Post on 12-Mar-2020
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
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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"
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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
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Quality Assurance category determines the scope of developed QA documents and necessity of its approval by the General Designer
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The Quality Assurance category determines the scope of developed QA documents and necessity of its approval by the General Designer
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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
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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
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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
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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.
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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
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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;
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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
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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
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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
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- 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:
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- 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
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Thank you for attention!