KOREA HYDRO & NUCLEAR POWER CO., LTD ... 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

Engineering Department

KOREA HYDRO & NUCLEAR POWER CO., LTD

Made by cheon se bin in Shinkori 1 plant


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Contents

II. Analysis of environment to KHNP

III. Analysis of Outage extension trend

IV. Method of outage optimization

I. Plant operation status



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



I. Operation status in KHNP

2

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)



3

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



4

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




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

5

Trend of Regulation



6

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




7

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


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

8

Trend of outage Extension

III. Analysis of Outage trend



IV. Method of Outage optimization

9

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 )



10

• 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


Outage work flow chart



11

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)




12

Reference outage schedule (Critical path based on 20 hours, reference plant is Shinkori 1)

Outage duration standardization & optimization

5D


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



13

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




14

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


Outage Feedback List

Category : OH schedule, procedure, design change, education, FME, Safety, operation



15

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


Maintenance order master file

2,235



16

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



17

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)




Management (FME)

Follow the Basic

Recognition importance of FME Impact

Follow FME Process


18



19

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%


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



20

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


Daily report of Safety inspection

Best Practice Best Practice

4M-Risk Assessment table



21

Management (Industrial Safety)

Summary of the key Safety procedure

Final report by Safety guidance Team

Select the work of high risk for Industrial safety


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



Management (Fire Protection)


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

22

Best Practice Poor Practice

Fire suppression drill



23

Dealing with regulator and the public


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



24

Outage Optimization

Experts

Process

Recognition

Management

Relationship

Source

Conclusion



All person in plant do their best for successful outage and outage optimization with safety mind, by the full use of method


25



Documents

KOREA HYDRO & NUCLEAR POWER CO., LTD ... 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