Quality assurance during the manufacture of safety class 4 equipment at NPP construction

abroad

Quality assurance during the manufacture of safety class 4 equipment at NPP construction

abroad

JSC NIZHNY-NOVGOROD ENGINEERING COMPANY

ATOMENERGOPROYEKT (JSC NIAEP)

Head of Quality and Normalization Division

of JSC NIAEP Moscow Representation Office

А.G. Moukhlynin

Generation of quality requirementsGeneration of quality requirements

2

Requirements of the Customer's national

regulatory basis

International quality requirements

(International agreements, Conventions, IAEA, ISO)

Requirements of Russian regulatory basis

Contractual requirements

Quality management

Quality assurance

programs, Quality

manuals (ISO)

Suppliers' evaluation,

QMS audits, QAPs

Quality plans, inspections

in the course of

work execution

Control

of non-conformances

Rev Document

codeDocument Abroad NPP projects

1

50–С–QA (Rev.1)Safety provisions of nuclear power plants:

Quality assurance at NPP (1990) Tianwan NPP

Belorussian NPP50–SG- QA1 ÷

QA11Safety Guide

250 – С/SG - Q

Provisions: Quality assurance for safety in

nuclear power plants and other nuclear

installations (1996)Kudankulam NPP

Bushehr NPP-1

Q1 part Q14 Safety Guide

3

GS – R – 3 Safety requirements Management Systems for

Facilities and Activities

Akkuyu NPP

Belene NPP

Temelin NPP

Khmelnitskaya NPP

GS– G– 3.1 Safety Guide. Application of Management

System for Facilities and Activities

GS –G– 3.5 Safety Guide. Management systems for nuclear

facilities

IAEA safety standards for quality applied in JSC NIAEP-JSC ASE for NPP construction abroad

IAEA safety standards for quality applied in JSC NIAEP-JSC ASE for NPP construction abroad

Graded approach to quality managementGraded approach to quality management

№ GS-R-3(IAEA), Safety requirements

2.6. …application of requirements of the management system is based on the following principles:

- Value and complexity of each type of products;

- Dangers and scope of the potential impact (risks) related to those elements of products related to issues of protection of safety, health, environment, physical safety, quality and economy;

- Probable consequences of the products defect

5

Graded approach to quality managementGraded approach to quality management

Quality assurance categories.

IAEA technical Report No. 328 "Grading of Quality Assurance

Requirements"

"The classification method specified in this Manual, regard those

aspects of organization, management and administrative management

which impact the quality".

"It does not apply to the technical requirements related to quality, which

are determined on the basis of expert judgments and estimates"

6

Application of Quality assurance categories. in STO SMK-ПКФ-015-06 of Rosenergoatom Concern.

Graded approach to quality managementGraded approach to quality management

Graded approach for equipment of

safety class 4

Equipment of QA2, QA3 category (category 2, 3)

Audits

QNC equipment (category 4)

Superv

isio

n u

nder

qualit

y p

lans

Accepta

nce

inspections.

Audits

Accepta

nce

inspections.

Qualit

y M

anagem

ent

Pro

gra

m

Qualit

y m

anagem

ent

syste

m.

Decis

ion o

n

Applic

ation

8

Quality Assurance category determines the scope of developed QA documents and necessity of its approval by the General Designer

9

The Quality Assurance category determines the scope of developed QA documents and necessity of its approval by the General Designer

10

Sequence of supervision over the quality in course of equipment manufacture of quality categories QA1, QA2, QA3 as per Quality plans

Example of filled in Quality plan

11

Sequence of supervision over the quality in course of equipment manufacture of quality categories QA1, QA2, QA3 as per Quality plans (continuation)

Example of filled in Quality plan

12

Sequence of supervision over the quality in course of equipment manufacture of quality categories QA1, QA2, QA3 as per Quality plans

(continuation)Example of filled in Quality plan

13

Sequence of supervision over the quality in course of equipment manufacture of quality categories QA1, QA2, QA3

Review and approval of working design documents of manufacturers and items

Performance of inspections, tests in control points of Quality plans

Notification and conclusion on inspectionRecords in Quality plan

Acceptance inspectionCertificate of acceptance inspection

Approved Quality Plan

Presentation of quarterly summarized data on identified non-conformances (quantity,

classification, dynamics)

Summarized information on identified non-conformances

Inspection of enterprise readinessPermit document for the right of manufacture (protocol,

quality plan)

Supervision over the manufacture

Approved Quality Plan

Assignment of authorized organization

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Non-conformance control

Non-conformance control is based on the graded approach which is based on the

relative importance of influence of non-conforming product on safety and reliability.

The non-conformance control activities include:

� identification of non-conformances;

� registration of non-conformances;

� marking and (if possible) separation of non-conforming products from

qualitative products;

� review of non-conformances;

� classification and evaluation of consequences;

� taking decisions on non-conformances;

� control of the corrective actions implementation

� account and storage of documentation on activity on non-conformance control.

