Joint KINS-IAEA Basic Professional Training Course on Nuclear Safety, 15 to 26 Oct. 2018, Daejeon, Korea Nuclear Quality Assurance Oct. 2018 Jae Hun LEE Korea Institute of Nuclear Safety
Joint KINS-IAEA Basic Professional Training Course on Nuclear Safety, 15 to 26 Oct. 2018, Daejeon, Korea
Nuclear Quality Assurance
Oct. 2018
Jae Hun LEE
Korea Institute of Nuclear Safety
Contents
I. Outline of Nuclear Quality Assurance
II. Regulatory Requirements on QA
III.QA Regulation in Korea
IV.QA Inspection Criteria
V. Concluding Remarks
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I. Outline of Nuclear Quality Assurance (QA)
• Quality• Overall feature and characteristics of the products and services related to the
capability to comply with the specified requirements
• Appropriateness of application (consumer's viewpoint)
• Conformity to the requirements or specifications (manufacturer's viewpoint)
• Nuclear QA• Nuclear QA is the control system to satisfy the requirements necessary for
design, manufacturing, construction, operation and maintenance of NPP
• To achieve the safety and reliability of NPP
• Definition of Nuclear QA• All those planned and systematic actions necessary to provide adequate confidence
that a structure, system, or component (SSC) will perform satisfactorily in service. (USNRC 10 CFR 50 Appendix B, KEPIC QAP)
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Comparison of the Quality Characteristics (Table 1)
Non-nuclear Industry Nuclear Industry
Characteristics of Items Light, Thin, Short, Small Heavy, Thick, Long, Bulky
Method of FabricationMass-production of various
ItemsSole Items Small Quantity
Duration of
ProductionBy Hour Basis By Month/Year Basis
Quality Verification Verified by manufacturer Verified by Third Party personnel
Methods of Quality
VerificationProduct Quality Product Quality with Quality Records
Purpose of quality Activity
Customer Satisfaction Safety & Reliability
Qualification
RequirementsNone
Personnel, Equipment, Procedures, Processes
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I. Outline of Nuclear Quality Assurance (QA)
• Characteristics of Nuclear QA
• Management Aspects
• Quality system and program shall be established in advance.
• Qualification required (personnel, process, procedures & equipment, etc.)
• Technical Aspects
• Regulatory, technical & contractual requirements are applied (design, purchase, process, inspection and test, etc.)
• Involvement of regulatory body and third party inspection agency
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I. Outline of Nuclear Quality Assurance (QA)
II. Regulatory Requirements on QA
• Nuclear Regulation
• Purpose
To prevent radiation disasters for the sake of public safety by setting forth matters concerning safety management for research, development, production, and use of nuclear energy.
• How safe is safe enough?
• Nuclear safety is not a matter of one country but an international one.
• Internationally acceptable level of requirements within the global nuclear safety regime. (Common rules based on state of the art)
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II. Regulatory Requirements on QA
• Fig.1 Global Nuclear Safety Regime
International Conventions
InternationalSafety
Standards
International Joint Research
& Safety Reviews
IAEA
OECD/NEA
National Nuclear Safety Infrastructure
Regulation Research/Education Operation
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II. Regulatory Requirements on QA
• Convention on Nuclear Safety (CNS)
• Objectives :
To establish and maintain effective defenses in nuclear installations against potential radiological hazards in order to protect individuals, society and the environment.
• General Safety Consideration :
Priority to safety, human factors, QA, assessment & verification of safety, radiation protection, emergency preparedness.
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II. Regulatory Requirements on QA
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Objective Essential Means
I Prevention of abnormal operation and failure
Conservative design and high quality in construction and operation
II Control of abnormal operation and detection of failure
Control, limiting and protection systems and other surveillance feature
III Control of accidents within the design basis
Engineering safety feature and EOP
IV Control of severe plant conditions and mitigation of the consequences of severe accident
Complementary measures and SAMP
V Mitigation of consequences of releases of radioactive materials
Off-site emergency drill
• Table 1. Defense in Depth (from INSAG-3, TECDOC-986)
II. Regulatory Requirements on QA
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• History of QA Standard
• 1963, US Department of Defense : MIL-Q-9858A, Military Specification –Quality Program Requirements
• 1968, NATO : AQZP-1, Quality System Requirements
• 1970, US NRC : 10CFR 50 App. B (18 Criteria)
• 1975, IAEA : 50-C-QA
• 1983, ASME committee : ANSI/ASME NQA-1(1983)
• 2000, ISO : ISO-9001
• 2001, Korean Government : Regulations on Technical Standards for Nuclear Reactor Facilities, Etc., Sec. 4, QA Requirements
• 2001, KEPIC : KEPIC/QAP was endorsed as QA Standard
• 2006, IAEA : GS-R-3, Management System
II. Regulatory Requirements on QA
• Korean Legal System and IAEA Safety Standards
IAEA Korea U.S.A.
