ML20127B776
| ML20127B776 | |
| Person / Time | |
|---|---|
| Issue date: | 06/12/1984 |
| From: | Russell W Office of Nuclear Reactor Regulation |
| To: | Harold Denton Office of Nuclear Reactor Regulation |
| Shared Package | |
| ML20127B779 | List: |
| References | |
| FOIA-85-63 NUDOCS 8406270037 | |
| Download: ML20127B776 (11) | |
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- 'o, UNITED STATES '
!' ..gi NUCLEAR REGULATORY COMMISSION
,, ,. E WASHINGTON. D. C. 20555
%, Af 8 June 12,1984 MEMORANDUM FOR: Harold R. Denton, Director Office of Nuclear Reactor Regulation j THRU: Hugh L. Thompson, Jr. , Director Division of Human Factors Safety, NRR FROM: William T. Russell, Deputy Director Division of Human Factors Safety, NRR
SUBJECT:
REPORT OF TRIP TO JAPAN REGARDING NUCLEAR POWER PLANT MAINTENANCE PRACTICES Between November 28, 1983 and December 9, 1983, meetings were held in Japan with the Japanese Ministry of International Trade and Industry (MITI), the Japanese Science and Technology Agency (STA), the Japanese Atomic Industrial Forum, (JAIF), Kyushu Electric Power Company (KEPCO), Tokyo Electric Power Company (TEPCO), Power Reactor and Nuclear Fuel Development Corporation, Mitsubishi Heavy Industries, Ltd., and Hitachi Ltd. Site visits were made to Genkai Nuclear Power Station, Fukushima-Daini Nuclear Power Station, Mitsubishi's Kobe Shipyard and Engine Works and the Hitachi Works.
The purpose of the meetings and site visits was to gain a better under-standing of. the Japanese approach to nuclear power plant maintenance and the -
reasons for their recent excellent operating experience.
I was accompanied on this trip by Dr. Richard Badalamente Battelle's Pacific Northwest Laboratory l
Mr. Mike Morgenstern Battelle's Human Affairs Research Center, Seattle Mr. Tenro Yagi Battelle's Human Affairs Research Center, Tokyo Much of the success of this trip is a direct result of the excellent cooperation of the involved Japanese officials, the background work done by JAIF, PNL and HARC and the excellent support by the Office of International Programs. Schedules for plant visits and appointments with utilities, vendors and government officials were coordinated by llr. A. Yamaguchi (JAIF).
Questions and discussion subjects were prepared, translated to Japanese ard forwarded well in advance of the trip.
Personnel contacted during the trip are identified in Enclosure 1. Extensive F
documentation of Japanese maintenance planning, implementation, regulations and procedures were obtained. I also obtained written confirmation with
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- t facts on the low scram and forced outage rate. In 1982 for 24 o erating reac the total number of forced outages was 9 and only A v?co3 N 3,
n Harold R. Denton June 12, 1984 7 automatic scrams occurred. These documents are listed in Enclosures 2 and 3. Enclosure 4 is my joint trip report with PNL. The report follows the outline of the oral presentations I have made to ACRS, AE0D EDO, IE, NRR, and RES staffs. Copies of the VuGraphs used in these presentations are attached as Enclosure 5. I agreed to obtain MITI review and approval prior to public release of Enclosure 4 or 5.
Plant maintenance personnel and plant management were very willing to discuss and provide detailed information and MITI was extremely cooperative. In l
fact, MITI proposed direct coordination between their contractor and PNL/HARC to better understand the differences between U.S. and Japanese approaches to Surveillance Testing and Preventive Maintenance. MITI has also agreed to review and coment on our analysis of the documents provided by the
, utilities. Mr. T. Taniguchi (MITI) suggested a return visit for September or October 1984 as a follow-up on these activities. He indicated that a joint U.S.- Japan effort to study and optimize nuclear power plant preventive maintenance requirements is desirable.
I estimate that 3 1/2 to 4 months of effort are required to complete a draft report on the differences between USA and Japanese preventive maintenance programs. We have contracted with PNL for a detailed comparison of the Genkai program with two comparable U.S. PWRs (Turkey Point 4 and Prairia Island 2) and for a similar comparison of Fukushima-Dafni Unit 1 (LaSalle 1
. and Susquehanna 1). We also obtained detailed operating experience on these Japanese units and the reports of the most recent annual inspection for each
- plant.
