CONTROLLING CONSTRUCTION AND MANUFACTURING ACTIVITIES
THROUGH
QUALITY MANAGEMENT SYSTEM
NUCLEAR INDUSTRY
SUPPLIERS FORUM8-9 OCTOBER 2019
by:
Mohamed SalehSenior Quality Engineer
Controlling construction and manufacturing
activities through quality management system.
October 8, 2019
Session 2. Approaches to Equipment Acceptance
Al Manara International Conference Center
PRESENTATION
CONTENT
About Petrojet
Implementation
ASME Nuclear Quality Assurance ProgramN
• QMS History• Manufacturing Certificates• Nuclear Quality Assurance Certificates• Quality Dept. Human Resources
• Nuclear QA Program • Issues covered by the QA Program•. Brief of the QA Program• Utilization of Unqualified Source Material
1. Case Study on USM2. Well V1-13. Russian Standards Compliance
UNLIMITED ACHIEVEMENTS & AMBITIONS
PETROJET Certifications
•Based on
•PTJ was a pioneer in making the ISO:2015transition in its QMS Program and it extended this transition to all of its domestic and foreignbranches.
Quality Management System
PETROJET posses
Boilers and Pressure Vessel-BPV since 1987.
1. Central W/S - Cairo
2. IDKU W/S – Alexandria
3. Suez W/S – Suez
4. Marine Fabrication Yard – Alexandria
Non Nuclear ASME Certificates
ASME N stamps Certificates – PETROJET Central Workshops
Nuclear QA Programs & Certificates
Nuclear QA Programs & Certificates
ASME N stamps Certificates – PETROJET Northern Branch
Not far from Quality….
PETROJET took the initiative towards
“social responsibility”
since it is the FIRST in ARE to acquire
the
ISO 26000:2010-CSR certificate
26000:2010 CSR
HSE Management System
QA/QC Department
THE PETROLEUM PROJECTS AND TECHNICAL CONSULTATIONS COMPANY
QA/QC Manpower Total No.
Quality Assurance Engineers 66
Material Control Engineers 61
Quality control Engineers (Mechanical) 320
Quality control Engineers (Civil) 71
Quality control Engineers (E&I) 75
Radiographers & NDE Operators 353
Painting Inspectors 35
Heat treatment Team 40
Total 1021
Quality control Engineers
(Mechanical)36%
Quality control Engineers (Civil)
8%
Quality control Engineers (E&I)
8%
Radiographers & NDE Operators
40%
Painting Inspectors
4%
Heat treatment Team
4%
QA/QC Personnel
QUALITY HUMAN RESOURCES
THE PETROLEUM PROJECTS AND TECHNICAL CONSULTATIONS COMPANY
Remark : Some QA/QC Personnel have qualified in several methods of NDE (RT, UT, MT,PT)
as well as some QA/QC Personnel have qualified in multi phases NDE & welding
3%
47%
19 %
14%
19%
13%
Qualification of QA/QC Personnel
Level III
Level II
CWI(AWS)
CSWIP
Internal Auditor
Lead Auditor
Qualification
NDE Welding InspectorsQuality Assurance
(Auditors)
Level III (ASNT NDT)
Level IISNT TC 1A
(RT,UT,MT,PT, VISUAL)
CWI(AWS) CSWIP Internal Auditor(From independed body)
Lead Auditor(From independed body)
Numbers 24 392 155 114 156 106
0
50
100
150
200
250
300
350
400
450
Level IIILevel IICWI(AWS)CSWIPInternalAuditor
Lead Auditor
NDEWelding Inspectors(Auditors)Quality Assurance
QA/QC Personnel Qualification
PERSONNEL QUALIFICATIONS
ASME Nuclear Quality Assurance
Program
QA Program
QA PROGRAM
QA MANUAL
QA PROCEDURES QC PROCEDURES
Work Instructions
QA Program
• OrganizationRequirement 1
• Quality Assurance ProgramRequirement 2
• Design ControlRequirement 3
• Procurement Document ControlRequirement 4
• Instructions Procedures and DrawingsRequirement 5
• Document ControlRequirement 6
• Control of Purchased Items and ServicesRequirement 7
• Identification and Control of ItemsRequirement 8
• Control of ProcessesRequirement 9
QA Program
• InspectionRequirement 10
• Test ControlRequirement 11
• Control of Measuring & Test EquipmentRequirement 12
• Handling, Storage, & ShippingRequirement 13
• Inspection, Test, & Operating StatusRequirement 14
• Non Conforming Materials, Parts, or ComponentsRequirement 15
• Corrective ActionRequirement 16
• Quality Assurance RecordsRequirement 17
• AuditsRequirement 18
Work Order Review
Design Activities(if any)
Nuclear QA Program
Design Specifications
Construction Specifications
Design Drawings
Software verification
Design Plan
Design Report & Drawings
Design Review
Procurement
Control of Purchased Items & Services
Issue of Shop & Field Drawings
Formwork Drawings
Fabrication Drawings
QA Requirements
Technical Requirements
Receiving Inspection
Source Inspection
Acceptance of Services
Technical Control
Procedures
Examination
Testing
FabricationConcrete
Placement
Post Tensioning
System
Special Processes
Welding, Splicing, Heat Treatment … etc.
