programme of self assessment and condition report at qinshan npp iaea conference 27 june – 2 july...

Programme of Self Assessment and Programme of Self Assessment and Condition Report at Qinshan NPPCondition Report at Qinshan NPP

IAEA Conference 27 June – 2 July 2004 Russia

Jiapeng YANJiapeng YANQinshan Nuclear Power Company,

Haiyan, Zhejiang, 314300

CHINA

YAN Jia-Peng, the Deputy General Manager of Qinshan Nuclear Power Company(QNPC)

20 year’s of experience in nuclear power industry

To receive the RO, SRO license in 1985 & 1990 and work as RO and Shift-Supervisor for seven years

Assistant General Manager in 2001 and responsible for all aspects of plant operations safety, nuclear safety surveillance and QA

Deputy General Manager in Sept. 2002 and responsible for plant operating, planning, system engineering, physical health and technical support

RESUMERESUME

Introduction System Development Practice of SA and CR Conclusion

TOPICSTOPICS

IntroductionIntroduction

Part onePart one

Introduction-QNPPIntroduction-QNPP

QNPP is the first NPP of 310MWe PWR in China Mainland which was designed, constructed and operated domestically. It is located inside Haiyan county, Zhejiang province and is 100km west to Shanghai city and 90km east to Hangzhou city.

QNPP began to construction on March 21th,1985,

QNPP first connected to the grid on December 15th, 1991

QNPP Carried out the OSART mission on Jan, 1997

QNPP has continuously improved its safety, reliability and achieved the better operation performance through upgrading equipment and system, developing five-year goal, enforcing operating experience feedback, carrying out ten-year Periodic Safety Review (PSR) and Probability Safety Analysis (PSA) etc.

QNPP has been continuously operated 443 days without scram in the 7th fuel cycle.

WANO Performance Indicator Index of the plant reached the world median level first time in 2002.


No. Indicator 2001 2002 2003

1 Unit Capability Factor 93.9% 67.8% 89.2%

2 Unplanned Capability Loss Factor 0.5% 2.8% 0.20%

3 Forced Loss Rate 0.22

4 Unplanned Automatic Scrams Per 7000H Critical

1.7 0 0

5 Safety System Performance

HPSIS 0.0009 0.0003 0.0004

AFWS 0.0052 0 0.0018

E D/G 0 0 0.0004

6 Fuel Reliability (Bq/g) 0.46 0.64 0.46

7 Chemistry Performance 1.31 1.11 1.07

8 Collective Radiation Exposure (Man.Sv) 0.15 1.24 0.80

9 Industrial Safety Accident Rate 0.20 0 0.10

10 PI Index 75 88 92


1998 2003 Performance I ndi cator I ndex－

86

7275

8588

90

92

88

60

70

80

90

100

Medi aQNPC

Medi a 86 85 88 90

QNPC 72 75 88 92

2000 2001 2002 2003


Unit Capability Factor

76. 8

81. 9

93. 9 89. 2

86. 1 85. 8

87. 285. 9

50

100

2000 2001 2002 2003

%

QNPC

Medi an


Unplanned Automatic Scram per 7000 Hours Critical

0

1. 70

01. 00

00 0

00. 000. 200. 400. 600. 801. 001. 201. 401. 601. 80

2000 2001 2002 2003

QNPC

Medi an


Safety System Performancehi gh pressure safety i nj ecti on system－

0. 0004

0. 001

0. 00030. 001 0. 0009

0. 001

0. 0010. 001

0

0. 001

0. 002

2000 2001 2002 2003

QNPC

Medi an


Safety System Performanceauxi l i ary feedwater system－

0. 0052

0. 0005

0. 001 0. 00180. 001

0. 001

0. 0010. 001

0

0. 001

0. 002

0. 003

0. 004

0. 005

0. 006

2000 2001 2002 2003

QNPC

Medi an


Safety System Performanceemergency AC power system－

0. 011

0 0 0. 0004

0. 003 0. 0020. 003

0. 002

0

0. 002

0. 004

0. 006

0. 008

0. 01

0. 012

2000 2001 2002 2003

QNPC

Medi an


Collective Radiation Indicator

0. 81. 24

0. 150. 65

0. 77

0. 71

0. 710. 85

0

0. 4

0. 8

1. 2

1. 6

2000 2001 2002 2003

man.Sv QNPC

Medi an


Chemistry Performance Indicator

1. 071. 111. 311. 09

1. 01 1. 011. 021. 08

0

0. 4

0. 8

1. 2

1. 6

2000 2001 2002 2003

QNPC

Medi an


I ndustri al Safety Acci dent Rate

0. 10. 0

0

0. 2

0. 31

0. 280. 330. 33

0

0. 2

0. 4

2000 2001 2002 2003

QNPC

Medi an


Purpose of Self-Assessment(SA)/Condition Report (CR) establishment is to sustain improvement of plant’s safe operation and good performance

