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