0 mitsubishi’s quality assurance naoki miyakoshi general manager nuclear quality and safety...

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Mitsubishi’s Quality AssuranceMitsubishi’s Quality AssuranceMitsubishi’s Quality AssuranceMitsubishi’s Quality Assurance

Naoki MiyakoshiNaoki MiyakoshiGeneral ManagerGeneral ManagerNuclear Quality and Safety ManagementNuclear Quality and Safety ManagementNuclear Energy SystemsNuclear Energy SystemsMitsubishi Heavy Industries, Ltd.Mitsubishi Heavy Industries, Ltd.

■ 　 Introduction of Mitsubishi

■ 　 Challenges for Achieving high-quality works

■ Challenges for Integrated Quality Assurance Program As a Global Plant/Component Supplier

■ 　 Introduction of Mitsubishi

■ 　 Challenges for Achieving high-quality works

■ Challenges for Integrated Quality Assurance Program As a Global Plant/Component Supplier

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1. Introduction of Mitsubishi1. Introduction of Mitsubishi1. Introduction of Mitsubishi1. Introduction of Mitsubishi

1) Overall MHI Organization1) Overall MHI Organization

PresidentPresident

Technical Headquarters

Technical Headquarters

Shipbuilding & Ocean Development Headquarters

Shipbuilding & Ocean Development Headquarters

Power Systems Headquarters

Power Systems Headquarters

Nuclear Energy Systems Headquarters

Nuclear Energy Systems Headquarters

Machinery & Steel Structures Headquarters

Machinery & Steel Structures Headquarters

Aerospace HeadquartersAerospace Headquarters

General Machinery & Special Vehicle HeadquartersGeneral Machinery & Special Vehicle Headquarters

Air-Conditioning & Refrigeration

Systems Headquarters

Air-Conditioning & Refrigeration

Systems HeadquartersPaper & PrintingMachinery Div.

Paper & PrintingMachinery Div.

Machine Tool Div.Machine Tool Div.

CorporateDepartments

CorporateDepartments

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Mitsubishi Heavy Industries

MHI Takasago Machinery Works

Mitsubishi Electric Corp.

Nuclear Power Training Center

MHI Kobe Shipyard & Machinery Works

MHI Fuel Development Center

Nuclear Plant Service Engineering Co.

Mitsubishi Nuclear Fuel Co. Nuclear Fuel Manufacturing

Operator Training Services

Post-operational Services

Research and Development

Research and Development

PWR plant Basic Design

Primary System DetailDesign and Manufacturing

Secondary System DetailDesign and Manufacturing

Electric Equipment Designand Manufacturing

Mitsubishi Heavy Industries Ltd. (MHI)

MHI Takasago R & D Center

2) Nuclear Organization2) Nuclear Organization


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TOKYO

YOKOHAMA

KOBETAKASAGO

TSURUGA P/S

MIHAMA P/SOHI P/S

TAKAHAMA P/S

GENKAI P/SSENDAI P/S

IKATA P/S

TOMARI P/S (50Hz)

In Operation

Under Construction(3 loop PWR)

2 2

2 2

2 2

2 2 3

3 3 3 3

3 3

3

3

44 4 4

4

4

4

4 4

ＮNumber of Loops

Under Licensing(APWR)

Mitsubishi has constructed 23 PWR NPPs. The 24th PWR plant named Tomari Unit 3 is under construction. A twin APWR named Tsuruga Units 3/4 is under licensing.