Observations In Japan the scope of preventive maintenance activities includes periodic testing, inspection and overhaul. Many, if not most, of the testing and inspection requirements for systems which would be classified as safety related are similar to NRC surveillance requirements. The unique maintenance requirements are for periodic disassembly, overhaul and replacement of components. The schedules are conservatively set to minimize the potential for failure during operation.
The type and schedule for preventive maintenance is based upon the manufacturers recommendation.
i Technical documentation (i.e., manuals with maintenance procedures and recommendations) are procured with the equipment -- TEPC0 provided their standard specification for such documentation.
The utilities develop a 10-year maintenance plan which is submitted to MITI for approval prior to licensing. (Plants are permitted to operate 12 months + 1 month between inspections, thus the 10 year plan is for 10 years oT operation.)
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Harold R. Denton June 12, 1984 Many "open and inspect" items require visual inspection and approval by MITI. MITI inspectors (or 3rd Party Inspectors approved by MITI) can give on-the-spot approval such that the component can be returned to service.
In other cases inspection reports are provided for MITI review.
The magnitude of the preventive maintenance effort is large -- verbal
. estimates on the order of $I2 million not including refueling were provided. Detailed information on staffing and resources were provided by Kyushu Electric Power and are still under review.
MITI and the utilities feel that their successful operation is a direct result of their extensive preventive maintenance progran.
I was frequently asked why U.S. plants scram so freouently and have so many forced outages. I couldn't provide a good answer.
Genkai-1, which started operating in 1975, has only experienced one automatic scram (other than planned testing) over the life of the plant and only two forced outages.
Fukushima-Daini Unit I during its first year of operation operated continuously for over 400 days. (Note: The first year of operation starts after the warranty run such that they were allowed to operate more than 13 months.)
Plant cleanliness and housekeeping at Genkai is better than any plant I have visited in the USA and is comparable to the Swiss units I visited in March 1983 (BEZNAU 1 & 2 and Mullenberg).
Extensive color coding of piping systems, use of flow direction, posted procedures, valve name and numbers end other Job Performance Aids were evident. For example, multi-point recorders used colored ink consistent with color coding of radiation monitor locations on posted charts. Trend analysis was much easier because multiple points could be easily identified. Most U.S. plants use black ink with a black number next to the point.
Diagnostic tools (i.e., vibration monitoring) were used to monitor performance of rotating machinery.
Conclusions The trip was very productive and worthwhile. We obtained substantial detailed information on the Japanese approach to nuclear power plant maintenance and regulation. Firsthand observation of Japanese plants leaos me to the conclusion that there is room for inprovement in many U.S. plants.
The following points are my principal conclusions:
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Harold R. Denton June 12,1984 Japanese plants experience fewer trip and challenges to safety systems I between periodic inspections than U.S. plants experience between planned refueling outages.
Japanese emphasize preventive maintenance to insure high plant reliability and reactor safety Japanese maintenance programs should be evaluated for applicability in the U.S.
.{1)1Ld- - T. ,b - 'W William T. Russel'1, Deputy Director Division of Human Factors Safety Office of Nuclear Reactor Regulation
Enclosures:
- 1. List of Personnel Contacted During Trip to Japan
- 2. Japanese Language Documents Translated by NRC (All Proprietary) 3.EnglishLanguageDocuments(All Proprietary)
- 4. Trip Report: A Review of Japanese Nuclear Power Plant Maintenance, Regulation and Practice
- 5. VuGraphs - Report on Visit to Japan to Review Nuclear Power Plant Maintenance Regulation and Practice ,
cc: E. Case R. Mattson D. Eisenhut R. Vollmer .
T. Speis W. Houston J. Taylor, IE J. Partlow, IE W. J. Di rcks R. Minogue C. J. Heltemes J. LaFleur R. J . B ra dy J. R. Shea
ENCLOSURE (1)
LIST OF PERSONNEL CONTACTED DURING TRIP TO JAPAN November 29, 1983 Gerard F. Helfrich, Counselor for Scientific and Technological Affairs, Embassy of the United States of America Toshiaki Okubo, Energy Liaison Specialist, United States Department of Energy, American Embassy Hideo Uchida, Commissioner, Nuclear Safety Comission Dr. Fumio Amano, Chief Reviewer, Nuclear Safety Bureau, Science and Technology Agency Shinichi Kuroki, Reactor Regulation Division, Nuclear Safety Bureau, Science and Technology Agency Tatsuya Yamauchi, Electric Machinery Section, Heavy Water Reactor Development Project, Power Reactor and Nuclear Fuel Development Corporation Yoshinobu Suzuki, Heavy Water Reactor Development Project, Power Reactor and Nuclear Fuel Development Corporation November 30, 1983 Kazuhisa Mori, Executive Managing Director, Japan Atomic Industrial Forum, Inc.
