Nuclear Quality Assurance · ‘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

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

2

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)

3

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

4


• 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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• 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)

6


• 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

7


• 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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9

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)


10

• 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


• 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

11


• 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

12


• 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


• 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.

14


• 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


• GS-R-3 Requirements

16

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


• 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.

18


• 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.)

19


• Regulatory Inspection

20

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


• Nuclear Power Plant

21

□ 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

22

□ 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


23

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


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

25


Fig. QA ProgramRegulation 26


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

27


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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□ 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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Design Plan

30


Design Verification Checklist

31


Quality Regulation

□ Procurement Document Control (Criterion 4)

• Preparation of procurement document

- Technical specification

- QA requirement

• Procurement document review

• Subsequent change procedure

32


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)

33


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


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

35


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


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


Manufacture QA Inspection General

Application of Special Process

Welding, NDE

Manufacturing

Assembling& Erection

Pre-operationalInspection

Replacement

Maintenance

Periodic Inspection

Construction Operation

38



39

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


40

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


General Manufacturing Process

V. QA Inspection Criteria

41

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


Quality Regulation Inspection & Test Plan (ITP)

43


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

44


Quality Regulation

45


Transportation of RV

Quality Regulation

46


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

47


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

48


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

49


V. Concluding Remarks

50

• 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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