ML20024C856

Reliability Sys Engineering Program Plan Safety Assurance & Failure Elimination, Draft Rept of Differing Prof Opinion

ML20024C856
Person / Time
Issue date:	06/30/1983
From:	Lakner A NRC OFFICE OF NUCLEAR REGULATORY RESEARCH (RES)
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ML20024C857	List: ML20024C856 ML20024E421
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NUDOCS 8307180352
Download: ML20024C856 (24)

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CRAFT RELIABILITY SYSTdG E!GI!EERI!G PROGDAM PULN SAFETY ASSURA!CE & FAILURE ELIMINATIO!! (SAFE)

DIVISION 7 RISK ANALYSIS (PROFOSED)

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A. 'AND A. LAKNER V

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PREACE A Reliability Systems Ergineering Progran has been initiated by this office to achieve l'RC's objective of supporting the lac recently published safety goals, the one step

- licensing process to assuring plant safety and systems reliability in light of the Salem ATWS event. Bis program, entitled " Safety Asstrance and Failu e Elimination (SAFE)" is a ecmprehensive, multidisciplina~y effort, aimed at the earliest possible elimination of obscure or hidden hardwe or procedural deficiencies missed by other techniques such as the probabilistic risk assesment (FRA), QA/QC and surveillance testing. It adopts a preventive approach to safety and reliability assurece by stressing renedial attention at the conceptual and design stages of plant developnent.

The entire process is structured in a life-cycle cost context to provide a firm basis for cost effective decision making. The program gains a great deal of momentum through its orientation toward the adaptation of existing reliability managenent and engineering practice fran other high technology fields. Be implementation of this program plan will decrease the nunber of accident sequences and daninant failure contributcrs as identified by the current PRA efforts.

This plan describes the " SAFE" Program as it is currently perceived, with the expectation that it will be an evolutionary docucent. In defining sn initial approach to implementation it presents the prograns basic Irovisions in sane detail together with a time table for achievenent. The plan is intended to serve as an internal

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management guide, or " road map" for the developnent and timely implenentation of a practical plant safety assurance progran. In meeting that objective, it offers a systematic approach to reliability engineering which is fully in accord with tac 7

policy.

The plan sets forth tasks and procedures,to support and assist ' the licensing process and to aid in the cost effective achievenent of safety goals.

Included in this document are descriptions of several on-going and p1mned research effcets which tcken together lead to: -

(1) The developnent of an overall methodology for " SAFE' based on

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probability-risk analysis (PRA), plant availability analysis techniques, life-cycle cost analysis and proven reliability systens l

engineering practice, i

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(2) 'IM 6:vele;rrent of handreks for mnagemnt planning and fcr icplecentatico of the SEE mt.%birgy.

(3). Ihe perrcem,ce of cowing engineering tasks to assess, control l

t and i. prove systa reliability, as a mans of assuring the safety i

of new nuclear pNer plants and the mintenance and inprovement of l

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safety levels in units already in operatico.

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TABLE OF CONTENTS i

FiEFACE 1.0 I!.TiODJCTION

1.1 Background

1.2 Objectives and Discursion 1.3 Purpere cf S.UE 2.0 ?!,JOR PPcI?AM MILESTONES

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3.0 :;RC RESEAECH FRIFA'S 3.1 Reliability Prog-am Survey / Evaluation (Program A); (an NRR

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program executed by USAF)

I 3.2 Reliability Arsurance Prcgram (RAP) (Program B) 3.3 special Reliability and Maintainability Techniques (SMART)

. (Pmgram C) 3.4 SAFE.v.ethodology (Program D) 3.5 SAFE Planning Handbook Guideline (Program E) 3.6 SAFE Iglemntation Handbeck Guideline (Program F) 4.0 PROGFAM.vA'!AGDENT AND IMPLEMENTATION 1

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1.0 IErOETION 1.1 Backs;reuM Re need for a safety-oriented reliability systems engineering program for the nuclear industry has been expressed by the NRC in NUREG-0660, "NRC Action Plan Developed as a Result of the TMI-2 Accident," August 1930. The IEEE/NRC-spcosored

'Arking Conference on Advarx:e Electrotechnology Applicatien to NPP Report, January 1980, also made specific recommendations to the nuclear industry fcr the iglenentation of an aerospace oriented reliability program. Supporting research to meet this need is outlined in 02 apter 10 of the Leng Range Research Plan FY 1983-1987, h"JREU-Ul40, March 1981. Accordingly, the basic objective of reliability research is to bring nuclear regulation into better congruence with the risks; that is, to identify and close gaps in regulatory requirements in risk-significant areas, to identify instances of off-target or unnecessary regulations, and ultimately to stabilize the licensing precess.

