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

Transcription

1 JSC NIZHNY-NOVGOROD ENGINEERING COMPANY ATOMENERGOPROYEKT (JSC NIAEP) Quality assurance during the manufacture of safety class 4 equipment at NPP construction abroad Head of Quality and Normalization Division of JSC NIAEP Moscow Representation Office А.G. Moukhlynin

2 Generation of quality requirements International quality requirements (International agreements, Conventions, IAEA, ISO) Requirements of the Customer's national regulatory basis 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 2

3 IAEA safety standards for quality applied in JSC NIAEP-JSC ASE for NPP construction abroad Rev Document code Document Abroad NPP projects 1 50 С QA (Rev.1) 50 SG- QA1 QA11 Safety provisions of nuclear power plants: Quality assurance at NPP (1990) Safety Guide Tianwan NPP Belorussian NPP 2 50 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 GS G 3.1 GS G 3.5 Safety requirements Management Systems for Facilities and Activities Safety Guide. Application of Management System for Facilities and Activities Safety Guide. Management systems for nuclear facilities Akkuyu NPP Belene NPP Temelin NPP Khmelnitskaya NPP

4 Graded 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 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" 5

6 Application of Quality assurance categories. in STO SMK-ПКФ of Rosenergoatom Concern. 6

7 Graded approach to quality management Graded approach for equipment of safety class 4 Equipment of QA2, QA3 category (category 2, 3) QNC equipment (category 4) Quality Management Program Audits Supervision under quality plans Acceptance inspections. Decision on Application Quality management system. Audits Acceptance inspections.

8 Quality Assurance category determines the scope of developed QA documents and necessity of its approval by the General Designer 8

9 The Quality Assurance category determines the scope of developed QA documents and necessity of its approval by the General Designer 9

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 10

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 11

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 12

13 Sequence of supervision over the quality in course of equipment manufacture of quality categories QA1, QA2, QA3 Supervision over the manufacture Assignment of authorized organization Review and approval of working design documents of manufacturers and items Approved Quality Plan Inspection of enterprise readiness Permit document for the right of manufacture (protocol, quality plan) Performance of inspections, tests in control points of Quality plans Notification and conclusion on inspection Records in Quality plan Presentation of quarterly summarized data on identified non-conformances (quantity, classification, dynamics) Summarized information on identified non-conformances Acceptance inspection Certificate of acceptance inspection Approved Quality Plan 13

14 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. 14

15 Management of non-conformances (continuation) Classification of non-conformances Non-conformance class 1 2 Decision taken on a non-conformance To rework according to the valid design and process documents; To reject (the decision is taken by the manufacturer) To repair according to the valid design and process documents; To accept as is based on the equipment designer s expert statement Result The item fully meets requirements of the procurement documents Reject the item is acceptable for the designated purposes 3 To rework according to newly developed design and process documents; To repair according to newly developed design and process documents; To accept as is based on the equipment designer s expert statement To reject based on the designer s expert statement. The item fully meets requirements of the procurement documents the item is acceptable for the designated purposes Reject 15

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. 2 rd 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. 3 rd 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; 16

17 Existing interfaces of the General contractor at implementation of the contractual obligations for the quality management Principal Rosatom State Atomic Energy Corporation Companies authorized for quality supervision FSUE VO "Safety" JSC VPO "Zarubezhatomenergostroy" General Designer Suppliers of equipment and services Equipment manufacturers Design, parent material science organisations mounting, commissioning organizations Regulation Quality Control Contractual relationships 17

18 Supplier evaluation report by the example of JSC Gidropress 18

19 Evaluation of conformance, Decision on application Conditions of imported products supply Guidance documents on the terms of imported products delivery Issuance of the decision on the imported products application Performance of conformance evaluation(quality supervision) 19

20 Guidance documents on the terms of imported products delivery Federal Law of IRI "On use of nuclear energy " RD "Conditions of imported equipment, items, materials and accessories supply for nuclear facilities, radiation sources and storage premises of Russian Federation". NP "Rules of evaluation of conformance of equipment, accessories, materials and semi-finished items supplied to the nuclear power objects". 20

21 Taking decision on application The basis for the use of imported equipment is the Decision on Application Procedure of taking the decision on application Suppliermanufacturer Expert organisations Draft decision on application Development, Approval а Coordination General designer / Customer Approval Regulatory (authorised) body 21

22 The decision on application is taken based on: - analysis of production; - expertise of documents (QAPs,ТТ,ТU, etc.); - positive results of acceptance tests; - analysis of data on observance of federal codes and standards in the field of atomic energy usage; - availability of positive experience in application of these equipment at nuclear facilities; - analysis of information about the identity (equivalence) of requirements of national or international regulatory documents with the requirements of Russian regulatory documents; - analysis of potential degradation of designed system parameters, which implies the use of imported equipment at the nuclear facilities. 22

23 The following documents shall be attached to draft Decision: - Technical requirements or specifications for the imported equipment supply - passports, quality certificates for the imported equipment - strength analyses, hydraulic and other analyses - quality plans - programs and procedures of tests (only for equipment and items). The test procedure is not developed for the materials, semi-finished items and accessories 23

24 At purchase of imported welding materials, the following documents shall be attached to Decision on application - technical requirements to materials - list of materials with their foreign designations - list of international norms and regulations on equipment manufacture - list of material suppliers - conclusion of material science organisation (for the newly used materials) 24

25 Scheme of quality supervision Contract, ITR (TA) Manufacturer Permit of the National Regulatory authority Licenses Certificates Decision on applicability Conformance of TP Designer Authorized Organization) Technical specification Documents development TP, working design documents Documentation expertise Supervision of the National Regulatory Authority (AA) Permit of the National Regulatory Authority (AA) Manufacturing Accepta nce tests Acceptance inspection prior to shipment Readiness of production Inspection 25

26 Thank you for attention! 26