Qinshan CANDU Project Construction Experiences and Lessons

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2003 February 7. QUALITY ASSURANCE PROGRAM 7.1 Quality Assurance System among TQNPC, AECL, Commissioning Team and Contractors In its capacity as the main contractor, AECL (through SPMO) was responsible for the overall Quality Assurance Program at the Qinshan Site. The primary responsibility for quality assurance and quality control rested with the construction contractors during construction and with the commissioning team (CT) during commissioning. SPMO Quality Surveillance conducted quality surveillance activities on the NSP contractors. STAR, on behalf of the owner, conducted quality surveillance on SPMO QS. SPMO Quality Assurance was responsible for overseeing the construction contractors’ Quality Control and QA programs, as well as SPMO’s QS and QA and the Commissioning Team’s QA programs. Significant improvements occurred in the Quality Assurance program of the CMT and the contractors during the execution of the Qinshan Project, particularly in regard to program implementation. Improvements also occurred as a result of lessons learned during the construction and commissioning of Unit 1. These lessons were applied to Unit 2 and resulted in less re-work, reduced costs and better quality control. These lessons may be applied to future projects and expanded further, to improve quality, reduce re-work and achieve greater cost reductions. A description of the overall site QA Program under SPMO’s responsibility is found in Appendix B. 7.1.1 General Responsibility to TQNPC SPMO Site Quality Assurance (SQA) was responsible for defining and ensuring the implementation of a Quality Assurance Program for the construction phase of the Qinshan CANDU Project, in accordance with CSA Standard CAN3 N286.3. SPMO’s activities and the construction contractors’ activities must comply with their respective QA programs. SPMO reviewed the requirements of Nuclear Safety Regulation HAF-0404 to ensure that the requirements were met or exceeded by CSA N286.3. In addition to the above, SQA was responsible for defining and, along with TQNPC, ensuring the implementation of a Quality Assurance Program for the commissioning phase of the Qinshan CANDU Project in accordance with CSA Standard CAN3 N286.4. SPMO reviewed the requirements of Nuclear Safety Regulations HAF-0405 to ensure that these requirements were met or exceeded by CSA N286.4. 7.1.2 SPMO Responsibility to the NSP Construction Contractors and CMT Each construction contractor and CMT was responsible for establishing quality assurance programs in accordance with CSA N286.3. NSP construction contractor and CMT QA manuals were reviewed and accepted by SPMO SQA to ensure that they met Project requirements. Each construction contractor also prepared QA procedures to support the QA manual and submitted them to SPMO for acceptance. To assist the construction contractors and CMT, SPMO carried out information sessions defining the requirements for their QA manuals and supporting procedures. SPMO recommended that the construction contractors and CMT follow the basic 18
2003 February format of the SPMO Construction Quality Assurance Manual to ensure consistency among SPMO, the construction contractors and CMT. SPMO’s responsibility included the review and acceptance of the CMT’s QA Manual and procedures and auditing the effectiveness of BOP construction management for the implementation of the BOP Construction Quality Assurance Program. 7.1.3 Quality Assurance Audits SPMO, CMT and construction contractors carried out QA audits of their own QA programs, the Commissioning Team and the quality programs of their subcontractors and suppliers. Audits of the Commissioning Team were performed jointly with TQNPC. a) Internal QA Audits - SPMO SQA carried out QA audits to confirm that the Site Project Management Organization had implemented the QA requirements specified in procedures and instructions, and that the QA Program was effective. b) External QA Audits - SPMO carried out audits of CMT, ZTPC (for one contract only) and NSP construction contractors’ activities to confirm implementation and effectiveness of their QA programs, as described in their procedures and instructions. c) TQNPC QA Audits - TQNPC carried out QA audits of SPMO and CMT to verify the effectiveness of the respective QA programs. SPMO and TQNPC performed joint QA audits as much as possible, including joint audits of the Commissioning QA program. 7.1.4 Records These include records required by applicable codes, standards, specifications, regulations and TQNPC. These records are assembled and retained as History Dockets for nuclear systems and as History Files for non-nuclear systems by the construction contractors during the construction phase of the Project, by the Commissioning Team during the commissioning phase of the project and by SPMO. History Dockets and History Files are also prepared for NSP equipment and materials. These permanent records are prepared by equipment and material suppliers and then reviewed and accepted by CNPM on behalf of AECL. 7.1.5 Trends Trends are analyzed on a continuous basis and reported monthly to TQNPC. Any negative trends are immediately addressed with the responsible party. Actions taken are documented in minutes of meetings, correspondence, QA Program Reviews, monthly reports and through other means such as non-conformance reports and Corrective Action Requests. 7.1.6 Equipment Surveillance by TQNPC AECL is fully responsible for the manufacturing quality of the equipment, while TQNPC possesses the right of conducting equipment surveillance. 19
Page 1 and 2: QINSHAN CANDU PROJECT CONSTRUCTION
Page 3 and 4: 2003 February TABLE OF CONTENTS SEC
Page 5 and 6: 2003 February TABLE OF CONTENTS SEC
Page 7 and 8: 2003 February design, which will ha
Page 9 and 10: 2003 February ECGD Export Credits G
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Page 13 and 14: Figure 1-1 AECL Overall Project Con
Page 15 and 16: AECL Project Quality Assurance Mana
Page 17 and 18: Figure 1-5 Qinshan CANDU Project -
Page 19 and 20: 2003 February 3. LICENSING AND REGU
Page 21 and 22: 2003 February 2) A technical suppor
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Page 25 and 26: 2003 February Figure 5-1 Major Mile
Page 27: 2003 February 6. DESIGN AND PROCURE
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Page 37 and 38: 2003 February 9. METHOD TO SUBCONTR
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Page 45 and 46: 2003 February 11. MATERIAL MANAGEME
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Page 53 and 54: 2003 February Open item management
Page 55 and 56: General Manager (TQNPC) Project Dir
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Page 59 and 60: 45 40 35 30 25 AECL BECHTEL M-M HIT
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Page 67 and 68: 2003 February • Improvements in p
Page 69 and 70: 2003 February Appendix A Design and
Page 71 and 72: 2003 February • RFC(S) BOP Tech S
Page 73 and 74: 2003 February Appendix B Quality As
Page 75 and 76: 2003 February To initiate this surv
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2003 February philosophy and includ
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