1.2 Objectives and Discussion he Safety Assurance and Failure Elimination (SAFE) Prtgram will accertplish the above objective; additionally, it will provide supplemental assurance that the required safety goals have been attained and unintained during the life of the nuclear pcwer plant in a cost effective manner.

The SAFE program is in support of the NRC recently published safety goals, the coe step licensing process, and the Severe Accident Research Plan (SARP). SAFE is a comprehensive, prevention oriented, cultidisciplinary effort, aimed at the earliest possible elimination of obscure or hidden hardware and/or operation procedural deficiencies missed by other techniques such as th'e prtbabilistic risk assessment (PRA), CA/QC and surveillance testing.

It adepts a preventive appreach to safety and reliability assurance by stressing remedial attention / action at the cowtual, design and cperational stages of the nuclear plant. The entire process is structured in a life-cycle cost context to provide a finn basis for cost effective decision neking.

The program gains a great deal of momentum through its orientation toward the adaptation of existing reliability :ranagement and engineering practices fYem other high technology fields; it is anticipated that the inplementation of this prcgram will decrease the number of accident sequences and dominant failure contributors as 1

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idwtified by the current PEA effcets.

By and large, it has been proven in large procuremnts of emplex weapco and space syste:s that it is cost effective to design reliability in % front." To this end, the purpose of this program is to criginate or transfer acceptable rmthMologies aM techniques to the ruclear arena that will cost effectively achieve the desired level of safety / reliability goals, concomitantly meeting the preestablished cost cffectiveres criteria, Figure 1-1 illustrates vividly this point.

f TotalLifeCyJe Cost Acquisition Cet Cost due to Downtime and M in+=a= (Unreliability)

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Reliability / Availability Optimum Rehability/ Availability level Figure 1-1 Cost Effective System Design d

The same principle of cost effectiveness has been proven by applying this approach to the operational phase of a cceplex hardse system.

Be SAFE pregram elements are closely interwoven with quality assurance (QA) activities as well as probabilistic risk assessmnt (PRA) efforts; ence the intrinsic reliability has been attained and the reliability design grMJ1 has been adieved, the PRA will determine quantitatively the risk involved, and in the process identify dardnant failure contributors.

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. The SAFE program will fulfill NRC safety goals through a unified program of standardized requirements, procedures, and criteria for designing, analyzing, comparing, and auditing the safety and reliability of ruclear plants as well as the 2

application of relisbility engineering techniques when ecrtined with PRA resulting in a esst. effective safety mna2e ent systet. Tne SAFE program will provide additional assurance that the system availability and safety in the nuclear power generating plants are augrented to an " acceptable" level and it will assist in expediting the decision process in licensing. It's purpose is not to define what an acceptable level cf reliability or risk is, but to outline a disciplined, methodical, systematic as well as ecst effective approach to a reasonable and iglementable reliability system engineering program for NRC and the applicant / licensees. The SAFE program will culminate by having NRC issue a series of guidelines addressed to the NRC staff and the nuclear industry. Figure 1-2 illustrates the total prog am approach.

GENSBAfs P E R PO R M PROCEDURAL QUIDES EPOINEERING TASES e DEVELOP NEW 03 SAFt METHODettGY SEPLACEMENT SYSTEMS

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9 RESEABCS PLANS Aggggg PLANT N U R 8 0-0 e e e 1EL1A3iLITi e RANDB00E0 SYSTEMS 4--- o-IN OPER ATING PLANTS A

1B AINING Figure 1-2 NRC's Reliability Prt5 ram Approach: Safety Assurance and Failune Elimination (SAE) 1.3 Pumsse of SAE The implementation of SAFE throughout the life of the NPP is an assurance to NRC that the plant will attain and sustain cost effectively a required safety level.

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Additienally, the SAFE programyill assess the feasibility of replacenent of or supplemnt to the current regulatory requirements. Furthermore, SAFE will it; prove / remedy the problems identified by PRA and it will also streamline the licensing process. Aerospace, weapons, and electronics industry practices in reliability engineering offer a very prtxt.ising nedel of hcw nuclear safety &uld be achieved and verified without many of the shortcomings of the current regulatory process. There is a limited exa ple (the FAA) of the adaptatico of these practices to the regalatory arena. Hcwever, there reliability managemnt practices have not been effectively adapted to the unique requiremnts and ecostraints of exmercial nuclear

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reactor safety. A substantial research effort is required to determine the feasibility of further adaptation and to delineate procedures for nuclear safety regulati:n alecg the lines of reliability managment systas.

