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Development of safety culture in

OKB «GIDROPRESS»

Quality engineer of 2 category

Ilya Gorokhov

IAEA Technical meeting,

Vienna, 2-4 November 2015

www.gidropress.podolsk.ru

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1. General information about OKB «GIDROPRESS»

2. Requirements for Safety Culture

3. Safety Culture Concept in OKB «GIDROPRESS»

4. Implementation of Safety Culture Principles

5. Assessment and improvement of Safety Culture

6. Safety Culture Fostering

7. Plans and prospects

CONTENTS

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1. GENERAL INFORMATION ABOUT OKB «GIDROPRESS»

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HISTORY OF OKB «GIDROPRESS»

Year 1946 : OKB

«GIDROPRESS» was established

Research heavy-

water reactor

Research heavy-water

reactor MR

Steam generator and heat exchangers for

the First NPP in the world

Steam generators for

industrial reactors

Land-based test bench prototype 27/VT

VVER-440 Novovoronezh NPP,

Kola NPP, «Greifswald» NPP, «Kozloduy» NPP, «Bohunice» NPP,

«Loviisa» NPP, «Paks» NPP, Rivne NPP, Dukovany NPP,

Armenian NPP)

VVER-1000 (Novovoronezh NPP, Unit 5)

Steam generators for NPP with

BN-350 RP

Separator for RBMK-1000

Development of experimental base

New generation of CPS

drives for VVER-1000 has been developed and their

manufacturing started

Manufacturing of equipment for NPP

RP for SVBR-75/100

(basic design)

RP for new generation of NPP

Steam generators for NPP

with BN-800 reactor plant

Nuclear steam supply systems

for nuclear submarines

RP with VVER for «Rheinsberg» NPP (Germany)

and Novovoronezh NPP (Russia)

Boiling-water reactor VK-50

Fast research reactor BOR-60

RP for VVER-1000 for Russia,

Ukraine, China, Iran, India

RP for new generation of NPP VVER-1500 (basic design)

RP VVER-1200 NPP-2006

Second generation of fuel

assembly TVS-2М

RP VVER-TOI

Steam generator for NPP

with RP BN-1200

Steam generator for research nuclear facility

MBIR

60’s 70’s 80’s 90’s 2000-2009 2010

VVER-1000

Zaporizhia NPP, Balakovo NPP, Khmelnytskyi NPP, Rivne NPP,

Kalinin NPP, South Ukraine NPP.

Steam generators for NPP with BN-600 reactor plant

Separator for RBMK-1500

Snubbers for NPP with VVER-440

and VVER-1000 reactor plants

50’s 40’s

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OKB «GIDROPRESS» ACTIVITY

Siting

Design

• Designing of RP equipment for VVER NPP

Manufactu-ring

• Equipment manufac-turing

Construction

• Designer's supervision of equipment

Commis-sioning

• Designer's supervision of mounting and commis-sioning activities

Operation

• Work for substan-tiation of operating life extension of NPP,moder-nization of NPP

• Designer's supervision

Decommis-sioning

• Elaboration of RP decommis-sioning documentation

OKB «GIDROPRESS» - the Designer of reactor plants

(RP) with water-cooled water-moderated pressurized

water reactors (VVER/WWER)

NPP life cycle

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GEOGRAPHY OF PROJECTS

Balakovo NPP

Kalinin NPP

Kola NPP

Novovoronezh NPP

Rostov NPP

Novovoronezh NPP-2

Kursk NPP

Leningrad NPP-2

Nizhniy Novgorod NPP

Russia

China

NPP«Loviisa»

NPP«Hanhikivi»

Vietnam NPP«Ninh Thuan»

Bangladesh NPP«Ruppur»

India NPP «Kudankulam»

Iran NPP«Bushehr»

Finland

Belarusian NPP

Belorussia

NPP«Tianwan»

NPP «Paks»

Hungary

NPP«Dukovany»

NPP «Temelin»

Czech Republic

NPP«Bohunice»