Safety Fundamentals Nuclear Safety Act (NSA) AEA, Policy Statements
Safety RequirementsEnforcement Decree and Enforcement Regulation
of the NSA10 CFR 50
Safety Guides, TECDOC KINS Regulatory GuidesRegulatory Guides of the
USNRC
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II. Regulatory Requirements on QA
• Legal Basis on QA
NSA
Notice of NSSC
Article 11/21 : Standards for CP & OL4. The contents of a QA program shall
conform to the standards as prescribed by the regulation of NSSC.
Enforcement Decree, Article 31 : QA InspectionRegulation on Technical Standards for Nuclear Reactor Facilities Etc., Article 67~85 (18 Criteria of QA)
Reactor.26(2016-13), Detail Requirements for QA of Nuclear Reactor Facilities (KEPIC/QAP)
Enforcement Decree &
Regulation of NSSC
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II. Regulatory Requirements on QA
• Legal Basis on QA (continued)
Industrial Codes and Standards(ASME, IEEE, ACI, KEPIC, etc.)
Nuclear Safety Act
EnforcementDecree of the Act
Enforcement Regulation of
the Act :Technical Standards
Notices of NSSC
Regulatory Standards
Regulatory Guides
Safety Review & Inspection Guides
□ Notice of NSSC, Reactor.26
For construction* : KEPIC/QAP (‘00 to ‘11 Ed.) or ASME/NQA-1 (1994 to 2009 Ed.) were endorsed as detailed requirements.
For operation : KEPIC/QAP (ASME/NQA-1) + ANSI/ANS 3.2 (1994 to 2009 Ed.)
□ Application of other Code & Standards
The addition and limitation of other codes and standards are given in KINS Regulatory Standards and Guides.
* Construction includes design, manufacturing and assembling of the components 13
II. Regulatory Requirements on QA
• Regulatory Requirements
• Procedural Requirements
• Authorization Process with Standards for Permit including QA Program
• QA Inspection and Enforcement Policy
• Technical Requirements*
• QA Criteria regarding Construction and Operation of NPP
• Design Criteria regarding Location, SSC, Installation, and Performance of NPP
* Regulation on Technical Standards for Nuclear Reactor Facilities Etc.
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II. Regulatory Requirements on QA
• 18 Criteria of QA in Korea
1. Organization 10. Inspection
2. QA program 11. Test control
3. Design Control 12. Control of measuring and test equipment
4. Procurement Document Control 13. Handling, storage and shipping
5. Instructions, procedures and drawings 14. Inspection, test and operation status
6. Document control 15. Control of non-conforming items
7. Control of purchased items and services 16. Corrective action
8. Identification of control of items 17. QA records
9. Control of special processes 18. Audit15
II. Regulatory Requirements on QA
• GS-R-3 Requirements
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Section Title Contents
Section 1 Introduction Background, Objective, Scope, Structure
Section 2 Management System (MS) General Requirement, Safety Culture, Grading Application, Documentation
Section 3 Management Responsibility Management Commitment, Satisfaction of interested Parties, Organizational Policies, Planning, Responsibility and Authority
Section 4 Resource Management Provision of Resources, Human Resources, Infrastructure and working Environment
Section 5 Process Implementation Developing Process, Process Management, Generic MS process
Section 6 Measurement, Assessment, Improvement
Monitoring & Measurement, Self & Independent Assessment, MS Review, Non-conformances & corrective & preventive actions, Improvement
III. QA Regulation in Korea
• Safety Assessment on QA Program
• Purposes• To confirm the contents of QA Program satisfies the requirements in the standards for permit or license and KEPIC/QAP
• To review the change of QA Program especially organization
• Objects• NPP : 25 units in operation, 4 units under construction and 1 unit under preparation for decommissioning
• Research Reactor : I in operation 1 under construction
• Fuel cycle facilities : 1 KNF and 1 Rad-waste storage facility 17
III. QA Regulation in Korea
• QA Inspection
• Purposes
• To verify that QA program of objects are complying with applicable industry codes, standards, and reg. requirements.
• To verify effective implementation of QA program.
• To verify identification of root cause of problems such as non-conformances, and adequacy of corrective actions.
• To verify feed-back of problems arose in previous audits and/or inspections, reflection of design modifications and results of those modifications.
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III. QA Regulation in Korea
• QA Inspection
• Objects
• Reactor Licensee : Perform construction & operation of NPP, procurement and/or control activities of vendors (KHNP HQ, Site, Changwon, NY, and Paris Office)
• Designer : Supplies design service (KEPCO E&C)
• Manufacturers : Manufactures and supplies major components to reactor licensee (Doosan, KNF)
• Vendors : Supplies components, or service to reactor licensee or manufacturer (Samshin, Weir, Target Rock, Andritz, etc.)