The specific objectives of SAFE are:

(1) To quantify plant systems reliability levels, provide input data to PRA as well as pinpoint trtuble spots, cenfirming PRA findings.

1 (2) Suppcrt CC/QA possible redefinitico by NRC and reduce the likelihood of C7 ccosequences.

(3) Pmvide faC an auditable mechanism to verify that the licenseas are doing a. satisfactory job in inmring public health and safety.

(4) Identif'yblindandobscurespots,undeteethibyothertechniques,and periodic updating of PRA results by renitoring critical PRA assmptico items.

(5) To cenplenent CA and pmvide a disciplined approach to nulti-disciplinary systens engineering in the design of nuclear plants, the developrent of startup test procedures, the developcent of cperating rnintenance and emergency procedures and in cperations.

(6) Culminate with the developnent of handbook / specification for acceptable reliability assurance progrm:s to be implemented by operating licensee holders, constructi:n permit holders, a'd fbture construction permit applicants.

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(7) Stutj, assess and make recETendations regarding the current interface problems areng suppliers, the RSSS, the A/E and the curer.

The SAFE Program is organized to facilitate the selective transfer of REA and other high technology systems reliability analysis techniques and practice to nuclear power plant systems, focusing particularly on the reliability / quality assurance asp <rts.

In structuring the SAFE program, prime consideration has been given to ensuring plant safety by selecting and specifying program elemnts that can be applied as individual tasks or in sequence with other tasks to ensure safety function availability. These elements as they are planned and applied during a systems l

life-eyele will help in meting requirements (both quantitative and qualitative) for l

ensuring design integrity, maintaining component availability, preventing a ufacturing errors, preventing installation errors, ensuring proper operating and maintenance procedures, controlling system configuration, providing feedback from cperating experience and conducting personnel training. Figure 1-3 depicts this stnacture.

In addition the SAFE program will be continually monitored to assess its effectiveness and benefits including:

1.

The ability or limitation of the SAFE program in providing assurance that safety / reliability goals are attained and sustained.-

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'Ihe cost effectiveness of the SAFE program when coupled with the revision of the current licensing process for both the NRC and licensees.

3. Le cost of SAFE program 1::ple:rentation during the conceptual design as well as operational phases.

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'Ihe usefb1 ness and applicability of SAFE when ecrrbined with PRA as l

a safety renagement system during the plant life cycle.

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2.0.GJDR PiOGRN MIIISimES Figure 2-1 &picts the ma,br milestcoes fcr the develo;mmt and irrplementation of the SAFE program.

1981 1982 Initiate Reliability Develop SAFE Research Program Progrem Plan

• 1985 - 1987 1984 1983 e Establishment of Preparation of Implementation e

e and Fcllovup SAFE Planning Reliability Assu-Handbook; rance Program Training of NRC 4

Program E (RAP); Program B e

and Utility Preparation of e Development of Personnel e

SAFE Implemen-Special M&R Tech-tation Hand-niques (SMART);

book; Program F Program C e Development of SAFE Methodology; Program D Figure 2-1 SAFE Prq; ram Pdlestcoes Mote: Prqsram A, originated by the USAF, RADC, Entitled Reliability Survey.

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3.0 l E FIZEARCH PR33?feG Figure 3-1 depicts !K's plan to develcp the everall " SAFE" prcgram and outlines the research pro 6 ram that are being carried out to develcp the everall methodology, and to prepare necessary doeurentation including planning and inplecentation handbooks that would assure its irpleaentaticr2 on an on-going basis.

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Figure 3-1 IK Safety Assurance & Failure Elimination " SAFE" Program Included are several intimately interrelated, tutually ' supportive research programs specifically structured to support the development of the " SAFE" program. 'Ihese research prcgra.e will provide:

lhe identification of plant system to be affected by " SAFE", their e

1 pact of safety as detennined fran safety and risk analyses, and the relevant cu rent regulato"y requirements and their reans of 1::plecentation, so as to ultimately provide a safety and reliability needs and requirements classification for all plant system.

