FCN

Operation

By Government Decision no. 24/2019, the Environmental Authorization was issued for the National Company “Nuclearelectrica” ​​SA-Subsidiary, “Fabrica de Combustibil Nuclear” Pitesti, published in the Official Monitor of Romania no. 87 bis on 04.02.2019.

PILLS SECTION

IMG_2080The activity of the Pills Section is the manufacture of UO2 pills, using uranium dioxide powder as raw material.

To carry out this activity, the Pills Section: 

 fully uses the processing technologies established by the manufacturing documentation;

  • keeps control of the material throughout the manufacturing flow and in the storage areas;
  • apply actions to optimize the individual technological processes and the technological flow in the assembly;
  • participate in the production analysis team.
 
 

ASSEMBLY SECTION

   The activity of the Assembly Section is the manufacture of:

  • zircaloy components for the beam;
  • combustible elements;
  • fuel bundles type CANDU.

The main activities of the Assembly section are:

  • IMG_2243ensures the manufacture of zircaloy components for the beam, combustible elements and CANDU type combustible beams;
  • fully uses the processing technologies established by the manufacturing documentation;
  • keeps control of the material throughout the manufacturing flow and in the storage areas;
  • initiates and applies actions to optimize the individual technological processes and the technological flow in the assembly
  • participates in the team in the analysis of the stage of physical production and quality objectives.
 

Utilities mechanical-energetic section

  • Performs specific preventive and corrective maintenance works, ensuring the operation of the equipment on the manufacturing line at the designed parameters, reducing downtime
  • Produces and distributes the utilities required for the nuclear fuel manufacturing flow (hydrogen, nitrogen, compressed air, demineralized water, cooling water)
  • Operates the ventilation systems in order to ensure a suitable climate in the manufacturing halls, simultaneously with the reduction of the noxes discharged into the atmosphere
  • Ensures the supply of electrical and thermal energy, potable and fire water to FCN equipment and buildings
  • Executes and reconditions the SDVs used in nuclear fuel manufacturing equipment

Engineering department

Objectives:

  • Develops CANDU fuel manufacturing documentation;
  • Recommend strategies to optimize manufacturing efficiency;
  • Recommend strategies regarding new equipment investments, SDVs;
  • Establishes training requirements for manufacturing personnel;
  • Develop manufacturing technologies for special orders or research contracts;
  • Monitors the performance of the processes of the integrated management system in the area of ​​responsibility.

The Engineering Department is made up IMG_2261 of the following collectives:

Process Engineering Collective:

  • elaborates and updates the engineering documentation (operating and manufacturing procedures, repair/recovery procedures, etc.)
  • analyzes and updates the execution drawings for components and fuel bundle;
  • permanently monitors the performance of equipment and SDVs;
  • qualify the manufacturing processes;
  • establishes requirements for training and qualification/authorization of manufacturing operators;
  • proposes preventive maintenance programs;
  • analyzes the evolution of manufacturing processes;
  • participate in evaluation, selection and qualification actions of suppliers;
  • establishes specific consumption of raw materials, SDVs, spare parts.

Equipment Engineering Collective:

  • elaborates commissioning procedures for manufacturing equipment;
  • establishes the requirements regarding the utilities necessary for the exploitation of the equipment;
  • participate in the training of the operating staff;
  • provides technical assistance for establishing and correcting equipment malfunctions;
  • establishes the need for programmable automata used on equipment and elaborates the related documentation;
  • identify the equipment needed for production requirements;
  • act as the technical resource for maintenance services.

Design Collective:

  • elaborates and keeps under control drawings for equipment and SDVs;
  • based on the requirements of the process engineering, he elaborates the execution drawings for the fuel beam and components;
  • provides technical assistance for the execution, commissioning and exploitation of equipment and SDVs;
  • participate in the development programs of manufacturing technologies.

