Management System Requirements

Transcription

1 Management System Requirements Identification, Recognition, Application IAEA Technical Meeting Grading of the Application of Management System Requirements Vienna, January 2012 RWE Technology GmbH Dr. Thomas Schöße RWE Technology Jan 2012 PAGE 1

2 Preamble (1) > Presentation describes views of a Project company based on the experience of an Operator. RWE Power... Operator of several units at different stages RWE Technology... Project consultant for conventional and nuclear power plant projects > Issues are based on experience within the German regulatory environment, however can be generalised and extended to an international one. > Experiences during preliminary phases in Nuclear New Build projects outside of Germany (UK, Romania, Bulgaria) PAGE 2

3 Preamble (2) > The overriding interest of all involved parties in the design, construction, operation and decommissioning of Nuclear installation is Nuclear Safety... however other interests are to cover as well: Nuclear Regulator Other regulator and organisations... Nuclear Safety... Specific issues (Environment, Industrial Safety, local development... ) Licensee / Vendor / Contractor... Nuclear Safety, Industrial Safety, Env.... Commercial Success (Profit). > No differences of successful Management Systems for conventional and nuclear activities... General Management Standards provide appropriate guidance. Specifics are added adequately and consistent. PAGE 3

4 Definition of Scope In General: > Management System describes the sum of all coordinated tasks and activities including the determination of values, structures and processes, rules and tools to make a best possible contribution in attaining the company's objectives. > The nature of an applied Management System are defined by legal and regulatory requirements (external) and corporate framework condition (internal). For example: Legal and regulatory requirements (prescriptive / non-prescriptive) Applied code and standards (ASME, RCCM, EN, KTA) Roles and responsibilities of involved parties (Licensee, Vendor, Regulator, Independent Third Party Agency,...) PAGE 4

5 Management system Limits Responsibilities and task regarding the management system Normative Management Strategic Management Steering operational processes Definition of corporate governance Definition and communication of: corporate policy corporate culture and values corporate visions and goals Set up and steering of management systems Definition of organisational structures Definition of processes and projects Fostering of problem-solving and learning abilities Implementation of management systems Definition and steering of processes and tasks Steering of projects and orders Fostering of personal performance and cooperation Board of Management Line Managers (HL)/ Process Owners Line Managers (LL) or Project Manager/ Process Owners M A N A G E M E N T S Y S T E M Fulfilling and Execution of processes and tasks Process Executors (employees / external staff) PAGE 5

6 One company... One integrated approach. Policy Objectives Rules & Regulations Processes & responsibilities Tools & Templates Org. Structures, Roles PDCA H&S L1 Project Management L1 Quality Management Environment Management RWE T L1 Risk & Crisis Management L1 Continuous Improvement (PDCA) Integrated Management System brings together the different perspectives. PAGE 6

7 Experience driven Success factors System View > Strong leadership and commitment by TOP management > Appropriate number and qualification of staff with regard to the activities ( or project stages) > Defined and documented targets based and updated on the identified requirements > Integrated, consistent and central controlled approach for Management System arrangements, documented in e.g. Organisational roles and responsibilities Management Manual and system description down to an appropriate level of detail Processes documentation > Adequate document control system > Strong review, assessment and improvement process > For new build projects: Consideration of management system requirements from Day 1 PAGE 7

8 Grading of Management System Requirements Example: QA /QC activities in Nuclear New Build Projects > Based on the experience in present conventional (all project phases) and nuclear project (here phase before construction) > Flexible but systematic approach is required to reflect individual conditions of the projects Highlights > Identification and definition of the framework Roles and responsibilities of the actively involved parties and their interactions applicable requirements (e.g. legal requirements, Code & Standards) > Determination of the quality arrangements in all project phases > Consideration on Licensee-Vendor/Contractor Relation with regard to QA/QC arrangements (definition and contracting of expectations) > Systematic approach for allocation of QA /QC activities PAGE 8

9 Framework for the QA/QC activities Definition of the project scope Determination of involved parties ASME Section III RCC M Sect. 1 B KTA / IAEA/ NQA HSE Requirements Law and Directives Licensee Contract Report Third Party AgencyA What actions should be done by the Lincensee? Vendor ITPIA What activities must be done by the ITPIA? Supplier all Tiers What actions are necessary by the vendor? What are the expectations of the Regulator regarding Licensee? Authorized Nuclear Inspector / ANI Regulator Sub-Contractors/ Suppliers Qualifications? Code Requirements? What deliverables are needed? Which criteria have to be fulfilled and how? ASME Section III NCA Sub Section NB/NC/ND for Nuclear Components Cl.1-3 Vendor /Main Contractor Contract Report Supplier all Tiers Contract Report NOBO Auth. Inspector AI EC Directives EN/ ISO Standards 13480; AD 2000 Natianal Law Rules and Regulations IEC / ISO ASME Sect. I - Pow er Boilers ASME Sect. VIII - Pressure Vessel ASME B Pow er Piping Reference Code ASME Sect. II - Material ASME Sect. V - NDE ASME Sect. IX - Welding PAGE 9

