Supply of technical training tools for the NMMTC Zaporozhye NPP Ukraine, Lot 1 (Refueling machine MPS-1000 simulator) Lot 2 (Control Rod Drives Test Rig Simulator).

In the framework of the TACIS 2007 Programme, the European Commission agreed with NAEK-Energoatom and Zaporozhe Nuclear Power Plant (ZNPP) on the improving the nuclear safety of Ukrainian NPP's by implementing the project of “Completion of the National Maintenance and Management Training Centre for SE NNEGC “Energoatom” Personnel at Zaporozhye NPP, Ukraine (U1.05/07A).

The key element of the Programme is the establishment of the National Training Centre for maintenance personnel, which will allow NPP personnel to have practical training in all areas of NPP maintenance.
Management training is another important component of the NPP training system. It is common knowledge that competency of managers effects not only the business activity of an organisation, but also its culture. Competency of junior level managers is a significant element for ensuring high standards of Safety Culture.

Enhance the safety of Ukrainian NPPs through further improvement of the training system for maintenance and management personnel of SE NNEGC Energoatom

The objective of the project is to establish a state-of-the-art national centre for training of SE NNEGC “Energoatom” maintenance and management personnel on the basis of Zaporozhye NPP Training Centre to ensure:

• Sustainable improvement in safety culture and improvement of the overall safety management capabilities of NPP personnel at all levels
• Sustainable and continuous improvement in the capability of SE NNEGC “Energoatom” high level, junior and middle level management.
• Sustainable and continuous improvement in maintenance activities with regard to NPP plant and equipment, through:
• improvement of the quality assessment system of the maintenance personnel training
• improvement in the quality of maintenance works;
• reduction of the period of exposure of NPP staff to ionising radiation, in accordance with the ALARA principle, due to training for complex maintenance operations in realistic simulated conditions prior to execution in radiation hazardous areas;
• promote the adaptation of maintenance tools following the needs emerging from the training feedback and the feedback from plant managers

The project U1.05/07 has been launched in 2009 and is divided into three parts.

U1.05/07A (Part A): includes review and study of best international practices in maintenance and management training, training needs analysis for maintenance and management personnel, development and delivery of training programmes and materials, development of technical specifications for technical training tools of general and special assignment, training of trainers and implementation of pilot training courses.

U1.05/07B (Part B): Supply of general assignment technical training tools for arrangement of areas for the pre-simulator training and specialized classrooms as specified in U1.05/07A (general assignment tools are standard equipment for pre-simulator training that may be ordered from catalogues, including: projectors, computers, office devices, furniture, standard tools, instruments, etc.)

U1.05/07C (Part C): Supply of special assignment technical training tools as specified in U1.05/07A (special assignment tools are full scope and local simulators of process equipment prepared for practical training which have to be made according to special requirements)

The supply of equipment and technical training tools of this part of the project (U1.05/07C) is divided into six lots and are specified in six (6) Technical Specifications. The six Lots are:
Lot 1 Refueling Machine MPS-1000 Simulator of the “Refueling” Laboratory
Lot 2 Control Rod Drives Test Rig Simulator of the “FSS – Mechanical part of CRD” Laboratory
Lot 3 - Valves Test Rig Simulator of the “Pipeline Valves” Laboratory
Lot 4 - Test Specimens and Technical Training Tools/Equipment for Ultrasonic Inspection Personnel Training in the “Metal Inspection” Laboratory
Lot 5 High Voltage Electrical Equipment Training Simulator for Testing and Diagnostic of “High Voltage Testing and Electrical Equipment Diagnostics” Laboratory
Lot 6 Emergency Protection and Warning Protection System Simulator for Reactor Control and Protection System of “Maintenance & Repair of CPS and Neutron Flux Monitoring Equipment” Laboratory
Lot 1 and 2 contracts were awarded after successful tender procedure
Lot 3 and 6 contracts were awarded via negotiated procedure after unsuccessful tender procedure
Lot 4 and 5 tender procedure were cancelled

The present project covered the Lot 1&2 supplies which were combined in one contract.

Lot 1 - Supply of technical training tools of special purpose for a Refueling Machine MPS-1000 Simulator of the “Refuelling” Laboratory”.