Akihiko Yamaguchi, Senior Staff, Office of Planning and, International Affairs, Japan Atomic Industrial Forum, Inc.
December 1, 1983 Hideaki Hironaga, Supdrintendent, Genkai Nuclear Power Station, Kyushu Electric Power Co., Inc.
Shojiro Ohta, Kyushu Electric Power Co., Sub-superintendent, Genkai Nuclear Power Station December 2,19p Junzo Kuroboshi, Coordinator, Nuclear Power'Dlant @les Department, MitsubishiHeavyIndustries,Ltd.,KobeShipyardars}EngineWorks H. Higuchi, First Nuclear Plant Section, Nuclear Poder Plant Sales Department, Mitsubishi Heavy Industries, Ltd., Kobe Shipyard and Engine Works Yoshiharu Takahashi, Group Leader, Nuclear Plant Post-Operational Service Engineering Section, Nuclear Plant Construction Department, Mitsubishi Heavy Industries, Ltd., Kobe Shipyard and Engine Works
' Kiyoshi Sasagawa, Deputy Manager, Nuclear Plant Construction Department, Mitsubishi Heavy Industries, Ltd., Kobe Shipyard and Engine Works December 5,1983 and December 9,1983 Tomihiro Taniguchi, Director, Nuclear Power Safety, Administration Division, Agency of Natural Resources and Energy, MITI Sei-Ichi Matsuo, Deputy Director for Technical Affairs of Nuclear Power Safety Administration Division, Public Utilities Department, Agency of Natural Resources and Energy, MITI December 6,1983 Shigemi Sugino, Manager, Nuclear Power Plant Department, Nuclear Power Generation Division. Hitachi, Ltd.
Yoshihiro Abe, Senior Engincer, Business Administration Department, Hitachi Work, Hitachi, Ltd.
Toshihiko Tanikoshi, Department Pfanager, Nuclear Plant Construction, Engineering Department, Hitachi Woris, Hitachi, Ltd.
Tsutomu Hayashi, Manager, Nuclear Equipment Des,ign Department, Hitachi Works, Hitachi, Ltd.
Atsushi Komeno, Deputy Chief Eng1neer, Hitachi Works of Hitachi Ltd.
Masao Miyake, Senior Engineer, Computer Control System Design Department, Omika Works, Hitachi, Ltd.
Masaharu Sakagami, Ph.D., Senior Researcher, Energy Research Laboratory, Hitachi, Ltd.
,Kohyu Fukunishi, Ph.D., Senior Researcher, Energy Research Laboratory, Hitachi, Ltd. ,
December 7, 1983 M. Ogino, Director and Superintendent, Fukushima Daint Nuclear Power Station and Manager. Fukushima Daini Nuclear Power Station Construction Office, The Tokyo Electric Power Co. , Inc.
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Masato Idesawa, Manager, Engineering Division, Engineering Department, Fukushima Daini Nuclear Power Station, The Tokyo Electric Power Co., Inc.
Mamoru Murayama, Deputy Superintendent of Fukushima Daini Nuclear Power Station, The Tokyo Electric Power Co., Inc.
F. Naito, Maintenance Section Manager, Fukushima II, The Tokyo Electric Power Co., Inc.
December 8,1983 Kensuke Fueki, Deputy Manager, Nuclear Power Plant Operation and Maintenance Department, The Tokyo Electric Power Co. , Inc.
Teiji Goto, Manager, Nuclear Power Plant Operation and Maintenance Department, The Tokyo Electric Power Co., Inc.
Hironobu Yamashita, Senior Engineer, Nuclear Power Plant Maintenance Division, Nuclear Power Plant Operation and Maintenance Department, The Tokyo Electric Power Co. , Inc.
Kiyoshi Itano, Manager, Nuclear P.ower Plant Operation Division, Nuclear Power Plant Operation and Maintenance Dep,artment, The Tokyo Electric Power Co.,
Inc.