10 Quality arrangements in project phases for the NNB Supply Chain > Based on the experience in present conventional and nuclear project Pre Contract Phase Design Phase Fabrication Phase Construction Phase Commissioning Phase Operation GDA Process Extended Stand.Design Supplier Qualification Site Preparation Cold Commissioning Request Information Basic Design Procurement Civil Works Nuclear Fuel Supply RFP/Vendor Selection Extended Basic Design Supplier Engineering Pre-fab Mech. E Hot Commissioning FEED Phases RFP/ Supplier Shop Fabrication Erection/ Assembly Trial Run Delivery Contract Supplier Selection Packing & Transportation Electrical Completion COD Quality Assurance Activities Quality Control Activities Remark: Project steps only for illustartion PAGE 10

11 Determination of the Licensee-Vendor relation Idendify and agree on Licensee Oversight activities Code A1 A2 A3 A4 D1 D2 D3 D4 Extract of Definitions..Licensee has the right to attend on listed activities and also the right to additional attendance..licensee has the right and option to attend on activities and to extend the level of involvement, mainly Licensee has the right of sporadic attendance. Licensee has the right of attendance where sub standard execution may induce a major risk. Licensee must receive certain documents prior Licensee may require receipt of certain documents prior Licensee will indicate the requirement to access selected documents on a sample basis "FOR INFORMATION/ FOR REVIEW" prior Licensee reserve the right of document review and approval where sub standard execution may induce a major risk on the project regarding quality, cost and time. Licensee Oversight Plan Level 1 Level 2 Topic Level 3 SC1 SC2 SC3 QL A QL B QL C Fabrication Fabrication / Execution Fabrication / Execution Fabrication / Execution Fabrication / Execution Fabrication / Execution Fabrication / Execution Inspections Inspection Inspection Inspection Inspection Inspection Document or Activity QA/QC/ENG Welders qualification certificate QA/QC/ENG Welding supervision procedure QA/QC/ENG Welding supervision QA/QC/ENG Batch Test Plan for Weld Material/Welding Consumables QA/QC/ ENG Welding Procedure Qualification Records QA/QC/ ENG Accompanying Material Tests and Specimen Plan QA/QC/ ENG Test specifications QA/QC/ ENG Inspection program schedule QA/QC/ ENG Inspection announcement form QA/QC/ ENG Intermediate inspections QA/QC/ ENG Final inspections - Single equipment audits QA/QC/ ENG Inspection reports D1 D1 D1 D1 D2 D4 D1 D2 D3 D2 D4 D4 A1 A2 A3 A3 A4 A4 D1 D2 D2 D2 D3 D4 D1 D1 D1 D2 D2 D4 D1 D2 D2 D2 D4 D4 D1 D2 D2 D2 D4 D4 D1 D2 D2 D2 D2 D4 D1 D2 D3 D3 D4 D4 A1 A2 A3 A2 A4 A4 A1 A2 A3 A2 A4 A4 D1 D2 D3 D2 D4 D4 Expediting activities QA/QC/SC Expediting Kick-off Meeting A1 A2 A3 A2 A4 A4 Expediting activities QA/QC/SC Document Expediting D1 D2 D3 D2 D3 D3 Expediting activities QA/QC/SC Shop Expediting A1 A2 A3 A2 A4 A4 Expediting activities QA/QC/SC Expediting Status Report D1 D2 D3 D2 D4 D4 Factory acceptance test (FAT) QA/QC/ ENG Quality Assurance Records/Test Reports/Welding Records QA/QC/ ENG Tightness test procedures Nuclear Island (NI) Convent.Island (CI) Bal. of Plant (BOP) D1 D2 D3 D2 D4 D4 D1 D2 D3 D3 D4 D4 PAGE 11

12 How to identify specific QA/QC activities? d approach > has to consider various conditions integrated approach > considers the activities of independent inspection agencies/code requirements appropriate use of resources > has to be flexible and easy to handle > Utilize a risk matrix Level of complexity of equipment Influencing factor reflecting the integrated approach > Identified Risk Level lead to allocation of predefined QA and QC activities. Influence Factor Complexity Grading A B C D E F Low risk 22 Medium risk 23 Medium high krisk CR 4 24 CR 3 High risk 25 CR 2 26 CR 1 27 PAGE 12

13 Allocation of SSC (in general equipment) Complexity Allocation by Engineering Department considering the safety classification and engineering complexity Allocation System Structure/ Machinery Single Equipment Material A Major Engineered Commodity Primary circuit Steam Generator Safety Valve Diverse B Major Electrical Commodity HV System Machinetransformer Bus Ducts, Power Cables Diverse C Main Static Commodity Feed Water System Pressure Piping PED-Cat III Elbow, Tubes Support Diverse D Rotating Commodity Condensate System Main Condensate Pump Pump, Motor Diverse E Static Commodity Diverse Secondary Steel structure Coloumns, Beams, Plattforms Diverse F Standard / Cataloque Commodity Diverse Standard Pumps Motors, Gears, Actuators, Diverse PAGE 13