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III. QA Regulation in Korea
• Regulatory Inspection
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Category Construction Operation Type
PlannedInspection
QA Inspection
Regular and Announced Inspection
Pre-operationalInspection
PeriodicInspection
Vendor Inspection(QA/SAR)
Reactive
Daily Inspection(Site Office) Irregular and
UnannouncedInspection
Special Inspection
III. QA Regulation in Korea
• Nuclear Power Plant
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□ Organization (Criterion 1)
• Division of responsibility (DOR) of organizations
- Performing activities affecting quality (QAO) :
Siting / designing, purchasing, fabricating, handling, shipping / receiving, storing,
cleaning, erecting, installing, inspecting, testing / operating, maintaining, repairing,
refueling, modifying / and decommissioning
- Quality verification activities (QVO) : QA,QS, etc.
IV. QA Inspection Criteria
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□ Organization (Criterion 1 : Continued)
• Organizational freedom of QVO from cost and schedule
- to identify quality problems
- to initiate, recommend, or provide solutions
• Direct access to responsible levels of management
• Delegation of work to AE, NSSS, T/G, Nuclear Fuel, Construction, etc.
• Interface control
IV. QA Inspection Criteria
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Quality Regulation□ QA Program (Criterion 2)
• Identification of SSC and activities to an extent consistent with their
importance to safety
• Establishment and implementation of documented QA program such as
procedures and instructions
• Control over Activities:
- Appropriate equipment
- Suitable environmental condition
- Prerequisites for the performance of activities24
IV. QA Inspection Criteria
Quality Regulation□ QA Program (Criterion 2 : Continued)
• Regular assessment of QA program adequacy and/or effectiveness
• Education, training and personal qualification to assure that suitable proficiency
is achieved and maintained with records
- Inspection & test personnel
- NDE personnel
- Auditor and lead auditor
- Personnel education and training
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IV. QA Inspection Criteria
Fig. QA ProgramRegulation 26
IV. QA Inspection Criteria
QA Program (continued))
□ Appendices• Appendix 1
- Organization Diagram (Headquarters) - Personal Responsibility (Headquarters)
• Appendix 1-1
- Organization Diagram (Site Office) - Personal Responsibility (Site Office)
• Appendix 2
- Application of Quality Class
• Appendix 3
- Terms and Definitions
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IV. QA Inspection Criteria
Quality Regulation Quality Class of SSC in Korean Industry
- Q Class : Safety Related Items such as RCS(RCP, SG, Prz), ECCS, SCS, CVCS,
etc.
- AQ Class : Safety Impact Items such as Spent fuel handling facility, T/G, Trans
former, Condenser, etc.
- S Class : Industrial Standard Items
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IV. QA Inspection Criteria
□ Design Control (Criterion 3)• Design plan to define & control the design of SSC
- DOR of design process : AE, SD and CD
- Expected output : design report, specification, drawing, etc.
• Design input to assure the translation of applicable regulatory requirements and the design bases
- Identified, reviewed and approved
• Verification of design adequacy - Design review, alternate calculation and qualification test
• Internal and external interface control
• Change control
• Software control
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IV. QA Inspection Criteria
Design Plan
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IV. QA Inspection Criteria
Design Verification Checklist
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IV. QA Inspection Criteria
Quality Regulation
□ Procurement Document Control (Criterion 4)
• Preparation of procurement document
- Technical specification
- QA requirement
• Procurement document review
• Subsequent change procedure
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IV. QA Inspection Criteria
Quality Regulation Procurement Documents
Procurement Document
QA Program
Requirements
Others
(Right of Access
Inspection, Audit)
Document
(Records retention,
disposition)
Technical Requirements
(Dwg., Specification,
Test, Inspection &
Acceptance Criteria)
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IV. QA Inspection Criteria
Quality Regulation□ Instructions, Procedures, and Drawings (Criterion 5)
• Organizational responsibility performing activities
• Acceptance criteria
• Change control
□ Document Control (Criterion 6)
• Documents to be controlled
• Preparation, review, approval, and release
• Change control34
IV. QA Inspection Criteria
Quality Regulation□ Control of Purchased Items and Services (Criterion 7)
• Procurement planning
• Source evaluation and selection
- AVL (Authorized Vendor List)
• Verification of contractor QA program implementation
- Source inspection and audit
• Acceptance of items and services : Receiving inspection
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IV. QA Inspection Criteria
Quality Regulation□ Control of Purchased Items and Services (Criterion 7)
• Control of contractor’s non-conformances
• Control of submitted documents : Certificate of Conformance (C of C)
• Commercial grade items (CGI)
- Identified in an approved design output document with critical
characteristics and acceptance criteria
- Identified in the purchase order
- Acceptance of CGI, combination of the following shall be utilized:
specific testing, inspection or analysis
survey for the Supplier's CGI
source verification
performance record of supplier/item36
IV. QA Inspection Criteria
Quality Regulation□ Identification and Control of Items (Criterion 8)
• Identification methods
- Transfer when divided
• Control and verification of assembly
• Documentation
□ Process Control (Criterion 9)
• Special processes
• Approved and/or qualified work procedure
• Personnel qualification
• Process control by traveler, Quality Plan, etc. 37
IV. QA Inspection Criteria
Manufacture QA Inspection General
Application of Special Process
Welding, NDE
Manufacturing
Assembling& Erection
Pre-operationalInspection
Replacement
Maintenance
Periodic Inspection
Construction Operation
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IV. QA Inspection Criteria
Manufacture QA Inspection General
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IV. QA Inspection Criteria Manufacturing & Construction Process
Design Specification
Procurement Doc.