3)MHI PWR Construction Experience in Japan3)MHI PWR Construction Experience in Japan


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U.S.A

Turbine:2sets

Mexico

Turbine:2setsTaiwan

RV:2units 、 RCP:8units ､ CHP:12units

China

PBMRTurbine Generator/Core Barrel Assembly

South AfricaTurbine:１ set

Spain

Turbine Rotor:2sets

　

Slovenia

RV:1unitFinland

RVCH:3unitsSweden

SG:6units

France

RV:Reactor Vessel

RCP ： Reactor Coolant Pump

CHP ： Charging Pump

Prz ： Pressurizer

SG:Steam Generator

RVCH:Reactor Vessel Closure Heads

Commercial Operation of Demonstration Plant:2011

RVCH:15units SG:6units Prz:1unit

SG:10units

Belgium

4)MHI PWR Export Construction Experience 4)MHI PWR Export Construction Experience


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Deming Prize (1973)

・ Construction management・ Work Control・ Training of worker

Reflection of DomesticNuclear Power Plant Construction Experience ･ Duplication of Heat

treatment Record･ Falsification of data of Cask Resin･ Fake Data of MOX･ Disastrous Nuclear Accident at ＪＣＯ

19801965 1970 1985 1995 2000

Development of basic QA System

Improvement of Quality Assurance Program reflecting Nuclear Plant Construction and Operation experiences

Challenges for improvement in plant Operability and Economy

・ Challenges coping with interference 　 activities and ethic problem・ Brush-up 　 of Quality Assurance Program considering human factors

Adoption ofUS QC methodology

Re-establish facility classification SystemFacilities classification systems

・ New Design Control・ Control of Start-up Test・ Foreign Material Control Growing the

Requirement of Corporate Ethics

ＡＳＭＥN-Stamp(1974) Challenge for

Economy in plant construction

Disgraceful affairs in JP

1)History of Nuclear QA Activities in MHI1)History of Nuclear QA Activities in MHI

2. 2. Challenges for Achieving high-quality works2. 2. Challenges for Achieving high-quality works

Graded Approach based on facility classification system (1978)

Reflection of DomesticNuclear Power Plant Operation Experience

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1) History of Nuclear QA Activities in MHI 1) History of Nuclear QA Activities in MHI

Ⅰ ｓｔ　 Era （ 1965-1978 ） - Introduction of American Style Quality Assurance (10CFR50 App.B) - Establishment of Nuclear Quality Assurance Program

Ⅰ ｓｔ　 Era （ 1965-1978 ） - Introduction of American Style Quality Assurance (10CFR50 App.B) - Establishment of Nuclear Quality Assurance Program

Ⅱnd 　 Era （ 1979-1985 ） - Improvement of Quality Assurance Program reflecting Nuclear Plant Construction and Operation experiences

Ⅱnd 　 Era （ 1979-1985 ） - Improvement of Quality Assurance Program reflecting Nuclear Plant Construction and Operation experiences

Ⅲrd 　 Era （ 1986-1995 ） - Challenges for improvement in plant Operability and EconomyⅢrd 　 Era （ 1986-1995 ） - Challenges for improvement in plant Operability and Economy

Ⅳth 　 Era （ 1996- 　　　） - Challenges coping with interference activities and ethic problem - Brush-up 　 of Quality Assurance Program considering human factors

Ⅳth 　 Era （ 1996- 　　　） - Challenges coping with interference activities and ethic problem - Brush-up 　 of Quality Assurance Program considering human factors

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3) Representative Activities up to now 3) Representative Activities up to now

- Graded Approach for Quality Assurance Classification of systems and components based on nuclear safety and plant reliability Example⇒ ①

-Systems to assure that approved licensing items are translated into working documents and surely inspected

- Establishment of Construction management program Integrate plant construction planning Plant scheduling Comprehensive design check Comprehensive facility inspection 　 ⇒ Example② - New design and construction method control- Foreign material control- Start-up test control- Preventive actions from other plant experiences


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S1 S2 S3･ PRESSURE-BOUNDARY OF REACTOR COOLANT SYSTEM (RCS) [CLASS-1]･ PRESSURE-BOUNDARY OF CON- TAINMENT-VESSEL (CV) [CLASS-2]･ REACTOR SHUT-DOWN SYSTEM [CLASS-3]･ EMERGENCY CORE COOLING SYSTEM (ECCS) [CLASS-3]･ VENTILATION SYSTEM AT EMERGENCY CONDITION [CLASS-5 ］

･ SUPPORTING SYSTEM 　OF

ECCS [CLASS-4]

･ SPENT FUEL STORAGE

SYSTEM [CLASS-4]

