Integrated Quality System of JSC Rosenergoatom Concern Basis for Ensuring Safety and Enhancement of Efficiency

Transcription

1 Integrated Quality System of JSC Rosenergoatom Concern Basis for Ensuring Safety and Enhancement of Efficiency Speaker: Prof. Blinkov Vladimir Nikolaevich, QA Director Technical Meeting to Share Experiences and Lessons Learned from the Application of Different Management System Standards in the Nuclear Industry th of December 2014, Vienna, IAEA

2 JSC Rosenegoatom Concern Operating Company of Russian NPPs MWt Installed Capacity Operating Units in RF Under Construction in RF Floating Unit under Construction Integrated Quality System 2

3 Quality System (QS) of JSC Rosenergoatom Concern is a Basic Subsystem of Integrated Management System Operator Top Management Responsibility/Analysis Resources Personnel Federal Rules and Regulations IAEA GS-R-3 INSAG-4 Requirements NPPs/Branches/Headquarter Life Cycle Processes of Electricity and Heat Production Operation Decommissioning Siting Time Finances Infrastructure Information Effective and Safe Production of Electricity and Heat Commissioning QA Programs Designing Construction Manufacturing of Equipment Development of Equipment ISO Requirements Regulations (R&R) Requirements to Quality Assurance (QA) Programs in Area of Applying of Nuclear Energy Contractor s Works/Services QS Procedures 3

4 Hierarchy of Concern Quality System Standards State Administration and Regulation IAEA Requirements S-R-3, GS-G-3.1, INSAG-4, INSAG-18, GSR DS 456 ISO Requirements Integrated Quality System НП-090 Quality Assurance Manual General Quality Manual ISO General NPPs Quality Assurance Programs Concern Quality System Procedures Operation Quality manual Commissioning Specific NPPs QA Programs on Licensed Activities Decommissioning 4

5 Coordination Areas of Functional Subordination Rosenergoatom Quality System Structure (Employees Involvement) Headquarter Director for ROSATOM Production System First Deputy General Director Operating NPPs Constructed NPPs Quality Management Division Concern Quality Policy QA Director, Representative of Administration on Quality Quality Department Division for Equipment Manufacturers Control Chief Engineer (CE) Deputy CE on Maintenance and Quality/Representative of Administration on Quality Quality Management Department Deputy Director on Construction Quality Control Department Reports of Quality Monitoring Authorized Staff on Quality Management in Divisions An Order of REA by N 9/257-П (Standard Formulations Referring to Quality used in Regulations of Subdivisions and Job Descriptions) Authorized Staff on Quality Management in NPP Divisions 5

6 Cooperation with State Corporation Rosatom Rosatom Production System (RPS) Projects Quality Monitoring of Equipment, Works and Services Internal Control of Safety and Quality RPS Projects on Quality 2014 г 7 RPS Projects on Quality Rosatom Regulations for Monitoring Process Rosatom Inspection Bodies in Headquarter and NPPs Rosatom Production System QA Director, REA General Inspection of Rosatom General Inspection of REA QA Director, REA Built-in Quality Headquarter Divisions Oriented on Quality Control Procedures Optimization NPPs of REA Assurance Requirements 6

7 JSC Rosenergoatom Concern Quality System Certification on Compliance to ISO Requirements, IAEA Safety Requirements N GS-R-3, НП , Requirements to Quality assurance Programs in Area of Applying of Nuclear Energy Atomcertifica TŰV Concern Headquarters TŰV Operating NPPs NPPs under Construction Concern Branches Balakovo NPP Bilibino NPP Leningrad NPP-2 Baltic NPP Design and Construction Branch NPP Construction Branch Additional Certificates: Beloyarsk NPP Kalinin NPP Kursk NPP-2 Smolensk NPP-2 Floating Unit Branch Technology Branch Kola NPP STC AEW Kursk NPP ERC Leningrad NPP TDEC Novovoronezh NPP Rostov NPP Certification Bodies: - IQNET - Russian Register - Atomcertifica - Certification System GOST R Smolensk NPP The Scope of TŰV Certificate: Management of Electricity Production and Supply 7

8 Execution by JSC Rosenergoatom Concern of Operating Company Functions in Accordance with Rules and Regulations NPP Quality Assurance Programs Organization of Development, Confirmation, Implementation, Control and Effectiveness Assessment of General and Specific NPPs QA Programs Requirements Specific NPPs QA Programs on Licensed Activities Approval, Realization Control and Assessment of Quality Assurance Programs Effectiveness of Contractors Quality Assurance Manual СТО Procedure of Approval and Confirmation of Quality Assurance Programs and Quality Manuals РД ЭО Typical General Program of Quality Assurance for JSC Rosenergoatom Concern ТПРГ

9 Internal and External Audits in Organization Standards, Regulation Documents of Operating Company NPPs Branches Headquarter Divisions Authorized for Quality Inspections Companies Manufacturers Inspection Results Confirmation and Expansion of the Quality System Certificates of Concern, Inspection of Implementation of NPPs Quality Assurance Programs Realization Control of Quality Assurance Programs, Identification of Nonconformities, making Decisions to prevent their Appearance and Repeating 9

10 Quality Assurance Instruments on Equipment Purchased for JSC Rosenergoatom Concern Selection stage Licence of Regulator Manufacturing 75-90% QAP ISO experience (for 1-3 safety classes) (price) 25% (10% - experience) Assessment stage Voluntary certification of manufacturers and their contractors Siting Designing Equipment purchasing Purchase Standard Selection of suppliers Tender may be won by a company with appropriate documents, but incapable to produce qualitative equipment Construction Assembly Work Pre-commissioning/ commissioning Technical Control Unit + Authorized Organization + General Contractor + NPP Identified and eliminated nonconformities of manufacturing Equipment manufacturing 1-3 safety class equipment units (including components and intermediates) 500 manufacturers Equipment Manufacturing 4 safety class AO is not presented 2013 year Data NPP Entry Control 68% complete after 1 st presentation Average time for nonconformities elimination ~60 days 10

11 Quality Assurance of Products Manufactured for Concern NPPs: Common indexes of 1-4 safety class equipment entry control in 2012/2013/Jan-Sept 2014 (operating/under construction NPPs) Operating NPPs, Unit/% % 2012 г г. Jan Sept of % 779 1% % % % % % % NPPs under Construction, Unit/% % % % % % % % % % EC completed after 1 presentation EC completed after remarks elimination EC failed remarks elimination 11

12 Continuous Improvement Dynamics of the Company s Numbers Commissioned 3 Kalinin Electricity Output at NPPs of Concern ~ Commissioned 4 Kalinin Commissioned 2 Rostov Commissioned 3 Rostov Automatic Emergency Shut-downs of the Reactors in the World (According to WANO) World Average 0, Forecast Operating Units in Installed Capacity in 2030 MWt 35 Output in 2030 bln. kw h. 255 France UK USA Russia Who is my contractor?? Org. Structure of a Company? Main Priority cooperation with contractors (chief designers, general contractors, manufacturers ) control by means of management systems audits Technologies? Quality Management System Procedures, Resources, Personnel? 12