NUCLEAR QUALITY KNOWLEDGE (NQK) Version 2 – 2013 NQK: Cover Contents and Preface May 2013 Nuclear Quality Knowledge (NQK) Initial Version September 2011 Version 2 May 2013 NQK has been produced by the CQI Nuclear Special Interest Group. Significant effort has been made to ensure that the contents are correct and will be valuable to the reader, nevertheless, CQI accept no responsibility for negative consequences resulting from the use of NQK. NQK is published by: The Chartered Quality Institute (CQI), 2nd Floor North, Chancery Exchange, 10 Furnival Street, London, EC4A 1AB Tel: +44 (0)20 7245 6722 Fax: +44 (0)20 7245 6788 Email [email protected] Page 2 Chartered Quality Institute© NQK: Cover Contents and Preface May 2013 CONTENTS CHAPTER SECTION Cover, Contents and Preface 1 Introduction 1.1 Tiers in Supply Chain 1.2 UK Nuclear - A summary 2 Background 2.1 Fundamentals 2.2 International & National Infrastructure 2.3 UK Government, Regulatory Organisation and Nuclear Industry 2.4 UK Legal and Regulatory Requirements 3 Leadership and Management 3.1 Leadership and Culture 3.2 Management systems 3.3 Key Concepts 3.4 Expectations of supply chain 3.5 Stakeholder engagement 4 Project Management 4.1 Introduction 4.2 The Gated Process for Project Management 4.3 Typical Project Quality Arrangements/Standards 4.4 Nuclear Safety Focus in Projects 4.5 Independent Nuclear Safety Assessment (INSA) 4.6 Nuclear Safety Committees (NSC) 4.7 Integrated Planning 4.8 Key Learning from Nuclear Projects – why they fail. 5 Operational Management 5.1 Introduction 5.2 People Issues, SQEP, DAP, Control and Supervision 5.3 Radiological Control and Criticality Safety 5.4 Asset Management 5.5 Operational information and documentation 5.6 Nuclear materials and Radioactive Waste 5.7 Emergency arrangements and preparedness 6 Supply Chain Management 6.1 Introduction 6.2 Globalisation 6.3 Specification 6.4 Sourcing 6.5 Post Contract Management 6.6 Product& Service Completion 6.7 Further Information 7 Product Quality Management 7.1 Introduction 7.2 Product Quality Planning 7.3 Specifications, Codes and Standards 7.4 QA grading 7.5 Special Processes 7.6 Inspection and Test 7.7 Metrology and Calibration Page 3 Chartered Quality Institute© NQK: Cover Contents and Preface May 2013 7.8 Certification 7.9 Traceabiliy 7.10 Storage, Handling, Packaging and Delivery 7.11 Non Conforming Product & Concessions 7.12 Nuclear New Build EPR 7.13 Regulatory Issues at Olkiluoto 3 7.14 Regulatory Issues at Flamanville 3 8 Knowledge and Information 8.1 Knowledge Management Management 8.2 Records Management 9 Assessment and Improvement 9.1 Assessment 9.2 Challenge 9.3 Operating Experience Feedback 9.4 Non-conformity & Event Investigation 9.5 Management Review 9.6 Bench marking 9.7 Continual improvement - Improvement programmes 10 History of UK nuclear 10.1 The six era of the UK nuclear industry 10.2 Reactors in the UK 10.3 Other licensed sites in the UK 10.4 Additional sources of information 11 International Approaches 11.1 Overview of Regulatory Approaches 11.2 USA 11.3 France Appendices 1 - Glossary 2 - NucSIG event topics correlated with NQK Chapters. Page 4 Chartered Quality Institute© NQK: Cover Contents and Preface May 2013 Preface The Nuclear Quality Knowledge (NQK) is a nuclear industry guidance document that has been written by members of the CQI Nuclear Special Interest Group (NucSIG) to complement the Chartered Quality Institute (CQI) Body of Quality Knowledge (BoQK). NQK aims to highlight the differences or nuances that a quality professional will experience on joining or supplying the nuclear sector, and which are a consequence of the special hazards and regulatory requirements that apply. This is a significant part of what is sometimes called the “Nuclear Delta”. It is not expected that you read this document from cover to cover, rather that you will use it in two ways: 1. As text for a structured course. 2. As a source for revision on a specific aspect or to dip into as you come across topics or issues during your career. This second version has been substantially rewritten; NQK is now set out in a number of Chapters, containing related topic Sections. In this way it is hoped that it provides an easier logic, and correlates more easily with International standards. In response to comments references and web links have been added in line and as endnotes to each Chapter. A single consolidated Glossary is provided as Appendix 1 to NQK. The primary format of the NQK 2013 will be as a series of PDFs, one per Chapter or other major content heading, held on the NucSIG web page. Periodically individual Chapters will be reviewed and revisions will be made; thus readers should regularly check for updates though it is anticipated that members will be advised of them