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o An aeross/ discipline assessmnt of state-cf-the-art "i',FE" approaches and associatc3 mthods for ect;.arison with current regulatory practice and identified needs, o The developmnt of procedures for systematically allocating "SArT" requiremnts based on infennatial on risk precursors fran PRAs.

o The inte6 ration of the above into a total progam applicable to all phases of a nuclear plant fran conceptual design through cperation. "Ihis includes the establish ent of boile plate statements of work (SCW) for defining consistent requiremnts for the manufac-ture, intcgration, and operaticn of nuclear plant systems.

o Demrstration studies of the progam.

o Preparation of "SXE" plarning and inplemntation handbooks.

o Procedures for integrating the program with the current regulatory requirenents, which stress a clear treatment of the organizational interfaces that can affect eccpliance and the handling of noncompliance.

As shown in figure 3-1, the following six separate research programs are planned:

Program A (RADC) is to identify all applicable reliability elenents.

Program B (ANL) is to develop (& validate) those reliability elemnts that can be readily transferred (Fran A).

Program C (SMART) is to research those 9 ement/mthods that 1

need fbrther developent for nuclear application (Fran A & B).

Program D (For::ulation of " SAFE" Methodology) is to include results of Programs B & C plus effort to tailor current PRA, plant availability & LCC methods to fit the

" SAFE" methodology.

o Program E (Planning Handbook) is to provide reliability design guidelines and engineering procedures for new systems / equipment (in new plants, or in plants under construction or for replacement for systems / equipment in operating plants).

Program F (Irplementation Handbook) is to provide criteria a.x!

proceoures to assess / audit the safety reliability of existing t

systems / equipment in operating plants.

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These programs are fbrther descrited in the following pararaphs.

3.1 Feliability Prcgram SurveyEvaluation (Program A); (an 11RP rregram executed by USAF)

Objective The objective of this effort is to survey the nuclear and non-nuclear fields and assess the extent of reliability as a discipline as applied currently to hardware systems; secondary objective being the origination of a Reliability Program Outline suggested for liRC use. Figure 3-2 depicts pregam detail and schedule.

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Daliverables Reports containing information and data relative to the objectives outlined above.

Utili: ation The information generated by this program will be applied in the execution of pres-ams "B", "C" and the for:ulation of SAFE mthodolcgy (Progra:n D).

3.2 Relisbility Assurance Program (RAF) (Program B)

Objective The objective of this ALS oriented research reliability assu-ance effort is to develop and inplement a pro 5 ram for the purpose of determining the feasibility and 1

cost effectiveness of an aerospace proven reliability concept for reactor risk limitation effectiveness as a regulatory option.

Proven the feasibility and cost effectiveness of RAP, the industry will benefit by attaining predetermined reliability design goals, improved plant operational features and an effective method to pinpoint weak system elements. The flRC will derive docrented and auditable results to assure ittelf that safety goals have been attained and plant anomalous behavior minimized to an acceptable risk level.

The pro 6 ram consists of two phases. The first to be completed by the end of FY 1983, will focus on development of a pilot program limited to add essing probleras associated with anticipated transients without scram (ALS). A cultidisciplinary team consisting of individuals from the nuclear, aerospace, electronics, and other industries will work in cooperation with a volunteer utility to develop a. program to minimize surprises caused by design errors, blind spots in surveillance testing, errors in test and maintenance, and the conduct of various plant operations and eyolutions.

The program will incorporate time-tested procedures for quality / reliability assurance and quality control from other industries that can be atpted to nuclear plants and by utilizing information generated by program A.

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Additionally, the program will appraise the safety needs of ATa3 related systs:s i

that.ust te factored into the reliability assurance program (RAP) vis-a-vis the cu-rent reCJ15tGry TequirOCents. figure 3.3 depicts prog c.m detail and schedule.

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Industry Techniques 1

Figure 3-3 Prcgram B Reliability Assurance Program (PAP) 4 f

I Deliverables A report containing matrices of functional, safety, reliability, risk l

e criteria and associated regulatory or supporting documents.

e Ccceise descriptions of current regulatory attributes for ATa5 related systems.

Utilization 4

The information generated by this program will be applied in the (a) execution

- and fo.wlation of SAFE methodology considering current reEulatory requirements, and 12

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3.3 Spacial Maintainability and feliability Technicues (SGRT) Prorram C)

Objective The SAFE methodology will incorporate proven life-cycle reliability ::etheds and practices as well as those techniques considered unique to the industry.

The objective of this research pmgram is to investigate, adapt and rodify those unique or special reliability and maintainability techniques to meet the needs of the nuclear industry and NRC and to reflect the characterirties of nuclear rystems, corponents and their potential failure modes and long term plant environmental factors. This research will be guided by the results of the su-vey and evaluation of reliability prcgram elesents and practices in the nuclear ar.d non-nuclea'- field performed as part of research pro 5 ram A.

he techniques developed during this research p-ogram will be evaluated and feasibility demonstrated by application to the specific plant and reference systems identified during research preg-am B.

