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Keywords: nuclear power valve; quality plan; management method Introduction Valve quality plan refers to the manufacturing management documents for the valve equipment manufacturing stage. Its manufacturing and inspection work must be carried out around the quality plan. Valve manufacturing quality is based on the valve design drawings, through the casting, forging, welding, cutting, heat treatment and protection processing and other manufacturing processes to complete the processing of parts and components, and the correct installation required to achieve. Valve manufacturing quality is an important prerequisite for the valve to achieve its intended function.
Fuqing Nuclear Power Plant has about 30,000 valves for two units, including 12029 nuclear island valves. According to the principle of quality planning, all QA3 and above valves need to have a quality plan for quality control. A total of 379 valve quality plans (including the quality plan for rework, subcontract quality plan for important parts), including 75 imported valve quality plans and 304 domestic valve quality plans. The quality plan data sheet differentiated by valve type is shown in Figure 1.
1Quality plan preparation submitted to face a number of valve suppliers, a large number of valves, must establish a quality planning principles and a unified template, easy quality plan review and management.
Based on the nuclear safety level of the valve equipment and the quality assurance level, considering the complexity of equipment manufacturing process, manufacturing cycle, and supply experience, etc., the principle of quality planning has been established: 1) No quality plan is required without quality assurance, and there is no contract Equipment for quality plan preparation does not require suppliers to submit quality plans; 2) If quality defects are exceeded within the equipment components of quality assurance level 2 and above, a special quality plan can be prepared; 3) After the non-conformity is generated, the supplier If a new manufacturing process, inspection test method, acceptance criteria, rework or repair must be developed, a special quality plan shall be prepared.
In order to standardize the specification, content and integrity of the quality plan prepared by different suppliers, the preparation of the quality plan is stipulated: 1) The quality plan must specify the equipment from the prerequisite inspection to the equipment acceptance, all manufacturing processes and quality control. Point of equipment and other content; 2) The quality plan cover should include the project name, equipment or parts quality plan name, code, supplier quality plan preparation/audit/approval column, version, etc.; 3) should include "preparation instructions", content Including the purpose, basis, quality control point (H/W/R) meaning, witness notification time, etc.; 4) The quality plan text should meet the table format of Figure 2, and the procedures are complete.
2 Quality plan review points 2.1 Quality plan review Quality plan review is a prerequisite for valve manufacturing quality assurance. It may be due to the supplier's adoption of new manufacturing processes, changes in quality planning personnel, and renewal of standards, resulting in a lack of quality in the quality plan itself. For example, in April 2017, our company completed 88 quality plan reviews, of which there are 37 problems. The quality plan for problems exists as shown in Figure 3. In the process of reviewing the quality plan, attention should be paid to the review of the following contents: quality planning scope, preparation instructions, basis documents, flow charts, process integrity, and rationality of supplier selection.
2.2 Basis for quality plan review and selection requirements Basis for quality plan review includes: Laws and regulations - RCC-M design and supervision of nuclear equipment for pressurized water reactor nuclear equipment, regulations for supervision and management of nuclear safety equipment for civil use, and letter of Central Nuclear Safety Center [2013] ] No. 203, etc.; design documents - technical specifications, design drawings, manufacturing inspection standards; company procedures - equipment quality plan management, equipment supervision and classification management rules.
In order to meet the quality requirements of nuclear power engineering equipment, reasonably allocate supervision resources, and improve the efficiency and quality of supervision and management, we need to select quality control points reasonably and effectively. 1) The imported valve equipment must meet the requirements of relevant key quality control points in the "Notice on Further Strengthening the Supervision, Construction, Pre-shipment Inspection, Supervision, and Color Management of Imported Nuclear Safety Equipment" (Central Nuclear Safety Center Letter [2013] No. 203) 2) The key parts of the equipment manufacturing process (such as prerequisite check, valve pressure test, functional test), or retest very difficult processes, use of special processes, new processes, can be selected as H/W point; 3) Equipment Processes that are more important in the manufacturing process, and those that are prone to quality problems may be selected as W points; 4) Processes for judging whether or not equipment quality meets regulatory requirements, or processes that cannot be monitored throughout the process, or under supervision In the case of human resources limitation, R point can be selected. According to the equipment supervision and manufacturing classification (JZ1/2/3/4), the experience of the supplier's supply, and the experience of previous similar equipments, the control point selection for valve equipment quality plan is shown in Table 1:
The valve specifications are different and there are many batches. In the specific implementation process, the quality plan needs to be split. The on-site supervision has a large workload and the quality control point management is cumbersome. For this purpose, for large batches and batches of equipment, our company has prepared the "Many Batches of Equipment Quality Planning Management Regulations", which clarifies the implementation method of large batch and multi-batch equipment quality plans and divides the quality plans into "maternal quality plans" and The "sub-quality plan" is managed to ensure the orderly conduct of the witness work. The parent quality plan refers to the quality plan submitted by the supplier and reviewed by the engineering company. The sub quality plan means that the supplier meets the production requirements according to the requirements in the factory or the product model, production batch (credit number) The quality plan for the first decomposition of the parent's quality plan usually decomposes the parent's quality plan into a number of sub-quality plans. Mother and son quality plan control flow chart shown in Figure 4.