The classification of non-conformances is determined on the basis of the available

experience and requirements of Contracts / Agreements.

15

Management of non-conformances (continuation)Classification of non-conformances

Non-conformance

classDecision taken on a non-conformance Result

1

To rework according to the valid design and process

documents;

The item fully meets

requirements of the

procurement documents

To reject (the decision is taken by the manufacturer) Reject

2

To repair according to the valid design and process

documents;

To accept as is based on the equipment designer’s expert

statement

the item is acceptable for the

designated purposes

3

To rework according to newly developed design and

process documents;

The item fully meets

requirements of the

procurement documents

To repair according to newly developed design and

process documents;the item is acceptable for the

designated purposesTo accept as is based on the equipment designer’s expert

statement

To reject based on the designer’s expert statement.Reject

16

Management of non-conformances (continuation) Format of non-conformance report

Non-conformance reports are made by the

manufacturer and approved by the supervising

companies Level of approval of non-conformance report

depends on the assigned non-conformance class.

Non-conformances of class 1 The decision on removal of

non-conformance is taken by the Manufacturer/Supplier

and is approved by the Authorized organization.

2rd class non-conformance A non-conformance report

agreed by the Authorised organization and JSC ASE shall

be sent to the Customer for review. The Customer has a

right to give comments on the proposed method of removal

to be accounted during corrective actions implementation.

3rd class non-conformance A non-conformance report

agreed by the Authorised organisation and JSC ASE shall

be sent to the Customer for review and agreeing;

17

Existing interfaces of the General contractor at implementation of the contractual obligations for the quality management

PrincipalRosatom State Atomic Energy

Corporation

General Designer

Suppliers of equipmentand services

mounting, commissioningorganizations

Companies authorized for quality supervision

Equipment manufacturers

Regulation

Contractual relationships

FSUE VO "Safety"

JSC VPO "Zarubezhatomenergostroy"

Quality Control

Design, parent material science organisations

18

Supplier evaluation report by the example of JSC Gidropress

Conditions of imported products supply

Guidance documents on the terms of imported products

delivery

Performance of conformance

evaluation(quality supervision)

Issuance of the decision on the

imported products application

Evaluation of conformance, Decision on application

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� Federal Law of IRI "On use of nuclear energy "

� RD-03-36-2002 "Conditions of imported equipment, items, materials

and accessories supply for nuclear facilities, radiation sources and

storage premises of Russian Federation".

� NP-071-06 "Rules of evaluation of conformance of equipment,

accessories, materials and semi-finished items supplied to the nuclear

power objects".

Guidance documents on the terms of imported

products delivery

20

а

The basis for the use of imported equipment is the

Decision on Application

Supplier-

manufacturer

Draft decision on

application

General designer /

Customer

Development, Approval

Coordination

Procedure of taking the decision on application

Regulatory

(authorised) body

Approval

Expert organisations

Taking decision on application

21

- analysis of production;

- expertise of documents (QAPs, ТТ, ТU, etc.);

- analysis of data on observance of federal codes and standards in

the field of atomic energy usage;

- analysis of information about the identity (equivalence) of requirements

of national or international regulatory documents with the requirements

of Russian regulatory documents;

- positive results of acceptance tests;

- analysis of potential degradation of designed system parameters, which

implies the use of imported equipment at the nuclear facilities.

- availability of positive experience in application of these

equipment at nuclear facilities;

- availability of positive experience in application of these

equipment at nuclear facilities;

The decision on application is taken based on:

22

- Technical requirements or specifications for the imported

equipment supply

- passports, quality certificates for the imported equipment

- programs and procedures of tests (only for equipment and items).

The test procedure is not developed for the materials, semi-finished

items and accessories

- strength analyses, hydraulic and other analyses

- quality plans

The following documents shall be attached to draft Decision:

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- technical requirements to materials

- list of materials with their foreign designations

conclusion of material science organisation

(for the newly used materials)

- conclusion of material science organisation

(for the newly used materials)

- list of international norms and regulations on equipment

manufacture

- list of international norms and regulations on equipment

manufacture

- list of material suppliers

At purchase of imported welding materials,

the following documents shall be attached to Decision on application:

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Contract, ITR (TA)

Manufacturer

Licenses

Certificates

Technical

specification

Documents development

TP, working design documents

Manufacturing

Accepta

nce

tests

Acceptance inspection

prior to shipment

Conformance of TP

Designer

Authorized

Organization)

Decision on

applicability

Documentation expertise

Readiness of production

Inspection

Permit

of the National

Regulatory

Authority (AA)

Permit

of the National

Regulatory

authority

Supervision

of the National

Regulatory

Authority (AA)

Scheme of quality supervision

25

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Thank you for attention!