SECTIA PASTILE

 IMG_2080Activitatea Sectiei Pastile este fabricarea pastilelor de UO2, utilizand ca materie prima pulberea de bioxid de uraniu .

Pentru realizarea acestei activitati Sectia de Pastile: 

 utilizeaza integral tehnologiile de procesare stabilite prin documentatia de fabricatie;

  • pastreaza controlul materialului pe tot fluxul de fabricatie si in spatiile de depozitare;
  • aplica actiuni de optimizare a proceselor tehnologice individuale si a fluxului tehnologic in asamblu;
  • participa in echipa la analiza productiei.
 
 
 

SECTIA ASAMBLARE

   Activitatea Sectiei Asamblare este fabricarea de:

  • componentelor de zircaloy pentru fascicul;
  • elemente combustibile;
  • fascicule combustibile tip CANDU.

Principalele activităţi ale sectiei Asamblare sunt:

  • IMG_2243asigura fabricarea componentelor din zircaloy pentru fascicul, elemente combustibile si fascicule combustibile tip CANDU;
  • utilizeaza integral tehnologiile de procesare stabilite prin documentatia de fabricatie;
  • pastreaza controlul materialului pe tot fluxul de fabricatie si in spatiile de depozitare;
  • initiaza si aplica actiuni de optimizare a proceselor tehnologice individuale si a fluxului tehnologic in asamblu
  • participa in echipa la analiza stadiului realizarii productiei fizice si a obiectivelor de calitate.
 

Sectia mecano-energetica utilitati

  • Executa lucrari specifice de mentenanta preventiva si corectiva, asigurand functionarea la parametrii proiectati a   echipamentelor de pe linia de fabricatie, reducand timpii de stationare
  • Produce si distribuie utilitatile necesare fluxului de fabricatie combustibil nuclear (hidrogen, azot, aer comprimat, apa demineralizata, apa de racire)
  • Exploateaza sistemele de ventilatie in scopul asigurarii unui climat corespunzator in halele de fabricatie, concomitent cu diminuarea noxelor evacuate in atmosfera
  • Asigura alimentarea cu energie electrica si termica, apa potabila si de incendiu a echipamentelor si a cladirilor FCN
  • Executa si reconditioneaza SDV-urile utilizate la echipamentele de facbricatie a combustibilului nuclear

 

Sectia inginerie

Obiective:

  • Elaboreaza documentatia de fabricatie combustibil CANDU;
  • Recomanda strategiile de optimizare a eficientei fabricatiei;
  • Recomanda strategiile privind noile investitii de echipamente, SDV-uri;
  • Stabileste cerintele de instruire personal de fabricatie;
  • Dezvolta tehnologii de fabricatie pentru comenzi speciale sau contracte de cercetare;
  • Monitorizeaza performanta proceselor sistemului de management integrat din aria de responsabilitate.

Sectia Inginerie este formataIMG_2261 din următoarele colective:

Colectiv Inginerie Proces:

  • elaboreaza si actualizeaza documentatia de inginerie (proceduri de operare si de fabricatie, proceduri de reparare/refacere, etc)
  • analizeaza si actualizeaza desenele de executie pentru componente si fascicul combustibil;
  • urmareste permanent performanta echipamentelor si SDV-urilor;
  • califica procesele de fabricatie;
  • stabileste cerinte de instruire si calificare/autorizare a operatorilor de fabricatie;
  • propune programe de mentenanta preventiva;
  • analizeaza evolutia proceselor de fabricatie;
  • participa la actiuni de evaluare, selectare si calificare a furnizorilor;
  • stabileste consumuri specifice de materii prime, SDV-uri, piese de schimb.