Figure 3-4 depicts program details and cchedule.

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Procedures figure 3-.4 Program C Special ';aintaimbility & Reliability Techniques (SHART) l 13 1

Deliverables A su r.ry of component selection criteria and s;>ecification/ control e

nethcds applied by the nuclear industr/ including a eccpariscri of current ecrponent reliability levels (on a selected system (s)) to systan and plant safety needs, A su~rary of alternative special reliability engir.eering nethods and e

practices.

Utilization Tne results of this effort will be used to support the develepcent of the SAFE methodology and specific outputs will be incorporated into the subsequent Planning and Inplenentation Procedures Handbooks, Programs E and F respectively. This research effort will also utilize results from Progam A.

' 3.4 SAFE FE~110DOLOGY (Program D)

Objectives

'Ihe results of the preceding research prograr.s plus other effort's to tailor current PRA, plant availability and LCC methods to meet SAFE objectives will be integrated into an overall nethodology. Initial efferts will include evaluating the effectiveness of present day reliability practice as defined by Program A.

This will involve assessing the benefits of the various reliability techniques based on actual experience factors as well as detemining and validating their applicability to the nuclear industry. Those techniques detemined to tie effective will be re-oriented for the purpose of determining an appropriate methodology for SAFE in view of the interrelationships between PRA, reliability, maintainability, LCC and plant availability. An output of this effort is the establishment of SAFE interface requirements from which specific implementable analysis methods will be derived.

Figure 3-5 depicts progran detail and schedule.

Deliverables SAFE inplementation requirenents report (preliminary) e 14 ll

'i u

Fro;;aa elccent effectiveness report e

Interface require ents report e

Definition of SAFE sccpe and rethodology e

Utilization The results of this program will be directly ulitized in the preparation of planning and isplerentation handbooks described in the parag"aphs wnich follcw as well as in the ecnduct of cn-going engineering tasks and analysis to ensure and raintain safety Ibnetion availability consistent with plant safety levels.

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Figure 3-5 Program D SAFE Pethodology 3.5 SAFE Planning Handbook Guideline (Program E )

Objective As a result of programs A, B, C and D previously outlined, a reliability planning handbook will be originated utilizing the application of SAFE methodology. The handbook will be used by the CP licensees, AK, NSSS vendors, and NRC. It will reflect reliability criteria and procedures for the application of reliability 15 o

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engineering practices to nuclear plant activities on a emprehensive and ccr. sister.t basis. The industry will apply tiiis handbook developed by NRC for acceptable and available reliability assurance pregams. Figure 3-6 depicts the handboek outline and schei>1e.

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Figure 3-6 Program E Reliability Planning Handbook Deliverables This effort will culminate with the production of a handbook meeting the scope of theobjective.

I Utilization t

f The NRC, as well as the industry, will utilize this hanctcok; NRC will apply it as a licensing criteria, the industry will use it in the planning activity of L

reliability program during the design phase.

16 e-

3.6 SAFE I@le entation Handtock Guideline (Proaram F)

Cbjective As a result of programs A, B, C and D previously outlined, a reliability inplemenation handbook will be originated utilizing the application of SAFE methodology. The handbook will be used by pri:arily the CL licensees and NRC. The licensees will apply the SAFE methodology in the operation, maintenance, and centinuous plant reevaluation efforts throu@ cut the life of the plant. Figare 3-7 d?picts the handbcok cutline and schedule.

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'Ihis effort will cul:rinate with the production of a handbock meting the secpe of the objective.

Utilization The !JRC, as well as the inintry, will utilize this handbook; !;EC will apply it as licensing criteria, the industry will use it in the implementation activity of reliability program daring the life of the plant.

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1e 4.0 Pf0]?JJ4 MA'lA2 err A!!D IFPLEGiTATION Planning and implementation of the SAFE program will be guided by a culti-representative Steering Ccamittee with representative members from industry, flRC, professicnal societies and other goverment agencies. Advice and direction from the Steering Ccmittee will be executed by several technical assistance organizations es depicted in Figure 3-1.

5.0 TRAINItc A training program will be originated for the purpose of NRC personnel indoctrination in the SAFE methodology and its implemenation. The program will be designed by the research group, its inplementation, however, will be performed by the fiRC training team in Chattanooga, Tennessee.

6 ' SCHEDULE 4

Figure 6.1 depicts the schedule for completing each of the SAFE research tasks described in Section 4.0.

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Figure 6-1 SAFE Program Schedule 20 l

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