14 Influencing factor > covers various aspects (standardised to ensure structured approach) > evaluated by experienced and competent persons Competence to be involved Process Engineering Mechanical Engineering Electrical Engineering Procurement process Scheduling Quality Assurance & Control Health, Safety & Environment Plant Operations Maintainance Influencing factors Risk / Consequence Score Low 1 Safety to Personnel/ Equipment: Moderate High 2 3 Environment Impact: Operational / Process significance: Design Maturity: Fabrication Complexity: (incl.replacement time and repairability) Design Data Requirement: Cost, Size: Assembly and schedule impact: Supplier Qualif./Capability: No significant impact Moderate Impact High Impact Faillure coverd by stand by Unit or without difficulty Some Loss of production but no loss of integrity Major Loss of production or jeopardise plant integrity Proven Frequently Used New Design Single known process One complex process More than one complex process Not significant in overall design Partly essential to design Essential to overall design Low cost, small item Moderate cost, moderate item Large and expensive item Not critical Significant important Vital important Main Qualified Supplier Status, Frequent Supplier Status Has to be qualified, no relevant experience Summary PAGE 14

15 Approach of Allocation of Risk Levels Complexity Grading Influence Factor A B C D E F 23 CR 4 24 CR 3 25 CR 2 26 CR 1 27 High risk CR 3 Medium risk Medium high krisk Low risk Increase of QA/QC Requirements Decrease in QC activities (inspection ) Allocation defines on required QA and QC activities

16 Level of required Quality Assurance activities Note: Vendor: Contracted by the Licensee Sub-Contractor:. Employed by the Vendor Sub-Vendor: Employed by the Sub-Contractor Commodity: All Systems, Structures / Machinery, Equipment and material. Level of required QA Activities Licensee to employ Independent Third Party Inspection (TPI) to monitor Vendor, Sub-Contractor and any Sub-Vendor and to issue Certificate of Compliance. Scope of Licensee s Quality Surveillance to be agreed and all Hold and Witness Points included in Vendor and Sub-Contractor Quality Control Plans. Risk Level Vendor shall review Sub-Contractor QA competence, prior to enquiry. Sub-Contractor shall submit with the bid an overview of their QA system (Quality Manual). Sub-Contractor shall submit with the bid a typical Quality Plan for a similar commodity. Sub-Contractor shall submit with the bid a List of qualified Sub-Vendor Sub-Contractor shall submit with the bid an proposal of Document Submission Schedule (DSS), confirming scope of document requirements and delivery times. Sub-Contractor shall submit after order a Document Submission Schedule( DSS) Licensee shall review and approve Vendors List of qualified Sub-Contractor Vendor shall approve any Sub-Vendors employed by the Sub-Contractor. Vendor shall agree scope of Sub-Contractor s and their Sub-Vendor s QA/QC. Sub-Contractor s shall include in the status report, the Sub-Vendor s performance. Vendor shall hold a pre-production meeting with the Sub-Contractor. Vendor shall audit the Sub-Contractor s Quality Plan during execution of the order. Vendor shall review the Sub-Contractor s corrective actions taken to rectify nonconformance. Vendor shall perform document review and random quality surveillance. PAGE 16

17 Minimum of Inspections related to Risk Level Involvement of Inspection parties Risk Level 1 = Inspection Class 1 Inspection by Vendor and ITPIA nominated by Licensee., ITPIA reports directly to Licensee. Risk Level 2 = Inspection Class 2 Inspection by Vendor or his nominated Third Party Agency (TPA). Monitoring of TPA execution by Vendor required. MINIMUM QUALITY INSPECTION ACTIVITIES INSPECTION CLASS Attend Pre-inspection/Manufacturing Meeting. X X X Inspect prefabrication layout, cutting, forming, machining and other X X preparations. Inspect raw material and review related documentation including X X certification. Inspect fit up, alignment, and assembly. X X Witness/verify welding and other special processes (PWHT). X X Witness/verify NDE and related processes. X X Inspect internal cleaning. X X Perform in-process and final dimensional checks for size, location, X orientation and configuration. Perform final dimensional checks for size, location, orientation and X X X configuration. Witness acceptance testing (hydro, performance, NPSH, etc) and sign X X X off testing sheets Witness Factory Acceptance Test. X X Vendor s specialist engineer shall witness Factory Acceptance Test. X X X Risk Level 3 = Inspection Class 3 Inspection by Vendor or Sub-Contractor with the nominated Third Party Agency (TPA). Risk Level 4 = Inspection Class 4 Review of Sub-Contractors / Sub-Vendor documentation/attestation by Vendors QA/QC and Issue of Release Note by QA/QC. Witness Site Acceptance Test. X X Vendor s specialist engineer shall witness Site Acceptance Test. X X X Review acceptance testing package/documentation X X Perform final visual inspection and final completeness check X X X Examine paint/coating/lining preparation and final surface condition. X X X Inspect painting, tagging and preparation for shipment. X X X Review documentation package - including concession requests. X X X X No Inspection Review test reports and Data required by Purchase Order. Issue Release Note erspectively Interim Certificate or Final Inspection Report X X X X X PAGE 17

18 for closure. The game is always the same. It will be decided by the best strategy, its application and the flexibility to act on changes. Assumption: You know the game. PAGE 18