･ EQUIPMENTS WHICH

INCLUDE RADIO- ACTIVE

MATERIALS [CLASS-4]

OTHERS

R1

EQUIPMENT WHOSE ACCIDENT LEADS TO PLANT-TRIP OR SHUT-DOWN

･ REACTOR VESSEL

･ STEAM GENERATOR

･ REACTOR COOLANT PUMP

･ CONTAINMENT VESSEL

･ CHEMICAL VOLUME CONTROL

SYSTEM

･ MAIN TURBINE (A)

･ GENERATOR (A)

･ MAIN TRANSFORMER

･ DEAERATOR

R2

EQUIPMENT WHOSE

ACCIDENT 　OBSTRUCTS

CONTINUOUS

PLANT-OPERATION

(INCLUDING POWER

REDUCTION)

･ SAFETY INJECTION PUMP

･ ACCUMULATOR TANK

･ CONTAINMENT SPRAY PUMP & HEAT

EX- CHANGER

･ DIESEL GENERATOR

･ BATTERY SYSTEM

・ SEA WATER PUMP

･ REACTOR COMPONENT

COOLING PUMP

･ SPENT FUEL PIT PUMP

･ INSTRUMENT AIR SUPPLY

SYSTEM

･ EMERGENCY TRANS.

･ MAIN FEED WATER

PUMP

･ FEED-WATER HEATER

･ RADIATION

　 MONITORING 　 SYS.

･ CIRCULATING WATER

PUMP

R3 OTHERS

･ SPENT RESIN DISCHARGE

TANK

･ MIXED BED

DEMINERALIZED (FOR

COOLANT)

･ BORIC ACID EVAPORTOR

･ GAS COMPRESSOR

･ DRY PELLET FORM

SYSTEM

･ PRIMARY MAKE-UP

WATER TANK

･ STEAM CONVERTER

･ BUILDING BILGE

PUMP

･ CRANE

･ FRESH PURE-WATER

TANK

INFLUENCE ONPLANT OPERATION

CONTAINABILITYOF RADIO-ACTIVE MATERIALS

DEFI-NITION[MITI-CODE]

DEFINITION

AA BB

CC

3)-1 Example① （ Graded Approach for Quality Assurance in Japan ）3)-1 Example① （ Graded Approach for Quality Assurance in Japan ）2. 2. Challenges for Achieving high-quality works2. 2. Challenges for Achieving high-quality works

① Procurement Control

② New design / method control

③Products Assurance Plan

④Material Identification and traceability control

⑤Participation of Utility

　⇒ Witness 　 Inspection　⇒ Submission 　

of 　　　　 Documents 　

　　　　(A,B,C : System and Component

Classification)

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■ To Substantiate the non-conformity recurrence prevention activity by identification of non-conformity in early stage.

■ To improve the equipment/facilities governing operability and maintainability in early stage.


3)-2 Example② （ Comprehensive Design Check and Facilities Inspection ） 3)-2 Example② （ Comprehensive Design Check and Facilities Inspection ）

Activities Time Improvement

Comprehensive

Design Check

Design Phase

・ To identify the new design be adequate elaborately

・ To confirm the conformity of licensing documents with design documents

・ To substantiate the plant design with model engineering improved

Comprehensive

Facilities Inspection

Construction Phase

・ To substantiate the facilities inspection activities in appropriate installation stage

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4) Backgrounds which support Quality Activities 4) Backgrounds which support Quality Activities- Regarding Craftsmanship as one of most important Feedback system from worker to engineer

- Precise and Concrete Work Instruction to be a practical and effective work instruction such as caution mark, failure points, figures,and numerical criteria to be a observable work instruction through review activities from worker’s view points

- Good Communication among design, manufacturing and construction and maintenance people intensive kick-off meeting ⇒Through study for new job and brainwashing of new requirements at early stage of the job reading out the procedures with all participants

- High Motivation Meister patrol 3 layers meeting (manager-foreman-worker) Award system for “Kaizen” plan Indoctrination for worker (CAI) Example⇒ ③

