintenance order master file
2,235
KOREA HYDRO & NUCLEAR POWER CO., LTD
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Revise the maintenance procedure near perfect and follow
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
II. Method of Outage optimization
Prevent Rework (by improving maintenance quality)
Maintenance procedure
KOREA HYDRO & NUCLEAR POWER CO., LTD
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classification part Incoming from outside
Tools total remark Metal non metal
Reactor internal
(including Fuel) 3 3 1 0 7 39%
Steam
Generator 1 1 0 1 3 17%
Primary or
Spent Fuel Pool 3 0 0 1 4 22%
Secondary
(GEN,, Feed
WTR)
1 0 2 0 3 17%
Excitor
Control
Pannel etc
1 0 0 0 1 5%
Total (ratio) 9
(50%) 4 (22%) 3 (17%)
2(11%
) 18 (100%)
· Simplify and make clear procedure
(reviewed by experts periodically)
· Supervise employees whether or
not to follow the 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
Management system
Procedure
· 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
Education
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
Management (FME)
IV. Method of Outage optimization
KOREA HYDRO & NUCLEAR POWER CO., LTD
Management (FME)
Follow the Basic
Recognition importance of FME Impact
Follow FME Process
IV. Method of Outage optimization
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KOREA HYDRO & NUCLEAR POWER CO., LTD
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Work management
Design change Malfunction
Human error
Management (LOV)
Improve the Procedure 1
Prevent Human Error 2
Advance reliability of LOV induced equipment 3
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%
IV. Method of Outage optimization
Arrange the maintenance schedule in order to supply the power to safety load at least 1 Off-site Power and 1 Diesel generator
Physical Barrier for LOV
Attention sticker for LOV
Block Diagram for Preventing LOV
KOREA HYDRO & NUCLEAR POWER CO., LTD
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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
IV. Method of Outage optimization
Daily report of Safety inspection
Best Practice Best Practice
4M-Risk Assessment table
KOREA HYDRO & NUCLEAR POWER CO., LTD
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Management (Industrial Safety)
Summary of the key Safety procedure
Final report by Safety guidance Team
Select the work of high risk for Industrial safety
IV. Method of Outage optimization
Heavy load weld Air
Tight High
ground Electric shock
Treat the heavy load and management of tools
Management of air tight(low oxygen) area maintenance work
KOREA HYDRO & NUCLEAR POWER CO., LTD
Management (Fire Protection)
IV. Method of Outage optimization
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
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Best Practice Poor Practice
Fire suppression drill
KOREA HYDRO & NUCLEAR POWER CO., LTD
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Dealing with regulator and the public
IV. Method of Outage optimization
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
KOREA HYDRO & NUCLEAR POWER CO., LTD
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Outage Optimization
Experts
Process
Recognition
Management
Relationship
Source
Conclusion
IV. Method of Outage optimization
KOREA HYDRO & NUCLEAR POWER CO., LTD
All person in plant do their best for successful outage and outage optimization with safety mind, by the full use of method
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