Process Control Doc.
Materials Welding Prep.
Machining, Forming
Welding
PWHT
NDE
Pressure Test
Data Reports
Manufacture QA Inspection General
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IV. QA Inspection Criteria Manufacturing Process of Reactor Pressure Vessel
VESSEL
ASSEMBLY
CLOSURE HEAD
ASSEMBLY
RV FINAL
ASSEMBLY
CLOSURE HEAD
LOWER VESSEL
UPPER VESSEL
INSTRUMENT NOZZLE
INSTALLATION
NOZZLE
INSTALLATION
CEDM NOZZLE
INSTALLATION
CLOSURE HEAD
DOME
CLOSURE HEAD
FLANGE
UPPER SHELL
INTERMEDIATE
SHELL
LOWER SHELL
BOTTOM HEAD
Manufacture QA Inspection General
General Manufacturing Process
V. QA Inspection Criteria
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Quality Regulation□ Inspection (Criterion 10)
• Inspection Planning (Inspection and Test Plan : ITP)
- Hold points and witness points
• Inspection procedures & Inspector qualification
• In-process inspection and final inspection
• Inspection records
□ Test Control (Criterion 11)
• Test Planning (ITP)
• Procedures with requirements and methodology
• Evaluation of test result by authorized personnel
• Data analyses & test records
• Computer program testing42
IV. QA Inspection Criteria
Quality Regulation Inspection & Test Plan (ITP)
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IV. QA Inspection Criteria
Quality Regulation□ Control of Measuring and Test Equipment (Criterion 12)
• Identification of M&TE to be controlled
• Calibration program and records
□ Handling, Storage and Shipping (Criterion 13)
• Control Procedures for handling, storage, shipping, cleaning and preservation to prevent damage or deterioration.
• Special equipment for handling
• Storage condition such as temp., humidity, test, etc.
□ Inspection, Test, and Operation Status (Criterion 14)• Indication of status
• Authority for indication
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IV. QA Inspection Criteria
Quality Regulation
45
IV. QA Inspection Criteria
Transportation of RV
Quality Regulation
46
IV. QA Inspection Criteria
Installation of RV
Quality Regulation□ Control of Nonconforming Items (Criterion 15)
• Prevention of inadvertent installation or use
• Identification of nonconformance (Non-conformance Report : NCR)
• Documentation and notification
• Segregation
• Evaluation and disposition
- Technical justification of use-as-as and repair
• Records
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IV. QA Inspection Criteria
Quality Regulation
□ Corrective Action (Criterion 16)
• Condition adverse to quality shall be identified promptly and corrected as soon as
practical to preclude recurrence.
• Significant conditions adverse to quality shall be reported to the regulatory body
• Documentation of cause analysis and corrective action (Corrective Action Report :
CAR)
• Follow-up action
• Trend analysis on a regular basis
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IV. QA Inspection Criteria
Quality Regulation□ QA Records (Criterion 17)
• Scope and classification of QA records
• Receipt control
• Retrieve-ability
• Storage, preservation and safekeeping
□ Audits (Criterion 18)
• Audit planning to verify the effectiveness of the QA Program
• Performing with written procedure or check list
• Trained personnel staffing, conducting and reporting
• Follow-up action
• Records
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IV. QA Inspection Criteria
V. Concluding Remarks
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• Safety in the operation of facilities and the use of radiation sources is of great importance. The purpose of QA regulation is to secure safety and reliability of nuclear system and to protect public and environment.
• Only strengthening of quality inspection does not provide an adequate confidence of the quality, a preventive and programmatic QA system is needed.
• Regulatory Authority shall set up the rules and regulations related to QA system for the nuclear industry.
Always we keep watching
our Atomic Power
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