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ENCLOSURE (2)
JAPANESE LANGUAGE DOCUMENTS TRANSLATED BY NRC (All proprietary)
Title Author Translation
- 1. Jx E ianation of Third Periodic Inspection Plans Power Reactor & Nuclear 1358 for'XTR Fugen Power Plant - August, 1982 Fuel Development Corporatica
- 2. Report on Implementation of Third Annual Inspec- Nuclear Reactor Regulatory 1359 tion, ATR Fugen Power Plant. - February,1983 Section, Nuclear Safety Bureau, STA
- 3. Report on Third Regular Inspection: Fugen Power Power Reactor & Nuclear Fuel 1360 Plant with New Type Conversion Reactor - Development Corporation March, 1983
- 4. Research' on Automated Operatinn and Human . Institute for Policy Science 1362 Factors in Nuclear Power Plant - March 1982
- 5. Research Concerning Operation and Maintenance TECHNOVA INC. 1363 of Nuclear Power Plants and Human Factors
- 6. Investigation into Human factors in Atomic Institute for Policy Science 1364 Power Plants
- 7. Equipment inspection Schedule Genkal Nuclear Power Plant 1346
- 8. Maintenance Request Sheet - No. I Unit Genkai Nuclear Power Plant 1347
- 9. Statistics of Maintenance Request Genkal Nuclear Power Plant 1348
- 10. Maintenance Procedure & Inspection List Genkai Nuclear Power Plant 1349
- 11. long Term Engineering Work Plan - Annual Genkal Nuclear Power Plant 1350 Inspection
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ENCLOSURE (2)
I 12. List of Tests to Be Conducted 2nd Annual Genkal Nuclear Power Plant 1351 Inspection Genkai No. 2 Unit l
- 13. Long Tenn Projected Regular inspections The Tokyo Electric Power Co. 1354 *
- No. I Unit, Fukushima No. 2 Station, Inc., Fukushima Daini (No. 2)
Planned on June 22, 1983 - Nuclear Power Station
- 14. Report of First Regular 1983 Fukushima Tokyo Electric Power Co. Inc. 1355 Daini (No. 2) Nuclear Power Station, No. I Unit - October, 1983
- 15. Inspection Guidelines Concerning Classifi- i STA 1361 4 tion of the Importance of Safety Functions e of Light Water Nuclear Power Facilities for Power Generation (draf t)
- 16. General Specification for Procurement of The Tokyo Electric Power Co. 1356
! Electrical Equipment - August, 1981 Inc. Fukushima Dai-Ichi (No.1) Nuclear Power Station I 17. The Basic Plan for Annual Inspection in The Tokyo Electric Power Co. 1357 1983 - March, 1983 Inc.
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i 18. Definition of Scram and History of MITI 1345 Operation in Japan - 1982 f 1.e.,
Confirmation of Scram Ratel b
ENCLOSURE (3)
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ENGLfSH LANGUAGE DOCUMENTS (ALL PROPRIETARY)
TITLE AUTHOR
- 1. Outline of Safety Regulations Administration for MITI Comercial Nuclear Power Plants in Japan September 1983
- 3. Energy in Japan, Facts and Figures, July 1983 MITI 4 Organization of Operations and Qualification Level TEPC0 of Operational Personnel at Nuclear Power Stations of Tokyo Electric Power Co., Inc.,1983 4
- 6. Development of Servicing Tools a d Equipment for TEPCO Maintenance of Nuclear Power Plaats,1983
- 7. Maintenance and Periodic Inspection of Nuclear TEPCO
. Power Plants in Japan
- 8. Role of Nuclear Power Plant manufacturer in HITACHI Development of Operating Plant Maintenance and Service Technology, January 1983
- 9. Nuclear Power Plant Design and Overall Adjustment HITACHI
! System based on Three-Dimensional Models
- 10. Automatic Inspection and Service Equipment for HITACHI BWR Plants (only one copy currently in use by PNL)
- 11. Periodical Inspection of Light Water Reactor Power KEPC0 Plants in Japan, 1979
- 12. Operating Experience Genkai Nuclear Power Station KEPCO Units 1 and 2 ,
- 13. Organization and Staffing, Genkai Nuclear Power KEPC0 j Staticn (3 charts) 14 Annual Inspection Experience, Genkai Nuclear KEPCO Station Units 1 and 2 (1 table)
- 15. Genkai Nuclear Power Station-Today (11-1-83) KEPC0 (2 tables) 1
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- 16. Outline of Safety Regulations Administration for . MITI Nuclear Power Plants (Draft)
- 17. The Japanese Approach to Nuclear Power Safety MITI
- 18. Emergency Operation Procedure In Japanese Nuclear SIND0C Power Plants (83)4 1
- 19. Operating Experience of Nuclear Power Station, TEPCO April 1983
- 20. Data on Nuclear Power Stations of Japan, June 1,1983 MITI W
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