through NucSIG newsletters. It is still the aim that the NQK will develop with time and use, and those of you using it are encouraged to comment with either corrections or opportunities for enhancement. In using the NQK , as with all documents referencing out to web-based information sources, we are conscious that organisations change their webs and thus you may have to use ‘search machines’ to locate such changes; please let NucSIG know of any such developments you identify. NucSIG If you are drawn to read NQK and are not a member of the CQI’s NucSIG then we would encourage you to join the group, as networking with professionals with the same or similar challenges may be found to be of even greater value than reading and self-tuition, although these are useful. Correlation of the NucSIG Past-Events with NQK Chapters is provided at Appendix 2 to NQK. Details on how to join NucSIG are to be found on the NucSIG web page Acknowledgements Thanks are given to the many members who have contributed to this document. The names of Chapter Editors and Contributors are shown on each Chapter cover sheet and listed at the end of this preface. Especial thanks are given to Iain McNair, Mike Underwood, Richard Hibbert and Susan J M Shaw who oversaw the overall document. We are grateful to many International, Governmental and industry bodies for extracts from their publications which are provided as identified and accredited in the document. Contains UK public sector information published by MOD, DECC, DEFRA, HSE/ONR, NDA and licensed under the Open Government Licence. Photographic images are reproduced by kind permission of the NDA. Page 5 Chartered Quality Institute© NQK: Cover Contents and Preface May 2013 Comments by external bodies Nuclear Institute The Nuclear Institute welcomes the second edition of the Nuclear Quality Knowledge publication. This document, compiled by experts from across the industry, enables knowledge and learning to be shared with all nuclear professionals. Office for Nuclear Regulation The ONR welcomes the CQI NucSIG’s achievement in gathering the collective experience and knowledge of its membership and publishing the Nuclear Quality Knowledge. We believe this document will help quality professionals to understand the unique requirements of the nuclear sector and how quality management principles and standards can contribute to safety in nuclear facilities. Nuclear Industries Association The Nuclear Industry Association Quality Working Group fully supports and welcomes this publication. The quality arena is growing, improving and gaining status. The high level Nuclear Industry Council, co-chaired by ministers and Lord Hutton, has a new Quality Working Group, giving greater prominence to all aspects of quality in construction, maintenance and decommissioning work. With the creation of tens of thousands of new jobs through the planned new nuclear programme it is essential that quality remains at the heart of our growing industry. Contributors Stuart Allen Sellafield Gavin Avery BAM Nuttall Alex Boughey BAe Systems Tony Colyer Sellafield John Day Sellafield Bob Dixon EDF Mark Harbor RSRL Richard Hibbert RSRL Michael Jones DSRL Michael Kelleher DNV Mark Lyons L2 Business Consulting Bob McGeary L2 Business Consulting Iain McNair Retired, formerly NII David Morgan ONR Andrew Mullinder Sellafield Vaughan Rees RSRL Phil Shaw UKAS Susan J M Shaw RSRL Mike Underwood Welsummer Quality Management Graham Watson EDF Page 6 Chartered Quality Institute© NQK : CHAPTER 1 – Introduction May 2013 Chapter 1 Introduction CONTENTS 1.1 Tiers in the Supply Chain ......................................................................................................... 2 1.2 UK Nuclear – A summary ........................................................................................................ 4 The UK Nuclear Sector Principal Organisations .................................................................................. 5 Historic Perspective ............................................................................................................................ 6 The future - 2013 to 2020, Future Systems and Fusion ...................................................................... 6 Editor Iain McNair Contributors Alex Boughey, Bob Dixon, Mike Underwood Chartered Quality Institute© Page 1 NQK : CHAPTER 1 – Introduction May 2013 1.1 Tiers in the Supply Chain In writing this revision we have tried to recognise differing levels of knowledge, of each component subject, that is required at varying levels (tiers) of the supply chain. A key to understanding the supply chain requirements is to understand the terminology used in the UK nuclear sector, which may be subtly different from that used elsewhere, such as the defence