South African Suppliers –Quality Management readiness for Nuclear

South African Suppliers –

Quality Management readiness for

Nuclear

Understanding the fabrication requirements

that affect your quality management system

Presented at the

Nuclear Supply Chain Conference

Cape Town 01-02 December 2015

Presenter: Larry Kloppenborg

22 March 2016 / 3 © 2013 – EON Consulting (Pty) Ltd

Nuclear Power Plants

Topical Nuclear Power Plant – quality requirements

• Conventional Island and Balance of Plant: ISO 9001, GS-R-3, ASME NQA-

1, ASME VIII, ASME B31 series, etc


Conventional Island and Balance of Plant

• Low Pressure casings, pipe work, steel linings &

structures, ducting, fans & motors, gear boxes,

feedwater tanks & heaters and pumps, ….

• Steel structures, buildings, …

• Cranes, valves, piping, storage tanks, electrical

equipment and panels, generators, heat

exchangers, HVAC units, filters, switchgear,

transformers, cables, dryers, certain pressure

vessels, …….

• Services, design & engineering, project

management, commissioning, testing and

maintenance, …….

• - Medupi and Kusile

Made in RSA


South Africa - ASME Stamp holders

PP - Power Piping; U – ASME VIII, Div1 or Div 2 or Alt; NA - Field installation and shop assembly of all items

NPT - Parts, appurtenances, welded tubular products, and piping subassemblies; NS – Supports; S – Power boiler

Company Name State/Province Certificate Status

DB Thermal Nigel PP- 44112 Active

DB Thermal Nigel S- 44113 Active

DB Thermal Nigel U- 44114 Active

DB Thermal Nigel U2- 44115 Active

F.P. Installations (Pty) Ltd. KwaZulu Natal U- 44935 Active

GasCon Western Cape U2- 35516 Active

GasCon Western Cape U- 35515 Active

GEA Aircooled Systems (Pty) Ltd. Gauteng U- 34999 Active

H.G. Molenaar & Co. (Pty) Ltd. Western Cape U- 32564 Active

Intertek Industry Services (PTY) Ltd Gauteng AIA- AIA-70 Active

John Bean Technologies (Pty) Ltd Western Cape U- 45205 Active

Nuclear Manufacturing North West Province U- 26768 Active

Nuclear Manufacturing North West Province NPT- N-3807 Active

Nuclear Manufacturing North West Province N- N-4254 Active

Nuclear Manufacturing North West Province NA- N-3946 Active

Nuclear Manufacturing North West Province NS- N-3853 Active

Welfit Oddy Pty Ltd Eastern Cape U- 35782 Active


RSA fabrication framework:

Pressure Equipment Regulations

• Pressure Equipment Regulations - October 2009: SCOPE

– These Regulations shall apply to the design, manufacture, operation, repair,

modification, maintenance, inspection and testing of pressure equipment with a

design pressure equal to or greater than 50 kPa, in terms of the relevant health and

safety standard incorporated into these Regulations under section 44 of the Act.

– PER 3 (1) Any person who manufactures, imports, sells, offers or supplies any pressure equipment

described in these Regulations for use in the Republic shall ensure that such equipment complies with

these Regulations.

– PER 3 (3) All pressure equipment for use in the Republic shall be categorized and submitted to the

applicable conformance assessments of SANS 347 in addition to the requirements of the relevant

health and safety standard incorporated into these Regulations under section 44 of the Act.

– PER 7(3) (a) The chief inspector's approval of inspection bodies operating in the Republic shall be

subject to the submission of an accreditation certificate issued by the accreditation authority in

accordance with the requirements of SANS/ISO 17020 and SANS 10227; Provided that the chief

inspector may set additional requirements before granting approval;


PER – Incorporated Health and Safety Standards

• Incorporated Health and Safety Standard –

– “SANS 347" means the Standard Specification for categorization and conformity

assessment criteria for all pressure equipment, SANS 347, published by the South

African Bureau of Standards (Based on PED requirements)

– “SANS 10227" means the Standard Specification for the criteria for the operation of

inspection authorities performing inspection in terms of the Pressure Equipment

Regulations, SANS 10227, published by the South African Bureau of Standards;

• Approved Inspection Authority -

– IPE and CP hold SAQCC registration for knowledge, training and experience (renew

every 3 yrs)

– Technical Manager – holding tertiary qualifications and ECSA registration


RSA PER Regulatory Framework

Manufacturer– NQA-1, ISO9001,

ISO3834, plus design code

Inspector of Pressure

Equipment

Approved Inspection Authority

SAQCC (IPE & CP)

South African Suppliers –

Quality Management readiness for

Nuclear

Understanding the nuclear regulatory

framework for nuclear requirements that

affect your quality management system

Nuclear

Quality

Management

System – key

documents

© 2013 – EON Consulting (Pty) Ltd

National Nuclear Regulator - rules

• RD 0034 sets the graded approach to the management systems applicable to

the classification of “Structures, Systems and Components”

• The Licensee has to establish the safety classification system for the nuclear

plant and assign accordingly.