Process Qualification
Welding (PQR )
Splicing
Heat Treatment
Personnel Qualification
Welders (WPQR)
Splice Installers
Heat Treatment Operators
Structural Integrity Testing
Hydrostatic/Pneumatic
Testing
Certification & Stamping Construction Report
Data Report
PETROJETQA Records Transfer
QA Records
Life Time QA Records
As Built Drawings
Final Hydrostatic Test
Non-Permanent QA
Records
Personnel Qualification Records
Purchase Orders
THE PETROLEUM PROJECTS AND TECHNICAL CONSULTATIONS COMPANY
Utilization of Unqualified Source Materials (USM)
Procurement of USM
Examinations and Tests are Performed upon the USM
Certification of Qualified USM
IMPLEMENTATION
CASE STUDY (Turning ASTM A516 Gr.70 into Class 1 Certified Material)
• Non-Approved Vendor
• No welding was performed
ASTM A516 Gr.70 Plate
•UT (straight Beam)
•Chemical Analysis
•Tensile Test
•Drop Weight
•Cv-notch
Class 1 components
(ASME SECIII, NB) •Approved Supplier
• ISO-17025 certified
Testing services
•Performed by PTJ Personnel
•Qualified & Certified personnel as per PTJ Written Practice
UT Straight Beam •Certified by PTJ
• Supplied as a Class 1 material
CMTR
Kattamia LaboratoryScope :Performing Destructive testing (Tensile test, Charpy Impact test, hardness test, Bending Test, Microstructure)
PTJ Laboratories
THE PETROLEUM PROJECTS AND TECHNICAL CONSULTATIONS COMPANY
Civil Mobile labsPTJ Laboratories
For Concrete For Soil
Concrete Temperature Standard Soil Sampling
Slump Test Sand Cone Test
Compressive Strength Test Moisture Content Test
Air Content Test Modified proctor Number Test
Unite Weight Test Sieve Analysis Test
Advance NDT techniquePhased Array UT (PAUT)
PTJ EXPERIENCE IN PAUT
PAUT is considered the main NDT method in
ZOHR project
Client : ENI
155000” – 30000 Joints
Diameter Range: ½”-48”
Thickness Range: 6-60mm
El Dabaa NPP Well V1-1 Case
Review ofDetailed Design Drawings
Alternative Materials Approval
(Local Market)
Implemented Procedures
Work Execution PlanApproval
Work Execution
Incoming Material Inspection
Concealed work Inspection Certificate
Document Transfer
Examinations & Hydrostatic Testing
Russian Standards Compliance
GOST – Russian National Standards
GOST R – National Standards of Russian Federation
SNiP- Construction Codes and Regulations
RD – Recommended Practices
SP – Design Guidances
PB – Safety Regulations
Russian Standards
Russian Standards• GOST 16037: Welded Joints in Steel Pipelines – Main Types, Design Elements, and
Dimensions
• GOST R 55276: Plastics pipes and fittings. Butt fusion jointing procedures for polyethylene (PE) pipes and fittings used in the construction of gas and water distribution systems
• GOST 33259: Flanges for valves, fittings, and pipelines for pressure to PN 250
• GOST 18599: Polyethylene Pressure pipes
• SNiP 3.05.04: Exterior Water Supply and Sewer Systems and Structures.