3 Execution and abandonment of quality plan 3.1 Quality plan execution The supplier shall, according to the type of quality control point of quality plan, according to the progress of equipment manufacturing, issue the equipment inspection witness notice in advance according to the agreed time. If there is the owner witness point, the witness notice shall be Copy the owner.
For W and H points selected by the engineering company, the supplier may not carry out the equipment manufacturing activities without notice, and the supervision personnel shall not arbitrarily give up the witnessing activities; the suppliers and supervisors shall not arbitrarily modify the type of quality control points.
? Before witnessing at W or H point, the supervisory personnel shall promptly adopt a review report, on-site quality inspection, etc. to confirm the quality of the relevant completed process. If the quality of the process is unqualified, the supplier shall not allow W or H points. Witness the operation of the process.
When the parties participating in the inspection confirm that the manufacturing process and results of the equipment comply with the specified requirements, they shall promptly sign the relevant quality control points in the signing column of the quality plan; the supplier shall at least timely complete the process quality records or report approvals for the quality control points. Work so that the supervision personnel can review it in a timely manner.
3.2 Quality Plan Witness Abandonment When the following matters occur, the supervisor may consider giving up the witness point: (1) The force majeure affects the attendance of the witness;
(2) The supplier has witnessed earlier stages of the same process and has experienced problems;
(3) The supplier did not notify the witnessing activities in accordance with the contract, and the supervisors could not witness the working time conflict;
(4) Other reasons to give up.
After witnessing abandonment, the supervising engineer shall check the quality of the abandoned witness points at the next witnessing, fill in the abandonment number, and if there is an intention to abandon the witnessing process or activity (H or W point), when there is an archived record or report, Change the witness point to point R, and close it according to the requirements of R point review; in principle, point R can not abandon 4 quality plan changes and close the equipment quality plan Partially if operation content, applicable standard/file name or number change, quality control point type In terms of such changes, the supplier can fill out the "Appliance Quality Plan Change Request Form" to change the quality plan, approval process and equipment quality plan approval process. After approval of the quality plan change, the supplier shall mark the revised content in the quality plan and indicate the letter number in the corresponding remark column; the quality plan shall be upgraded during execution, and the supplier shall attach the quality plan that has been implemented to the After the edition of the quality plan, and on the quality plan that has been implemented, identify the words that the quality plan will no longer be executed and that will be executed according to the new version quality plan.
After the execution of all processes in the quality plan is completed, the supervisors need to check the signing of the quality control points and confirm that all quality control points have been completed. The relevant parties have all signed the relevant signatures, and the quality plan is automatically shut down; The Quality Plan sets the "Quality Plan Close" control point. After the relevant parties have all signed the signature, the quality plan is closed. If equipment quality plans cannot be temporarily closed due to various reasons such as non-conformity items or legacy items, the equipment quality plan must be closed when the non-conformance items or the legacy items are closed and the conditions are met.
5 Dynamic tracking, continuous improvement During the execution of the quality plan, various problems will be encountered, such as valve design changes, model changes, valve deletions or additions, material substitutions, process improvements, excessive number of witness points, and supervision Insufficient personnel, accelerated manufacturing schedules, subcontractor changes, etc. Therefore, quality planning management needs dynamic tracking and continuous improvement. In this regard, we have established a supervision and management subsidy system and a supervisory and technical support system. Supervisors regularly visit the manufacturer to inspect the implementation of the quality plan, record problems and feedback questions, and find suitable solutions. Experience feedback or regular meetings on valve equipment supervision issues, supervision inspections, internal quality assurance audits, etc., identify problems, solve problems, and track and continuously improve quality plans.
6 Conclusion To ensure the quality of nuclear power valve equipment manufacturing, meet the safety standards and functional requirements of nuclear power plants, and strictly manage the quality of equipment manufacturing plans. From the quality plan preparation, review, approval, implementation, and closure of the entire process, closed-loop management should be implemented, dynamic tracking of quality plan execution, and continuous improvement, so that the factory valve can perform its specific functions safely and effectively, which will ensure the construction of nuclear power in China. Escort, so that efficient, clean, safe green energy improves the quality of people's lives, and provides new impetus for the sustained and healthy economic and social development.
Nuclear Power Valve Equipment Quality Plan Management Overview
Abstract: The quality planning management model is an important management tool for quality assurance in the manufacturing process of nuclear power plants. This paper takes Fujian Fuqing nuclear power station valve equipment as an example, combines the quality plan review and the problems encountered in the process of implementation, confirms the principle of the quality plan preparation, formulates the quality plan template, and reviews the valve quality plan basis and selection requirements. Conducted combing and summarization; established quality plan change and closure management processes; managed and continuously improved quality plans through supervision and management subsidence, supervision inspections, and experience feedbacks to ensure the validity of quality plan documents. Operable, make the valve manufacturing quality controlled.