The supply project is aimed at design, manufacturing, delivery, installation and commissioning of the modification of an existing refuelling machine to a refuelling machine simulator for maintenance personnel practical training and in specific:

• Missing elements of the existing Refueling machine mechanical parts
• Electric drives including electric motor, power supply, control unit, limit switches, encoders, cables, etc.
• Refueling machine control system (RMCS)
• Crash protective device
• Underwater TV camera system
• MPS -1000 operation video surveillance system
• Spare parts, consumables, tools and accessories

The simulator shall be used for practical training of refuelling operators and maintenance personnel, for the performance of works on and with the refuelling machine using a Systematic Approach for Training for the phases starting from initial knowledge control and up to the trainees’ demonstration of abilities and skills gained on the simulator.

The intended usage of the simulator is training of fuel transport and process equipment operators and maintenance personnel. In addition the simulator may be used for:

• examination of theoretical knowledge and practical skills within certification on a periodic scheduled basis for fuel transport and process equipment operators;
• training of contingencies and incidents in the approximated maximum real-life environ-ment;
• engineering support in the field of refuelling and decision-making for other tasks effecting NPP operation safety.

The pilot training courses are developed and executed in the framework of the service contract "'Completion of the National Maintenance and Management Training Centre for NNEGC Energoatom personnel at Zaporozhye NPP – U1.05/07A (Contract 171840). The generic list of training tasks, (i.e. terminal objectives) implemented in the course of personnel practical training with a simulator are:

• to maintain Refueling Machine mechanism drives prior to the performance of scheduled operations on refueling according to the Operations and Maintenance Manual requirements.
• to perform Refueling Machine integrated test prior to the performance of scheduled refueling operations according to the Operations and Maintenance Manual requirements.
• to handle Absorber Rod Simulator in reactor “core” according to the procedure for loading, the process regulations for power units safety operation.
• to test Fuel Assembly A cladding leak tightness according to the Operations Manual requirements.
• to displace Burnable Absorber Rods within refueling in the reactor “core” according to the Operations Manual requirement;
• to displace Control and Protection System Absorber Rods within refueling in the reactor “core” according to the Operations Manual requirement;
• to displace an absorber element within refueling in the reactor “core” according to the Operations Manual requirement;
• to perform preservation procedures for RM, equipment and accessories for the period between refueling in the reactor “core” according to the Operations and Maintenance Manual requirements.

Lot 2- Supply of Control Rod Test Rig Simulator of the “FSS – Mechanical Part of CRD” Laboratory

The supply project is aimed at design, manufacturing, delivery, installation and commissioning of the Control Rod Test Rig simulator for maintenance personnel practical training and in specific:

• Rig for the Control Rod Drive (CRD) testing (mechanical part)
• Control system for the CRD test rig
• Equipment for water supply and pressure test of the housing
• Electrical power distribution supply and auxiliaries
• Crane (lifting device for CRD disassembling)
• Drive shaft and movement unit base blocks
• Special tools for the CRD
• Spare parts, consumables, tools and accessories

The simulator shall be used for practical training of maintenance personnel, for the performance of works on Control rod drives using a Systematic Approach for Training for the phases starting from initial knowledge control and up to the trainees’ demonstration of abilities and skills gained on the simulator.

The pilot training courses are developed and executed in the framework of the service contract "'Completion of the National Maintenance and Management Training Centre for NNEGC Energoatom personnel at Zaporozhye NPP – U1.05/07A (Contract 171840). The generic list of training tasks, (i.e. terminal objectives) implemented in the course of personnel practical training with a simulator are:

• examination and preparation of the CRD for operating capacity in the rig CRD housing;
• checking CRD for operating capacity in the rig CRD housing working medium;
• full and partial disassembling/assembling of the CRD ;
• hydro-testing of the CRD flange joints

The Technical Specifications for the project were developed in 2010/11 under the service contract "'Completion of the National Maintenance and Management Training Centre for NNEGC Energoatom
The new equipment has been installed in the new extension of the existing Training centre building. The new extension building has been planned, erected and financed under the responsibility of Energoatom and ZNPP.

The equipment of Lot 1 was installed by the supplier under supervision of ZNPP. The site acceptance test (SAT) was performed in February 2013 and the Provisional Acceptance Certificate (PAC) was signed on 19.11.2014. The Final Acceptance Certificate (FAC) was signed after expiration of the warranty period 2.08.2016.

The equipment of Lot 2 was installed by the supplier under supervision of ZNPP. The site acceptance test (SAT) was performed in February 2013 and the Provisional Acceptance Certificate (PAC) was signed on 1.12.2014. The Final Acceptance Certificate (FAC) was signed after expiration of the warranty period 2.08.2016

The achievement of this project, when the national training centre is completed and all equipment (EU and Energoatom financed) are installed, is to ensure advanced training of maintenance personnel on simulators and mock-ups and through that an increase of safe operation of the plant due to accurate maintained equipment and trained operators.