Building Awareness of Horizon’s Values, Standards and Supply Chain Requirements
Richard Edwards Head of Supply Chain QA 27th April 2016
29/04/2016@ HorizonNuclear Page 1 Objectives . Understanding of Quality Culture . Origins of expectations for Quality in nuclear new build . Define the Graded Approach to Quality Assurance (QA) . Know how Horizon determines its QA Grades . Understand how and where in the process the QA Grade may effect the supply chain . Advise where help is available
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Quality Culture
Despite state of the art equipment, the Deepwater Horizon oil rig had an Achilles heel – the absence of a quality culture. The oil and gas sector traditionally dominated by a risk taking approach “normalised” as necessary for oil and gas exploration. • 11 dead • the largest accidental marine oil spill in the world • the largest environmental disaster in U.S. history Google Image A absence of a quality culture lead to the explosion – following quality failures identified:
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Quality Failures
Incorrect parts – key equipment used in drilling operations, were not to the required specification Breach of existing well design – to reduce costs an inadequate number of centralisers were used in the operations (6 instead of 21) No product verification - no receipt inspection tests were conducted on the cement foam; the cement failed the supplier’s own qualification tests Poor supplier management – development of good client supplier relationships is a corner stone to effective quality management; BP's relationship with their supply chain, could be described at best as ‘combative’ Poor process management – ‘Negative Pressure Test’ was not included in the Quality Plan for the work and there was no procedure No management of change procedure – ‘Negative Pressure Test’ was added at the ‘eleventh hour’. Confusion led to a single passed test being accepted despite a further three failed tests. This acceptance sealed the fate of the crew of the Deepwater Horizon platform.
@HorizonNuclear 4 Nuclear Industry Quality Expectations . IS0 9001 . IAEA’s GS-R-3 - nuclear safety culture, competency and oversight . UK Regulators; License Conditions and TAGs e.g. T/AST/077 (TAG77) . Manufacturing codes and standards e.g. ASME NQA-1 (adapted for UK) . Horizon’s specifications for Wylfa Newydd capture the above requirements for cascading to the supply chain
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Project Supply Chain Structure
Developer, owner, operator, decomissioner EPC Contract Tier 1 Joint Venture
Delivery Team
Tier 2s Owner’s scope Manufacture / Construction / Services
Includes Hitachi-GE
Tier 1 – n suppliers Tier 3 – n suppliers
6 @HorizonNuclear The Graded Approach . Horizon as Intelligent Customer at the head of the supply chain has ultimate responsibility for quality . Horizon must prioritise its oversight and quality controls in areas of most significant impact on nuclear safety . Conversely, work of low risk will receive minimal levels of oversight and control . Risks other than nuclear safety need to be considered in the graded approach
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Horizon’s Approach to QA Grading
Horizon Procedure: ‘QA Grading and the Application of Quality Assurance in Project and Procurement Activities’
. Benchmarked against AWE, EDF Energy, IAEA and Magnox best practice . Grades A,B,C,D or ‘exempt’ . Starting point of Safety Classification of the plant, but applies to services as well as items . Other risks; novelty, complexity, H&S, environment, security, programme and cost
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Requirements – Contract Development . Horizon determines QA grade for identified work . EOI to Registered and selected organisations . Pre-Qualification questionnaire (PQQ) . Technical Specification and Management Arrangements (includes QA requirements) + Request for Proposal . Tender assessment to select supplier - ability to meet specification and supply draft QAP and PQP . Approval of supplier – potential for further assessment by audit . Contract award – to approved supplier for identified scope of work
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Requirements – Contract Delivery . Inaugural meeting - Accepted QAP - Accepted and marked-up PQP - Agreement to start work . Monitoring and inspection – according to QPs and with involvement of Inspection Agencies . Acceptance and receipt – CFSI and records . Close out – review & improvement
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Application of the Quality Grades
Requirement Required Optional Not required ISO9001 certification AB C D Pre -qualification questionnaire ABC D Specification/RFP QA requirements ABCD Graded approach Tender/approval assessment - desktop evaluation ABCD Graded approach Tender/approval assessment - audit evaluation A B CD Provision of Quality Assurance Programme AB C D Provision of Quality Plan AB C D SQEP Assessment A BC D Review and acceptance of procedures A BCD Inaugural meeting AB C D Monitoring and inspection A BC D Receipt and close out ABCD Graded approach
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. Know the codes and standards that apply to your product or service . Awareness of regulatory guidance . Business Wales & Nuclear Advanced Manufacturing Research Centre (NAMRC) Fit for Nuclear (F4N) . National Skills Academy for Nuclear (NSAN) Triple Bar . Construction Future Wales (in Wales) . Other business support agencies e.g. CQI . Horizon’s Supply Chain QA Team provides advice on QA requirements and grading
12 @HorizonNuclear For more information
Horizon Nuclear Power channel
@HorizonNuclear
www.horizonnuclearpower.com
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