manufacturing quality surveillance as part of procurement control …€¦ · ·...
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1 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
Manufacturing Quality Surveillance as part of Procurement Control Process. EDF experience feedback
J.P. FeyteEDF China Holding
2 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
Summary
1. Current nuclear context and Basic Nuclear regulatory background
2. Analysis of Lessons learned
3. Procurement Control: A major challenge for EDF
4. Qualification of Equipment –preservation is a challenge for operator
5. Conclusion
3 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
Current nuclear context is characterized by Numerous nuclear New Builds, involving new partners and intelligent customers More complex new build projects framed by increasing level of safety (new international more demanding context after Fukushima)Difficulties encountered with respect to milestones and costsIncreasing requirements for operating fleet meant for better capacity, availability, and extension of operating life span
EDF is convinced thatThe long term competiveness of Nuclear relies on the success of New Build and Life span extension projects against increasing safety requirementsA key factor for the success depends on the "Procurement Control Process" ability to secure Safety, Quality, Lead time and Cost of nuclear projects
1. Current nuclear context and Basic Nuclear regulatory background
4 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
The owner/operator, facing increasing demands for quality:
Endorses the ultimate responsibility for the safety (French Nuclear transparency law 2006.06.13) and the first responsibility in case of nuclear accident (Nuclear operator civil liability in Environment Code)
Ensures that following provisions are addressed in it's management system (Nuclear installations French order 2012.02.07):
Identification of the elements and activities important for protection and attached defined requirements (Protection = safety of persons, public health and sanitation, protection of nature and environment), Compliance with the defined requirements and provisions related to technical inspections and verifications (audits); Identification and handling of deviations and significant events; Collection and handling of the operating experience feedback; Definition of the appropriate effectiveness and indicators.
1. Current nuclear context and Basic Nuclear regulatory background
5 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
Meanwhile, Technical regulation requires:Legal design and manufacturing conformity assessment of Nuclear pressure equipment (ESPN Order 2005.12.12 for France)
Level 1 directly performed by French Safety Authority (as per technical guide n°8)Level 2 and 3 performed by an authorized nuclear notified body or inspectorate (as per technical guide n°8)
Designers to demonstrate the compliance of the code they use to the essential legal safety and radioprotection requirements for design as well as fabrication (Appendix 1, 2 3 & 4 to ESPN Order 2005.12.12 addressed in RCC-M Appendix ZT, ZU & ZY)
1. Current nuclear context and Basic Nuclear regulatory background
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Better evaluation of supplier chain prior to the contract awarding
Ability to manufacture productAbility to apply nuclear codes and standardsAbility to manage NCR (Engineering capabilities)Ability to select and oversee sub-suppliers
New suppliersAttention needed at the early stage of the contract to verify the good understanding and management of code and standards in manufacturing procedures
Historic supplierPreservation of competence to be verified
2. Analysis of Lessons learned from recent new built / Selection of suppliers
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RCC-M versus ASME, a different approachRCC-M
State of the art code, continuously introducing the feedback from designers, manufacturers and customers.Few open options
ASMEMore general contentsOwners (designers and/or manufacturers) have to waive options and to add experience-based requirements
2. Analysis of Lessons learned from recent new built / Purchase specifications
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Nuclear codes and standards / Contractual technical specifications
Owner needs well trained and qualified personnel toDraft the specifications of the ownerReview the key documents of the contractor and its suppliers
Contractor needs well trained and qualified personnel toUnderstand, challenge and manage the specifications of the ownerWrite the equipment specification and proceduresManage the non-conformities
2. Analysis of Lessons learned from recent new built/ Purchase specifications
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Owner’s Inspection processHas to be continuously rebalanced, taking into account events, circumstances and level of confidence in the supplier’s chain
Element and activities important for the preservation of safety
Suppliers find difficult to identify the activities that may have an influence on safety performance of the productOwner must endorse the final definition
Identification of critical manufacturing process help to select documents to be reviewed
Criticality criteria based on safety, quality, schedule and cost impactsAdditional criteria
New specification/New supplier - New manufacturing process - Negative feedback of manufacturing process
2. Analysis of Lessons learned from recent new built / Surveillance & inspection
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Partnership is necessary abroadTo be developed abroad through specific associations such as PFCE or PFME French entitiesTo encourage suppliers, giving them visibility, to participate to some project, or to build facilities To share the qualification technical risk
Transparency is a key factor Controls have to be reinforced after a tong period without new built
2. Analysis of Lessons learned from recent new built / Partnership & transparency
11 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
3. Procurement Control: A major challenge for EDF"Procurement control project" was set up within EDF in 2010, aiming at:
Fixing a comprehensive approach of the Procurement control equallyinvolving the upstream and the downstream of the project,Better defining and explaining our requirements to the suppliers,Being more cautious and proactive in the selection of the sub-suppliers,Adapting more rapidly our inspection resources depending on the performance of the sub-suppliers,Reporting more efficiently to the project director,Making sure that from the bidding to the release of the product :
Every player is aware of the respective key-roles of the othersInterfaces management is focusing on: Transparency / Simplified communication / More frequent dialogues.