NPP«Mochovce»

Slovakia

NPP«Kozloduy»

Bulgaria

Rivne NPP

Zaporizhia NPP

Khmelnytskyi NPP

South Ukraine NPP

Ukraine

NPP«Akkuyu»

Turkey

Armenian NPP

Armenia

Under operation:

23 VVER-440 Units

32 VVER-1000 Units

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2.REQUIREMENTS FOR SAFETY CULTURE

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REQUIREMENTS FOR SAFETY CULTURE

Designation Name

International documents (IAEA)

SF-1 Fundamental Safety Principles

GS-R-3 The management system for facilities and activities

GS-G-3.1 Application of the management system for facilities and activities

GS-G-3.5 The management System for Nuclear Installations

75-INSAG-4 Safety Culture

75-INSAG-15 Key Practical Issues in Strengthening Safety Culture

Russian legislation Documents

NP-001-97 General provisions for safety assurance of nuclear power plants.

ОPB-88/97.

Customer State Legislation

e.g. Finland:

YVL A.3 Management system for a nuclear facility.

Requirements of the Contracts

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SAFETY CULTURE – qualification and psychological preparedness of all

individuals wherein ensuring NPP safety is a priority goal and intrinsic

need leading to conscious responsibility and self-control in executing all

safety-related activities. (Russian Legislation NP-001-97)

SAFETY CULTURE – is that assembly of characteristics and attitudes in

organization and individuals which establishes that, as an overriding

priority, nuclear plant safety issues receive the attention warranted by

their significance. (IAEA GS-R-3)

DEFINITION DIFFERENCES

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OKB "GIDROPRESS" Safety Culture Program

Assessment of the safety culture

Concept and principles of safety culture

Methods of implementation of

principles of safety culture

Improvement of safety culture

INTERNAL DOCUMENTATION

Policy

Regulations, Standards

Procedures, instructions

Documentation of

quality management

system

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3. SAFETY CULTURE CONCEPT IN OKB «GIDROPRESS»

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SAFETY CULTURE CONCEPT

Employees (personnel)

Management system

Documentation system

Tools and technologies

Sa

fety is integrated

in

all activitiesC

on

tin

uou

s le

arn

ing

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Safety as an overriding

priority

Safety is a responsibility of

everyone

Safety is integrated in all

activities

Leadership of management

Openness and trust in a collective

Continuous learning

SAFETY CULTURE PRINCIPLES

6 safety culture principles in OKB «GIDROPRESS»:

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4. IMPLEMENTATION OF SAFETY CULTURE PRINCIPLES

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1) Safety is an overriding priority

• …Priority of assurance of nuclear and radiation safety is established in quality policy of OKB «GIDROPRESS».

• Only employees who passed certification on safety assurance issues in the field of nuclear energy utilization are permitted to the work affecting safety…

2) Safety is a responsibility of everyone

• …Clearly allocation of power, responsibility, rights and obligations between subdivisions and personnel within the subdivisions.

• Agreements with sub-suppliers who execute the work affecting safety of NPP contain the requirements for safety culture…

3) Safety integrated in all activities

• …The subdivisions wherein and the specialists who perform the work important to safety is responsible for assurance of nuclear and radiation safety. The persons responsible for assurance of other kinds of safety (fire, industrial, ecological, physical and etc.) are appointed at the enterprise, respective regulatory NDs are valid, briefings and inspections are carried out.

• All processes at the enterprise are regulated by respective regulatory documents…

IMPLEMENTATION OF SAFETY CULTURE PRINCIPLES

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4) Leadership of management • …The Director General is appointed as a person responsible to promotion,

maintenance and development of safety culture.

• The management of OKB "GIDROPRESS" takes part in the work important to safety (coordination of Documentation of projects), part in work of scientific-technical commission of the enterprise and the State Corporation "Rosatom", in conferences on safety…

5) Openness and trust in a collective • …Job descriptions of all specialists describe a scheme of actions in case of

occurrence of conflicts with colleagues or a direct manager.