The establishment of the SA and CR systems were supported by IAEA CPR/0/009 TC Project (2000 to 2001). There were 46 QNPP’s senior managers and 24 host plant’s experts involved this project.

QNPP developed and implemented improvement’s plans and made significant achievements in ten areas on the past three years. The SA and CR systems are the two most successful areas.

Introduction-SA/CRIntroduction-SA/CR

Introduction-SA/CRIntroduction-SA/CR

IAEA CPR/0/009 Final Review Meeting

System DevelopmentSystem Development

Part twoPart two

System Development-System Development- OBJECTIVESOBJECTIVES

1. Detect and report the weakness of plant conditions and management problems to maintain the plant’s continuing improvement system and good performance.

2. Ensure all the management, plant system and equipment were under well controlled, the abnormal conditions are identified and corrected in time.

3. Ensure to carry out the Root Cause Analysis and develop Corrective Actions Enhancing personnel Safety Culture consciousness.

System Development-System Development- PROCEDUREPROCEDURE

1. Condition Report Management Procedure (QSZ-D-044)

2. Methodology of Root Cause Analyze (Manual)

3. Operation Experience Feedback Management Procedure (QSZ- D-022)

4. Operation Event Report Procedure (QSZ-D-053)

5. Operation Experience Feedback Engineer Procedure (QSZ-D-050)

6. Self-Assessment Management Procedure (QSZ-D-051)

7. Self-Assessment Committee Programme (QSZ-A)

8. Self-Assessment Criteria and Guidelines (Manual)

9. Self-Assessment Methodology (Manual)

System Development-System Development- PROCEDUREPROCEDUREManual Example:

Root cause Analysis

Self Assessment

Operation Experience

Human Performance

WANO PI

Self Assessment

C&O

System Development -System Development - PROCESSPROCESS

Departments decide and submit the SA plan to NSLD

Departments decide and submit the SA plan to NSLD

SA committee hold meeting to review the SA plan

SA committee hold meeting to review the SA plan

NSLD develop the plant SA plan.

NSLD develop the plant SA plan.

General manager review and approve the SA plan

General manager review and approve the SA plan

SA plan distributed to departments/Training

SA plan distributed to departments/Training

Department establish assessment team and implement the plan

Department establish assessment team and implement the plan

SA report was submitted to NSLD and reviewed by SA Committee

SA report was submitted to NSLD and reviewed by SA Committee

The AFIs and correction actions development / CR process

The AFIs and correction actions development / CR process

Self-Assessment (SA) Process flow Chart (simplified)

System Development-System Development- PROCESSPROCESS

Condition Report (CR) Process Chart (simplified)Condition Report (CR) Process Chart (simplified)

Equipment Deficiency

Equipment Deficiency

License Dep. Review

License Dep. Review

Discu. and Review daily CR Meeting

Discu. and Review daily CR Meeting

Close/ transfe

r ?

Close/ transfe

r ?

Classify

Sig. ?

Classify

Sig. ?

Analyze Root

Cause

Analyze Root

Cause

Develop CA &

Approve

Develop CA &

Approve

Develop Correct Actions

Develop Correct Actions

Implement CA

Implement CA

EvaluateEvaluate

CloseRepor

t

CloseRepor

t

Other programs

Manag. Weakness & SA AFIs

Manag. Weakness & SA AFIs

Outside Events (SOER, SER)

Outside Events (SOER, SER)

System Development-System Development- PROCESSPROCESS

Corrective Actions (CA) Process Chart (simply)Corrective Actions (CA) Process Chart (simply)

Determine Problem Determine Problem Investigate Investigate Analyze investigated Result

Analyze investigated Result

Determine Root Cause Determine Root Cause Develop Corrective Actions

Develop Corrective Actions

Approve Report Approve Report

System Development-System Development- ORGANIZATIONORGANIZATION

Self-Assessment (SA) committee.