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4) Example ⇒ ③ （ CAI for Worker ） 4) Example ⇒ ③ （ CAI for Worker ）


Criteria

Caution Point

Assumed Situation , Risk

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5) Challenges for next Construction 5) Challenges for next Construction

- Coping with Changes of Regulatory Inspection system in Japan

- Coping with new NRC requirements for next Construction in US 10CFR21, CGI, ITAAC, Construction Inspection, RAP----

- New Documentation System using advanced IT tool Measures to assure that DC and COL items are translated into working documents and surely inspected

- MHI original personnel performance improvement program

- Improvement of Procurement Control System

- Coping with Changes of Regulatory Inspection system in Japan

- Coping with new NRC requirements for next Construction in US 10CFR21, CGI, ITAAC, Construction Inspection, RAP----

- New Documentation System using advanced IT tool Measures to assure that DC and COL items are translated into working documents and surely inspected

- MHI original personnel performance improvement program

- Improvement of Procurement Control System

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3. Challenges for Integrated Quality Assurance Program 　 As 　 a Global Plant/Component

Supplier 3. Challenges for Integrated Quality Assurance Program 　 As 　 a Global Plant/Component

Supplier

Products Country Number Applied QA code

& Standard

Domestic Plant/ Components

Japan 23 Plants JEAC 　 4111

Oversea

Reactor 　Vessel Closure 　 Head

USA 11 Plants ASME 　 Sec /NPTⅢ

Europe 3Plants ASME 　 Sec /-Ⅲ

Reactor 　Vessel

Europe 1Plants RCC-M ， EN/-

China 2Plants ASME 　 Sec /-Ⅲ

Steam Generator

USA 2Plants ASME 　 Sec /NⅢ

Europe 3Plants ASME 　 Sec /-Ⅲ

2Plants RCC-M/-

Pressurizer USA 1Plant ASME 　 Sec /NⅢ

Reactor 　Coolant 　 Pump

China 2Plants ASME 　 Sec /-Ⅲ ASME 　 SecⅢ ＋ RCC-M/-

Containment Vessel

Mexico 1Plant ASME 　 Sec /-Ⅲ

Main Turbine Mexico 2Plants -

Europe 2Plants ISO9001

Taiwan 2Plants ISO9001

1) QA Codes and Standards in the World 1) QA Codes and Standards in the World

ASME 　NQA-1

ISO9001

RCC-M

JEAC4111

EN 　　　　　　　　　　　　　　　

ASME 　NQA-1

ISO9001

RCC-M

JEAC4111

EN 　　　　　　　　　　　　　　　

Diverse 　 QA 　Code 　＆　

Standard 　　　　　　　　　　　　　　　　　　　　　　

Diverse 　 QA 　Code 　＆　

Standard 　　　　　　　　　　　　　　　　　　　　　　

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U.S

. R

eg

ula

tio

n

MIL-Q-9858MIL-Q-9858 10 CFR50APP.A

10 CFR50APP.A

10 CFR50APP.B

10 CFR50APP.B

(‘59) (‘67) (‘70)

(‘68)

IAEA50-C/SG-Q

IAEA50-C/SG-Q

IAEA50-C-QA

IAEA50-C-QA

(‘78) (‘96)

ISO 9001-1987

ISO 9001-1987

ISO 9001-2000

ISO 9001-2000

JEA Code

4111-2003JEA Code

4111-2003JEA Guideline


4101-1981

Based onReference

ASME-Sec.IIIAPP.IX

ASME-Sec.IIIAPP.IX

RC

C-M

JEA

*IS

OIA

EA

AS

ME

* JEA :

Japan Electric Association



Supplier

NQA-1NQA-1

(‘80)

NQA-1NQA-1

ASME-Sec.IIINCA-4000

ASME-Sec.IIINCA-4000

JEA Guideline




4101-2000

IAEA 2006GSR-3

IAEA 2006GSR-3

ISO 9001-2008

ISO 9001-2008

2) Relationship of Codes & Standards2) Relationship of Codes & Standards

RCC-MRCC-M :Codes and Standards based on NQA-1

:Codes and Standards based on ISO9001

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Supplier

ISO9001: (QMS)

ISO9001: (QMS)

The target of ISO9001 is to make a strong organization by assessing the organization’s ability to meet customer, regulatory and the organization’s own requirements and performing the continuous improvement.