• The State Corporation "Rosatom" studies every year the involvement of personnel in work....

6) Continuous learning • …Various types of personnel training (inside the enterprise, in educational

institutions and specialized organizations, technical training).

• The Branch International Scientific and Technical Conference "Safety assurance at NPP with VVER" and Branch Scientific and Technical Conferences of young specialists .

• Probation of young specialists …

IMPLEMENTATION OF SAFETY CULTURE PRINCIPLES

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5. ASSESSMENT AND IMPROVEMENT OF SAFETY

CULTURE

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ALLOCATION OF RESPONSIBILITIES

Order

Direction

Director General (Promotion ,

maintenance and development

of Safety Culture)

Working group

(Assessment , review and

improvement of safety culture)

Quality Section (Department)

(Operative-methodical work)

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Arrangement of Safety Culture

assessment (issue of a direction) and appointment of the

working group

Information acquisition (safety culture indicators,

questioning of employees, audit

results)

Analysis of the obtained data

(working group)

Determination of current safety culture positive and negative features and required

improvements

Report on safety culture

Elaboration of corrective and

preventive actions

Plan on improvement and enhancement of

the safety culture

Implementation and check of

implementation of corrective and

preventive actions

Effectiveness estimation of the

performed actions and their correction

(if required).

ORDER OF ASSESSMENT AND IMPROVEMENT

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Indicators

Expert (working group)

assessment of safety culture requirements

(IAEA, Contract, legislation)

consideration in the organization

Questioning

Anonymous questioning for managers and

employees (working group)

Self-assessment for managers

Audits

Internal (quality section).

Checking the implementation of safety culture requirements in the organization

External (Customer)

SAFETY CULTURE ASSESSMENT

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SAFETY CULTURE IMPROVEMENT

- change (making new ones) in the ways (methods) of

implementation of safety culture principles;

- correction of quality management system documents of

OKB "GIDROPRESS";

- detection of new methods (activities) on assessment of

safety culture level;

- description and bringing of the concept and safety culture

principles to the notice of the employees;

- training of employees, etc…

Plan on improvement and enhancement of the

safety culture level:

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6. SAFETY CULTURE FOSTERING

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Trainings at educational institutions and specialized

organizations(Rosatom central institute for

continuing education and training, «Corporative

academy of Rosatom»)

Trainings inside OKB «GIDROPRESS» subdivisions (technical training, trainings for

management)

Trainings organized by Customer (workshops,

strategic sessions, working groups etc)

IAEA trainings (Workshops, technical meetings, strategic

sessions etc.)

SAFETY CULTURE TRAININGS

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SAFETY CULTURE FOSTERING

Feedback:

Nuclear Power Plant

Foundation value

system, attitude

development, education

Conditions (system of requirements):

Requirements of international

documents (IAEA No. GS-R-3) and

local legislation (NP-001-97, YVL A.3)

Contract requirements

Requirements of documents of State

corporation «Rosatom» (policies,

regulations)

Requirements of internal documents of

OKB «GIDROPRESS» (Safety Culture

Program, Standards, Procedures)

Influense

(levels of management):

State corporation «Rosatom»

Top management of OKB

«GIDROPRESS»

Line manager of employee

Control:

Inspections of Supervision

authorities

External audits Customer

Internal audits,

Self-assessment

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7 PLANS AND PROSPECTS OF OKB «GIDROPRESS»

Establishing the responsibility

and authority for safety culture

Safety Culture Promotion

- Correct regulations for subdivisions,

staffing tables and job descriptions for

managers and specialists responsible for

safety culture in organization

- Preparation of visual materials (booklets,

presentations, posters, etc.) on safety

culture for employees and sub-suppliers

Assessment of Sub-suppliers

- Elaborate criteria for sub-suppliers safety

culture assessment.

- Safety Culture Audits of Sub-suppliers

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Thank you for your attention!

Спасибо за внимание!

Vielen Dank für Ihre Aufmerksamkeit!

Merci pour votre attention!