-Review and approve the SA plan and Review the state of SA;

-Evaluate the implement of overall SA plan and Review SA report;

-Review the implementation of AFI.

Nuclear Safety Licensing Department.

-Accept and review CRs and report to the CR Review Meeting;

-Tracking the completion of the CA;

-The secretariat of the SA committee;

-Following up the state of SA plan implementation and AFIs;

-Provide supports to OEF engineers.

OEF Engineer System (more 20 engineers)

-Support their department managers to analyze the root cause, develop correct actions and follow-up;

-Promote OEF improvement in their departments

Condition Report Review Meeting (daily routine meeting at 11:00 AM )

-Report the coming CRs, review and clarify them.

-Assign the CRs to responsible department for develop the CA.

-Review class A CRs’ Root Cause Analysis results and Correct Actions.

-Review the industrial OE information.

System Development-System Development- ORGANIZATIONORGANIZATION

System Development-System Development- CR CR REPORTABLE AREA REPORTABLE AREA

1. Operational/Material/Maintenance/Welding-Related Conditions

2. Configurations/Systems/Equipment

3. Radiological Protection/Industrial Safety/Fire Protect/ Security Conditions.

4. Human Performance/Administrative .

5. Internal/External Operating Experience

6. Self-assessment AFIs

System Development-System Development- CR CR CLASSIFCATIONCLASSIFCATION

Category A: Significant CRs.Root Cause Aanalysis and Corrective Action are needed

Category B: Non-Significant CRs.Only corrective action is needed

Category C: No need further action, Condition can be directly closed or transferred to other process (Below A &B)

SigCRs

Non-SigCRs

CR B Threshold

CR A Threshold

OtherSystems

IndusSafety

QAQC

Ops Depart.

Impr Plan Equip

related cond.

Maint. Prob.

doc.Contl.

Plant Managers focus

Dep. Managers focus

Staffs focus

CR C Threshold

System Development-System Development- CR CR CLASSIFCATIONCLASSIFCATION

Practice of SA and CRPractice of SA and CR

Part threePart three

Practice-Practice- SELF-ASSESSMENTSELF-ASSESSMENT

Establish Committee and Procedures, Training, Planning, Team setup

Maintenance, Chemistry and Production Planning areas finished in 2003 as follow

Area AFIs Number

Strengths Number

1 Maintenance 32 5

2 Chemistry 7 2

3 Production planning

16 1

Plan in 2004: five areas as Operation, Radiological Protection, Training, Engineering Support and In-Service Inspection

Most reviewers come from own plant, but some external experts are invited



Self Assessment Plan in 2004

Practice-Practice- CONDITION REPORTCONDITION REPORT

Condi ton Report Number Trendi ng i n 2002

11 15 17 26 29 33 41 41 41 42 43 5032 45

5985 96

113136

156 164 174 180 186

5976 88

128150 160 171

192 201 211 219 222

0

50

100

150

200

Number

A 11 15 17 26 29 33 41 41 41 42 43 50

B 32 45 59 85 96 113 136 156 164 174 180 186

C 59 76 88 128 150 160 171 192 201 211 219 222

J an- f eb- Mar- Apr - May- J un- J ul - Aug- Sep- Oct - Nov- Dec-

CR report number in 2002


CR report number in 2003

Condition Report Number Trending in 2003

0 1 2 4 8 11 12 14 15 19 20 247 10 19

5581

100114 126 133 145

159 169

12 2545

7495

114 128141 149 160

196 210

0

50

100

150

200

250

A 0 1 2 4 8 11 12 14 15 19 20 24

B 7 10 19 55 81 100 114 126 133 145 159 169

C 12 25 45 74 95 114 128 141 149 160 196 210

J an- Feb- Mar - Apr - May- J un- J ul - Aug- Sep- Oct - Nov- Dec-

Administrative control

Configuration control

Equipment deficiency

Work practice

Area

Operation

Maintenance

Engineering support

Material condition

Radiation protection

Security

Training

Org. &admin

Emergency planning

Chemistry


CR Problem Trending by Areas (one month sample)