Mechanical Work
• GOST 26633: Heavy Weight and Sand Concretes
• GOST 5781: Hot-rolled Steel for reinforcement of concrete structures
• GOST 31108: General Structural Portland Clinker Cement
Civil Work
Sample for Petrojet Library GOST List# Standard name Description # Standard name Description
1 GOST 3.1102-2011Unified system of technological documentation. Stages ofdesigning and types of documents. General principles
25 GOST 8510-86 Hot-rolled steel unequal-leg angles. Dimensions
2 GOST R 15.301-2016System of product development and launching into manufacture.PRODUCTS OF INDUSTRIAL AND TECHNICAL DESIGNATION.Procedure of product development and launching into manufacture
26 GOST 8240-97 Hot-rolled steel channels. Assortment
3 GOST 22266-2013 Sulphate-resistant cements. Specifications 27 GOST 5781-82Hot-rolled steel for reinforcement of ferroconcrete structures. Specifications
4 GOST 30674-99 Windows of polyvinylchloride profiles. Specifications 28 GOST 7798-70Hexagon bolts, product grade B. Construction and dimensions
5 GOST 30970-2014 Door blocks of polyvinylchloride profiles. Specifications 29 GOST 11371-78 Washers. Specifications
6 GOST 10144-89 Enamels KhV-124. Specifications 30 GOST 25129-82 Primer GF-021. Specifications
7 GOST 25129-82 Primer GF-021. Specifications 31 GOST 6465-76 Enamels PF-115. Specifications
8 GOST 23118-2012 Building steel structures. General specifications 32 GOST 14918-80 Continuously galvanized sheet steel. Specifications
9 GOST 31173-2003 Steel doors. Specifications 33 GOST 30493-96 Ceramic sanitary ware. Types and principal dimensions
10 GOST 530-2012 Ceramic brick and stone. General specifications 34 GOST 18297-96 Enamelled cast-iron sanitary appliances. Specifications
11 GOST 6266-97 Gypsum plasterboards. Specifications 35 GOST 21485-94 Flushing tanks with accessories. General specifications
12 GOST 6141-91 Glazed ceramic tiles for lining of the walls. Specifications 36 GOST 23695-94 Enamelled steel sanitary appliances. Specifications
13 GOST 24866-2014 Insulating glass units. Specifications 37 GOST 1811-97 Traps for sewer systems in buildings. Specifications
14 GOST 5781-82 Hot-rolled steel for reinforcement of ferroconcrete structures. Specifications 38 GOST 10704-91 Electrically welded steel line-weld tubes. Range
15 GOST 6665-91 Concrete and reinforced concrete curbs. Specifications 39 GOST 32414-2013Polypropylene pipes and fittings for waste discharge inside the buildings. Specifications
16 GOST 8509-93 Hot-rolled steel equal-leg angles. Dimensions 40 GOST 23695-2016 Enameled steel sanitary equipment. Specifications
17 GOST 19903-2015 Hot-rolled steel sheets. Dimensions 41 GOST 483-75 Hemp ropes. Specifications
18 GOST 30245-2012Steel bent closed welded square and rectangular section for building. Specifications
42 GOST 33259-2015Flanges for valves, fittings and pipelines for pressure to PN 250. Design, dimensions and general technical requirements
19 GOST 103-2006 Hot-rolled steel strip. Dimensions 43 GOST 5915-70Hexagon nuts (standard precision). Construction and dimensions
20 GOST 6787-2001 Ceramic floor tiles. Specifications 44 GOST 9.402-2004Unified system of corrosion and ageing protection. Paint coatings. Metal surface preparation for painting
21 GOST 6141-91 Glazed ceramic tiles for lining of the walls. Specifications 45 GOST 7796-70Hexagon reduced head bolts product grade B. Construction and dimensions
22 GOST 5336-80 Single woven steel wire cloth. Specifications 46 GOST 16504The state system of testing products. Product test and quality inspection. General terms and definitions
23 GOST 8509-93 Hot-rolled steel equal-leg angles. Dimensions 47 GOST 25646-95 Service of building machines. General requirements
24 GOST 9548-74 Roofing petroleum bitumens. Specifications
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& AMBITIONS