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3. Details of Procurement Control upgraded process
It does not cope with:The Regulatory assessment of pressure equipmentThe Surveillance of design activitiesThe qualification of active components under accidental conditions The purchasing strategy
It includesFabrication, pre-assembly and on site erection activities of :
Mechanical & Electromechanical componentsElectrical componentsInstrumentation & Control, SoftwareCivil works activitiesNuclear Fuel
* Including the manufacturing oversight of active components qualified to accident conditions (reference file review & in-shop inspections).
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3. Details of Procurement Control upgraded process
11 sub-process are addressed
Surveillance oversight (when subcontracted)
Schedule and lead time oversight
MQSI Management and reporting
NCR Treatment
In-shop & OnsiteOversight & Inspection
Manufacturing Document
Surveillance
SurveillanceMandate
Technical specification
& other contractual
provisions
Evaluationof offers
Evaluation / Qualification of Suppliers1
End of manufacturing and shipping
11
9
8
7
6
5
432 10
Manufacturing Control Process includes
MQS and surveillance of Surveillance
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Evaluation / Qualification of Suppliers
Technical specification
& other contractual
provisions
11
1
3 4
5
6
7
9
10
8
2Evaluationof offers
SurveillanceMandate
In-shop & OnsiteOversight & Inspection
End of manufacturing and shipping
DocumentSurveillance
NCR Treatment
Management and reporting
Schedule and lead time oversight
Surveillance oversight (when subcontracted)
Comprehensive approach of existing practices: Evaluation &
validation of industrial organization scheme proposed by bidders prior
to the contract signature Empowerment of a preferred actor for management of NCR
treatment from detection to implementation of the
corrective actions
• A clearly documented interface between "customer-inspection-
contractor-supplier“• An anticipated & well detailed
mandate for surveillance
• Analysis of the possible contractual levers• Identification of their practical implementation• Integration of experience feedback in the technical specifications
CEIDRE defines principles and rules of surveillance
based on experience feedback of all actors
•Supplier and inspector plan Quality control
• Alert in case of delays
A new area for improvement
3. Details of Procurement Control upgraded process / Identified improvements
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Non-conformitymanagement
Non-conformitysurveillance(design point of view)
Contract management
Surveillancemandate
Designdocumentationsurveillance
TechnicalSpecifications
Contractualrequirements
Evaluation of the BID
Supplier selection& qualification
Surveillanceoffer
(based onvalidated principle)
Manufacturingdocumentationsurveillance
On-field Inspection(shop & site)
Evaluation of suppliers
Evaluationof industrial
scheme
• Reporting• Non-conformitysurveillance(manuf. Pointof view)• Surveillance feedback
Access into the factory, clear industrial scheme, sub-orders review, schedule,
oversight of sub-contractors, NCR treatment process…
Specific entry point for each project
Adapted offer to the Client expectation,
modularity, expediting, reporting
3. Details of Procurement Control upgraded process / interfaces
16 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
3. Details of Procurement Control upgraded process / integration
Non-conformitymanagement
Non-conformitysurveillance(design point of view)
Contract management
Surveillancemandate
Designdocumentationsurveillance
TechnicalSpecifications
Contractualrequirements
Evaluation of the BID
Supplier selection& qualification
Surveillanceoffer
(based onvalidated principles)
Manufacturingdocumentationsurveillance
On-field Inspection(shop & site)
Evaluation of suppliers
Evaluationof industrial
scheme
• Reporting• Non-conformitysurveillance(manuf. Pointof view)• Surveillance feedback
COST (Committee of EDF reference doctrine) Technical OFE,
codes
Industrial sectorknowledge capitalization
EMIB (EDF Manufacturing Inspection Body), Clear mandate
EMIB, rigorous management, OFE implementation
EMIB, tutorial training, competencies, inspectors'
posture, on-field supervision.
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4. Qualification of equipment – preservation is a challenge for operator
Qualification of the Equipment
Qualification of the Supplier
Preservation of the qualification
Supplier is able to make mass production of the qualified equipment, can provide qualified spare parts and deals with obsolescence
Equipment satisfies its qualification requirement
Qualification needs to be maintained during manufacturing, erection, andmaintenance for the whole qualified lifetime
Design Input
Safety requirement
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4. Qualification of equipment – preservation is a challenge for operator
DURING MANUFACTURE
Selection of a product-supplier pairing,
Analyses of the impact of changes on qualification , with surveillance of the Reference Files updated by the manufacturers.
ERECTION ON SITE
The Qualification Preservation Sheet indicates the key points for preserving EQ during installation or erection on site. This is particularly important for components assembled on site as electrical connectors. Installation procedures, based on manufacturer specifications, are part of the Reference File.
19 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
DURING OPERATION
Application of the Equipment Qualification Preservation File based on Qualification Preservation Sheets,Analysis of operating feed-back from the sites.Extensions potentially needed during the lifetime of qualified equipment
Initial qualification may take into account an assumption about length of life (qualified life) which is lower than the actual planned life of the equipment. Then, an extension of qualification must be achieved, before the lifetime exceeds the qualified life.
On-going qualification may use different methods.
4. Qualification of equipment – preservation is a challenge for operator
20 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014
5. Conclusion
Procurement control process is a long term key factor to manage both Safety and Performance of Nuclear Power station
Some events can appear 20 or 30 years after start up
It is necessary to establish long term partnership with key suppliers
New Built project must be based on a sharing of issues and on transparency
=> Procurement control is a pre-requisite to ensure the success of Nuclear industry in the long term