Number of CR

cl osi ng

Number of

under CA

i mpl ement i ng

Number of

Devel opi ng

CA not i n

t i me

Number of CR

cl osi ng not

i n t i me

Number of Devel opi ng CA not i n t i meNumber of under CA i mpl ementi ng

Number of CR cl osi ngNumber of CR cl osi ng not i n t i me


Follow up CR Corrective Actions implementation


CR in QNPP Intranet (example)

http://qnpc/

QNPC Main Web Page QNPC Main Web Page

Nuclear Safety Nuclear Safety

NSLD Main Web Page NSLD Main Web Page

Condition Report Condition Report Self Assessment Self Assessment

Condition Report Main Web Page Condition Report Main Web Page

CR list in latest 30 days CR list in latest 30 days

One of Condition Reports in Web Page One of Condition Reports in Web Page

WANO SER 2003-2WANO SER 2003-2


Root Cause Root Cause


Correct ActionsCorrect Actions

CR Search Web Page CR Search Web Page

Easy to searchEasy to search

Practice-Practice- CORRECT ACTIONCORRECT ACTION

Case Study –RCA and Corrective Actions development

On May 2001,QNPP had an event “Loss of Power to Protection System Results in RCP A/B Trip Signal Actuation, followed with Reactor and Turbine Trip Automatically”. (EAR TYO 01-004)

The Root Cause Analysis by Event Cause Factors was developed. Human error,Equipment deficiency, Lack of patrol control, Lack of safety culture consciousness were main 4 factors to cause this events

One workertwist the DC24V

power supply bushing as another

worker’s suggestion

Loss of power supply because of the shaking of power supply input lead, which connected

in a wrong pattern

RCPA/B trip intermediate relays in

the CP5414 lost its power supply

Reactor and turbine tripped

automatically

Position of the DC24V and DC220V breaker is near, even the input line

was tied together

DC220V power supply connected with the terminal in wrong

pattern

Preventive maintenance never carried out to these breakers

since the beginning of operation

Deficiency in equipment acceptance

The plant management system do not cover the preventive maintenance,

reliability and risky analysis of some

key equipments

Number labeled on the DC24V bushing toward

inside

Maintenance staff lack of the awareness in safety culture

and safety risk

Maintenance staff violating the plant safety regulation

and program

Maintenance staff lack of question attitude and the self

check requirement

Deficiency in safety culture, risk awareness management

and education

Two I&C maintenance workers cannot see the number labeled on the lead of DC24 branch power supply

management/ safety culture

management/ safety culture

Programe Programe

Work practice Work practice

Establishment and acceptance of equipment

Establishment and acceptance of equipment

Equipment maintenance / test/ surveillance

Equipment maintenance / test/ surveillance

EAR TYO 01-004, Loss of Power to Protection System Results in RCP A/B Trip Signal Actuation, followed by Reactor and Turbine Trip Automatically EVENT DATE: 10 May 2001

Conclusion Conclusion

Part fourPart four

Conclusion-1Conclusion-1

1. Develop a window and allow all the reportable condition and abnormalities covering all near missed incidents as well as management problems to report and follow up by this window.

2. The Plant Managers understand and timely control the unit’s conditions and significant issues by the systems

3. The Operation Experience Feedback (OEF) system has been significantly improved by the establishment of CR system.

4. The Operation Experience Feedback (OEF) system has been significantly improved by the establishment of CR system.

-Reportable number increased (50 to 400)

-Clearly classify to A B C

-OEF Engineers contributing to Root Cause Analysis

-More external events into CR system (Approximately 50 international OEF reports and all WANO SOER and SERs)



5. SA and CR systems made significant contributions to increase the plant’s risk control capability, and decreased the human error events , and improve the unit’s operation safety management and performance.

QNPC clearly recognizes that the plant will contiQNPC clearly recognizes that the plant will continue to recognize weaknesses and avoid complacenue to recognize weaknesses and avoid complacency in the future by continually striving for both ncy in the future by continually striving for both improving safety and operational perfoimproving safety and operational performancermance

THANKTHANK

YOU!YOU!

programme of self assessment and condition report at qinshan npp iaea conference 27 june – 2 july...

Documents

introductionqnpp qnpp

plant system

nuclear safety surveillance

improvement system

system engineering

plant operating

cr systems

nuclear power industry