International Conference on Research Reactors:
Safe Management and Effective Utilization

14-18 November 2011, Rabat, Morocco

In SAFARI-1 the rigorous maintenance programme, effective implementation of Structures, Systems and Components (SSC) upgrades since 1996 and well defined operational programmes have resulted in that the 20 MW reactor has operated for 1 million MWh in the last 7 years and in October 2010 surpassed the 3 million MWh mark [1]. Challenges to achieve this included replacement of skills lost through resignation and retirement, full utilization of reactor for the production of isotopes, changing operation from Monday to Friday to 24 hours - 7 days a week and planning all maintenance and upgrade tasks within the ten 5 days and one long 12 days shut downs annually. These challenges were met by changing the personnel culture and applying effective management measures. With a decreasing number of unscheduled reactor shut downs the operation days at 20 MW have increased over the last 20 years and are currently over 302 days per annum. This success can be ascribed to the ongoing upgrades and the maintenance programme which are executed by well experienced personnel, good infrastructure and support on the Necsa site at Pelindaba, in-house mechanical machining capability and a mechanical manufacturing facility at Pelindaba accredited to ASME VIII and recently to ASME III. Much experience has been gained and lessons learnt from some upgrade projects and failures of SSCs. These experiences are exchanged in annual meetings with the two sister reactors: HFR in the Netherlands and OPAL in Australia. The maintenance programme is implemented through a mature and well developed Integrated Management System (IMS) which covers Quality, Health, Safety and Environment (QHSE), nuclear material safeguards and physical security systems. The IMS is supported by a Necsa wide SEQH system which is applicable to all nuclear facilities (e.g., front and back end of the nuclear fuel cycle, SAFARI-1, nuclear waste, hot cells and laboratories) and complies with the requirements of the National Nuclear Regulator (NNR), international standards and relevant IAEA safety standards and documents. To ensure continued reliable reactor operation an ageing management programme was developed in 2010 in accordance with IAEA Guideline SSG-10 [2]. With the systematic methodology used not only were 18 ageing management projects, but also 38 development and upgrade projects as well as 24 maintenance projects identified for implementation over a 5 year period. This will enable that the SAFARI-1 operational life may be extended to 2030 and beyond. SAFARI-1 has a good safety record over its operational history. A Behaviour Based Safety (BBS) programme was implemented in 2003 which has resulted in that the total injury rate has been steadily decreasing. The ALARA and BBS programmes together with management commitment have been driving the safety culture in the reactor. In order to ensure safe reactor operation various IAEA safety standards, guides, TECDOCs and the Code of Conduct are applied and implemented.

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