Colectiv Inginerie Echipamente:

  • elaboreaza proceduri de punere în functiune pentru echipamente de fabricatie;
  • stabileste cerintele referitoare la utilitatile necesare exploatarii echipamentelor;
  • participa la instruirea personalului operator;
  • asigura asistenta tehnicapentru stabilirea si corectarea defectiunilor echipamentelor;
  • stabileste necesarul de automate programabile utilizate pe echipamente si elaboreaza documentatia aferenta;
  • identifica necesarul de echipamente pentru cerintele de productie;
  • acţioneaza ca resursa tehnica pentru serviciile de intretinere.

Colectiv Proiectare: 

  • elaboreaza si ţine sub control desene pentru echipamente si SDV-uri;
  • elaboreaza pe baza cerintelor ingineriei de proces, desenele de executie pentru fascicul combustibil si componente;
  • asigura asistenta tehnica la executia, punerea în functiune si exploatarea echipamentelor si SDV-urilor;
  • participa la programele de dezvoltare a tehnologiilor de fabricatie.

Structure:

  • Quality Control Service;
  • Quality Management Service.

 

Quality Control Service

According to the Management Manual, the Quality Control Service is made up of five control laboratories and represents the control authority in FCN for the control of raw materials, materials, components and the finished product. The SCC laboratories carry out specific control, measurement and monitoring activities as follows:

 

Chemical Analysis Laboratory:

  • UO2 powder reception control;
  • final control UO2 pills;
  • analysis of helium and hydrogen content in fuel elements;
  • analysis of beryllium content in aerosols;
  • analyzes of uranium content in sludges, mud waters.

 Pill Dimensional Control and Metallography Laboratory:

  • process/final dimensional and visual control UO2 pills;
  • metallographic assessment of brazed joints, beryllium deposition, butt-sheath welding;
  • ceramographic evaluation of UO2 sintered pellets

 Dimensional Control Laboratory Highlights Zy-4 and FC:

  • process/final control benchmarks: appendages, sheaths, plugs, fuel elements, grids;
  • final control of fuel bundles.

 Control Methods and Metrology Laboratory

Engineering control methods:

  • elaboration of technical documentation necessary for product measurement and monitoring activities (Quality Plan, Quality Control Instructions, Measurement and Control Methods);
  • identification of needs for the development and modernization of the necessary infrastructure in product measurement and monitoring activities (control equipment, materials, etc.), definition and provision of the requirements necessary for their procurement;
  • elaboration and implementation of plans for putting new equipment into operation and qualification of control methods.

Metrological checks:

  • gauges and devices;
  • in the pressure field (manometers, manovacuumometers, pressure switches, pressure transducers, vacuum gauges, vacuum indicators);
  • in the field of temperatures (thermoresistors, thermocouples, thermocouple thermometers, thermostatic baths, ovens, calcination furnaces);
  • indicators and recorders with different input signals;
  • in the field of lengths (comparator watch, micrometers and micrometric heads, displacement transducers).

 Materials and SDVs Control Laboratory

  • reception control Zy-4: bar, tubes, board;
  • reception control SDVs and purchased spare parts
  • quality control reconditioned SDVs
  • Fuel beam autoclaving test.

 

Organization of the Quality Management Service

The Quality Management Service consists of the group that designs and develops the Quality Management System and performs the independent evaluation of the FCN Integrated Management System and the Document Control and Archiving Department.

The main activities :

  • The design and development of a Quality Management System in accordance with the requirements of the Quality Management Norms issued by CNCAN and the reference standard SR EN ISO 9001:2008;
  • The independent evaluation, on behalf of the management, to ensure :

– determining the effectiveness of the management system in obtaining satisfactory performances;

– product quality supervision;

– promoting improvement measures;

– evaluation of the fulfillment of CNCAN’s regulatory requirements. 

The independent evaluation is carried out in a planned manner through internal audits at suppliers, document analysis, inspections, supervision and other similar methods (checking at mandatory parking points, participation in reception committees, etc.).

  • Keeping under control the documents of the FCN Integrated Management System and the quality records, in accordance with the requirements of the rules and standards applicable in the FCN.
  • Keeping in archival conditions the quality records associated with nuclear fuel.