Integrated Management System - Levels

• The IMS-structure of this RD consists of three levels:

• Level 1 (Direct influence on the safety performance of the nuclear installation): The

licensee as well as suppliers assigned responsible for products of high importance to

nuclear safety must additional to the Quality Management System (QMS) implement a

Safety Management System as part of an Integrated Management System (see section

6.3).

• Level 2 (Products important to nuclear safety): A QMS is required for organisations

providing products important to nuclear safety which is compliant with /3/ or any equivalent

international accepted QM standard. Accreditations according to accepted nuclear QM

standards (e.g. /5/) would be considered as a basis if provided for the organisation. In

addition QM processes, design codes and standards have to be applied that are specific to

nuclear installations. The safety and quality classification of the SSC and the application of

the nuclear codes and standards require additional QM and SSC related QA measures.

• Level 3 (All products of the Nuclear Installation): The implementation of an appropriate

QMS is mandatory as a basis for all organisations involved in the products related to an

application for or operation of a nuclear installation. The QMS requirements of the applied

QM standard should include the consideration of the Quality Assurance (QA) measures

specified for the particular products of the organisation. The determination of QM/QA

requirements and the associated QM/QA system for products with no importance to nuclear

safety rests with the licensee.

Safety

Culture

+

ASME

NQA-1

+

IAEA GS-R-

3

+

ISO9001

+

Licensee

determined


Quality Management System standards

• The NNR default position for the Level 3

and 2 quality management systems is ISO

9001 compliance plus applicable nuclear

and design code quality requirements,

namely -

– /3/ ISO 9000:2000 Series including ISO

9001:2000

– /4/ IAEA Safety Standard GS-R-3: The

Management System for Facilities and Activities

– /5/ ASME NQA 1:2008: Quality Assurance

Requirements For Nuclear Facility Applications

• Noting there is a great portion of a nuclear

plant that is not classified as Level 1.

Safety Culture Enhancement

Programmes to support the Quality

Management Systems

Principles of Safety Culture programmes


Nuclear Safety Culture

• The test is - Human Behaviour

• Strong Leadership sets direction


NNR Safety Culture Requirements: RD0034

• Para 6.2: “The NNR requires that an appropriate level of SC be adopted within

each organisation involved in processes with high nuclear safety importance.

The NNR considers the following aspects as important to reach an appropriate

Safety Culture within all level 1 organisations:

– Individual Awareness / Questioning Attitude

– Knowledge, Authority and Competence

– Example Function of Management (Safety Leadership)

– Commitment to Safety

– Acceptance of Authorities

– Acceptance of Rules

– Motivation to reach goals

– Safety Promoting Work Environment (Including Housekeeping)

– Open Communication (Including with Authorities)

– Monitoring of safety culture performance

– Operational Experience Feedback”


Safety Culture Principles

• Safety Culture Principles for a Strong Safety Culture

1. Everyone is personally responsible for nuclear safety.

2. Leaders demonstrate commitment to safety.

3. Trust permeates the organisation.

4. Decision-making reflects safety first.

5. Nuclear technology is recognised as special and unique.

6. A questioning attitude is cultivated.

7. Organisational learning is embraced.

8. Nuclear safety undergoes constant examination.

• Ref - IAEA INSAG Series No. 4: Safety Culture


Barberton Boiler


Case Studies: Barberton Boiler

• Failure by Management to provide proper

resources for the –

– Maintenance and Repair services

– Competent personnel to operate plant

– To hear the warnings


Injaka Bridge collapse


Case Study: Injaka Bridge

• Designer Management failure –

– Proper Oversight / Supervision of personnel

– Overloaded personnel

• Personnel failure –

– They are the Professionals and know best

– Failure to hear concerns / warnings

• Construction Management failure –

– Questioning attitude (Designer is responsible)

– Lack of oversight and validation


Where do you start as a Fabricator / Supplier

• Establishing an integrated management system embedding the –

– Compliance to ISO 9001

– Compliance to “Quality Plus” – design code quality requirements (ASME NQA-1, IAEA

GS-R-3)

– For Level 1 Suppliers –

– Compliance to Safety Management requirements

– Compliance to “Safety Plus” – design code safety requirements

– Implemented Safety Culture enhancement program (IAEA + INPO)

Questions and

discussions

@eon_consulting

[email protected]

www.eonconsulting.co.za

+27 (0)11 564 2300

EON Consulting services include –

• Understanding the Regulatory framework

and requirements

• Development of management systems and

processes

• Establishment of a Safety Culture

programme

• ASME endorsed NQA-1 training

• Supplier evaluations and approval

Engineering

South African Suppliers –Quality Management readiness for Nuclear