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WTP Commercial Grade Dedication of Complex Items Chris Hartz Bechtel National Inc. Procurement Engineering Manager
Bechtel National, Inc.
Waste Treatment Plant Project
Purpose Of Presentation
The WTP Project CGD: NRC vs. DOE projects
– Safety Related (NRC) – Safety Class (DOE) – Safety Significant (DOE) – Air Permit (State of Washington and DOE)
Application of NQA-1, EPRI 5652, 6406, to large new nuclear construction (EPC) To discuss CGD of complex pieces of equipment
Waste Treatment Plant Project
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New Nuclear Construction EQ versus CGD
New nuclear construction projects
– Design and/or licensing activities may not be complete (e.g., ash-fall) Risk analysis
– EQ and CGD may be in different sequences – CGD can start prior to or in concert with EQ, but is not complete until
EQ is complete Risk analysis
– Reconciliation of EQ with CGD required before item is dedicated as Q – Unique WTP EQ requirements – CGD ≠ Design Verification
Waste Treatment Plant Project
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Commercial Grade Dedication vs. Equipment Qualification
Equipment Qualification: Suitability Evaluation (Criterion III) – NQA-1 Section 3, IEEE 344/323 – Validation that SSC will perform their respective safety functions
during and/or DBE – Prototype testing – EQ via testing: Destructive (item unfit for use after testing) – EQ via analysis or experience: Nondestructive (item fit for use)
CGD Acceptance Process (Criterion VII) – NQA-1 Section 700, EPRI NP 5652/6406 – Technical evaluation – Verification 4 Acceptance Methods = reasonable assurance the item
will perform its intended safety function – Dedication at normal conditions, not upset or accident (e.g., seismic) – Not directly related to design verification
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BNI CGD Process -Supply Chain-
Procurement Engineering (PE) is involved with both nuclear (Q) and commercial (CM) suppliers PE conducts assist visits to mitigate rework (cost savings) PE conducts performance based CGD surveys of
commercial suppliers PE participates as CGD experts on NQA-1 supplier audits PE reviews and accepts all NQA-1 suppliers CGD programs
and CGD plans
Waste Treatment Plant Project
WTP Examples of Complex Dedication
Thermal Catalytic Oxidizers Active valves Low Activity Waste Exhauster Pumps Emergency Turbine Generators
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Waste Treatment Plant Project
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WTP Commercial Grade Dedication
-Challenges- Technical Evaluations
Depth of evaluation –What is being dedicated (equipment vs. components vs. parts) –Design function –Safety function
FMEA –Depth –Level of detail
Use of proprietary data Access to sub-supplier resources and other information Suitability evaluation not complete Seismic and Environmental Qualification not complete Configuration control
Waste Treatment Plant Project
Low Activity Waste Exhauster
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Waste Treatment Plant Project
Pumps
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Waste Treatment Plant Project
WTP Emergency Turbine Generators: Case Study
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Waste Treatment Plant Project
Emergency Turbine Generator CGD Challenges
NQA-1 (2004) and EPRI 5652/6406 as written for spare parts
programs, not new construction Seismic/Environmental Qualification not complete Identification of item being dedicated: complete assembly vs. module
vs. part vs sub-parts How many critical characteristics
– Equipment/component/part/material Level of detail in technical evaluations
– Subpart safety classifications Software “Reasonable Assurance” vs “Absolute Assurance” Level of detail in CGD Plans and reports
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Waste Treatment Plant Project
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Bechtel National Inc.
**On Power Inc. Design
Fabrication
Rolls Royce (complete)
Turbine Design
Fabrication
Hyundai-Ideal Generator
Design Fabrication
Allen Gears Gear Box Design
Fabrication
*Seismic Dynamic Analysis
TBD
Third Party Reviews
Mesa Sequoyah
Woodward Controller
Design Fabrication
ATCO Silencer Design
JR Capital Silencer
Fabrication
Seismic Qualification Static Analysis
NQA-1 *Sub-contract to BNI
CM **ETG Prime Contractor
Waste Treatment Plant Project
Rolls Royce Turbine Engine 501KB7S CGD Strategy (Technical Evaluation)
BNI Challenges: – Develop an effective dedication strategy for a complex
mechanical system comprised of over 600 highly engineered engine sub-components
– Proprietary data – First of a kind dedication – Use of Rolls Royce product history – Use of Rolls Royce FMECA – Access to Rolls Royce SMEs – Access to Rolls Royce supply chain – Level of detail in CGD plans
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Waste Treatment Plant Project
Rolls Royce Turbine Engine 501KB7S CGD Strategy (Technical Evaluation)
Technical Evaluation:
– Series of ongoing technical meetings at Rolls Royce – Detailed technical review: Part drawings Production Travelers QA Program documents (AS 9100 quality program)
– Interface w/ Rolls Royce SME’s Design Engineers Manufacturing Engineers Supplier Quality
– Toured plant, focused on areas specific to the 501KB7S
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Waste Treatment Plant Project
501-KB7S Turbine Detail
4th-Stage Blade Vane
3rd-Stage Blade Vane
2nd-Stage Blade Vane
1st-Stage Blade Vane
Cast Front Turbine Bearing
Support Rear Turbine Bearing
Support
Wheel 1st, 2nd 3rd, 4th
Vane Case
Inlet Case
Waste Treatment Plant Project
Rolls Royce Turbine Engine 501KB7S CGD Strategy (Critical Characteristics)
Critical Characteristics: – Engine Assembly Performance Requirements
– Start time – Power Output
Item Markings – Representative Characteristics from Sub-Assemblies/ Items Markings Dimensional Chemical Properties Physical Properties Performance Properties
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Waste Treatment Plant Project
Rolls Royce Turbine Engine 501KB7S CGD Strategy (Acceptance Methods)
Method 2 – Identification of required QA program attributes – Identified attributes required to control selected CC’s – Verification QA program attributes on selected sub-set of CC’s
bounding of engine safety related components Method 3
– Witness factory acceptance test at Rolls Royce – Witness factory acceptance testing at OPI
Method 4 – Document extensive product history in similar applications. Power generation Stand-by power Navy marine applications
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Waste Treatment Plant Project
Turbine CGD Process: Lessons Learned Need for Project Execution Plan
– Technical requirements – Tailoring of IEEE 387 requirements – Equipment qualification – CGD
Early engagement of key stakeholders – Senior management – Quality Assurance – Customer representatives
Linkage between CGD Plans and Execution Plan Use of Method 4 Formal PEER review process
– Mesa Associates: 2013 – Sequoia: 2014 – Future assessments planned
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Waste Treatment Plant Project WTP Complex Items
CGD Process
QUESTIONS
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