The target of ISO9001 is to make a strong organization by assessing the organization’s ability to meet customer, regulatory and the organization’s own requirements and performing the continuous improvement.

3) Reconciliation of ISO9001 & NQA-1 3) Reconciliation of ISO9001 & NQA-1

NQA-1: (QA)

NQA-1: (QA)

The target of NQA-1 is to achieve nuclear safety and NQA-1 requires “organization” to establish quality assurance program to assure that all necessary works are properly done.

The target of NQA-1 is to achieve nuclear safety and NQA-1 requires “organization” to establish quality assurance program to assure that all necessary works are properly done.

In order to initiate more effective QA activities than the past,it is important to develop and integrate the concepts of the above two standards. In order to initiate more effective QA activities than the past,it is important to develop and integrate the concepts of the above two standards.

AS 9100Aviation 　 Industry

　 ISO 13485Medical Industry

　 ISO/TS 16949Automotive Industry

Ref. Sector StandardRef. Sector StandardIn each industry, global standard is made as the sector standard by adding the industrial specific requirements to ISO9001. In each industry, global standard is made as the sector standard by adding the industrial specific requirements to ISO9001.

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Measurement, Analysis & Improvement

Product

Realization

Resource

Management

Management

Responsibilities

Item

•Design Control•Procurement•Instructions, Procedures and Drawings•Document Control•Control of Purchased Materials, Items and Services•Identification and Control of Items and Materials•Control of Special Processes Inspection /Test Control•Control of Measuring and Test Equipment•Handling, Storage and Shipping•Inspection, Test and Operating Status•QA Records

•Control of Nonconforming Items•Corrective Action•Audit

Data Analysis

Management Review

Instruction of resource

management

Establish of Quality Policy Quality management planning

Education



Supplier

Resource management

NQA-1 prescribes this area as Organization QA ProgramComprehensively

ISO 9001 prescribe as planning and practice of work comprehensively.

4) ISO9001 & NQA-1 QA Requirements4) ISO9001 & NQA-1 QA Requirements

ProcessProcess

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Supplier

-MHI developed integrated Quality Assurance Program in 2007. The new QA Program is now being applied for next 1100MWe reactor .

-MHI is still trying to reconcile JEAC4111(JAPAN) and NQA-1.

-Quality Assurance Requirements for vendor are determined based on graded approach (under consideration)

-MHI developed integrated Quality Assurance Program in 2007. The new QA Program is now being applied for next 1100MWe reactor .

-MHI is still trying to reconcile JEAC4111(JAPAN) and NQA-1.

-Quality Assurance Requirements for vendor are determined based on graded approach (under consideration)

NQA-1 & ISO9001Newly DevelopedQA Requirements for Grade A

Safety Related A

(ISO9001)Manufacture’s

Standard

Non-Safety Related Non-Availability Related

C

Applicable Code(ASME Sec.Ⅰ 、Ⅷ、 API 　 ect)

With some of QA elements

Newly DevelopedQA Requirements for Grade B

Supplemented Grade Availability Related Safety Related 　　　　 ( excluding A)

B

Comply with ；QA RequirementsApplied to;Grade

-IAEA 　 Code 　 2006 　“ GS-R-3” 　 requires comprehensive management system including safety ,healthy, environmental , security , quality and economy elements.

-IAEA 　 Code 　 2006 　“ GS-R-3” 　 requires comprehensive management system including safety ,healthy, environmental , security , quality and economy elements.

5) Now in MHI5) Now in MHI

10CFR50Appendix 　 B

10CFR50Appendix 　 B

Details are determined by quality classification systemDetails are determined by quality classification system

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Supplier 6) MHI’S integrated QA Program6) MHI’S integrated QA Program