Limits of competence and authority

Through the organizational chart, the Quality Management Service is assured of independence of action and a level of reporting that is not subordinated to the interests of cost and quantity.

In accordance with the Management Manual, the Quality Management Service is invested with the authority of  :

  • Execution for the design, development, maintenance and continuous improvement of the Quality Management System in particular and the Integrated Management System in general;
  • Control, through audit and supervision, to verify the implementation and maintenance of the Quality Management System and through audit to evaluate the effectiveness of the Integrated Management System.

The staff of   the Quality Management Service is trained and certified in accordance with the requirements of the applicable management norms and standards. 

Objectives in the field of safety and health at work for the year 2014

Quality Management Department consits of:

  • Department of Quality Control;
  • Service of quality management.

Department of Quality Control

In compliance with the Quality Manual, the Quality Management Department is made up offivecontrol laboratories and represents FCN’s control authority for raw materials, materials, components and finished products.The laboratories within the Quality Management Department perform specific control, measuring and monitoring activities as follows:

 

Chemical Analyses Laboratory:

  • Feldioara UO2 powder reception control;
  • UO2 pellets final control;
  • helium, hydrogen, beryllium content analyses;
  • sludge uranium content, residual waters, incinerator ash content analyses.

Dimensional Control of Pellets and Metallography Laboratory:

  • UO2 pellets dimension and visual control;
  • metallographic evaluation of brazed joints, beryllium deposition, end cap-sheath welding;
  • ceramographic evaluation of UO2 sinterized pellets.

Dimensional Control of landmarks Zy-4 and FB Laboratory :

  • process control/components final control: spacers, sheaths, end caps, fuel elements, end plates;
  • fuel bundles ultimate control.

 Metrology Laboratory:

Metrological check tests:

  • calibers and calibrating devices
  • pressure devices (manometers, compound gauges, pressure switches, pressure transducers, vacuum gauges, vacuum indicators);
  • temperature device (thermocouples, thermocouple thermometers, electric resistance pyrometers, thermostatic baths, ovens, calcinators);
  • indicators, detectors and recording instruments having various input signals;
  • length devices (dial gauge, motion transducers).

 Control Materials and TDV’s Laboratory

  • Zy-4 reception control: bar, tubes, sheet;
  • TDV reception control and spare parts purchased
  • reconditioned TDV quality control
  • Autoclaving test fuel bundle.

 Service of quality management.

Organization

The Quality Management is made up of the Supervision Group and Documents Control Department.

 Main activities:

Elaboration of specific documents (procedures, reports) and analysis of documents (procedures, plans, reports, etc.) elaborated by FCN departments, in compliance with CNCAN’s Norms applicable to the activity profile, elaboration of SR EN ISO 9001, SR EN ISO 14001 standards and of the OHSAS 18001 specification.

Surveillance of the nuclear fuel fabrication by continuously evaluating and analyzing the processes, registrations, procedures and by confirming the fact that the activities meet the specific requirements.

The internal auditing of the implementation method of the requirements set out in the documents of the management system developed and implemented in FCN.

Implementation of FCN documents control system set out by internal procedures, in compliance with the requirements of the norms and standards applicable in FCN.

Archiving of the proper records related to nuclear fuel.

 Competence and authority

In compliance with the organization chart, the Quality Management and Audit Department (QMAD) is independent to take the steps it considers necessary and is not controlled by the cost and quantity interests.

According to the documents of the management system developed and implemented in FCN, the Quality Management and Audit Department is invested with the authority of:

  • maintaining and permanently improving the Quality Management System especially, and the Integrated Management System generally
  • controlling, through audit and surveillance for checking the implementation and maintaining of the Quality Management System and the Environment Management System and through audit for checking the implementation of the Integrated Management System (IMS).

 The staff within QMAD is trained, qualified and certified in compliance with the requirements set out in the management applicable norms and standards.