South African Suppliers –Quality Management readiness for Nuclear Understanding the fabrication requirements that affect your quality management system Presented at the Nuclear Supply Chain Conference Cape Town 01-02 December 2015 Presenter: Larry Kloppenborg

1. South African Suppliers –
Quality Management readiness for
Nuclear
Understanding the fabrication requirements
that affect your quality management system
Presented at the
Nuclear Supply Chain Conference
Cape Town 01-02 December 2015
Presenter: Larry Kloppenborg

2. 22 March 2016 / 3 © 2013 – EON Consulting (Pty) Ltd
Nuclear Power Plants
Topical Nuclear Power Plant – quality requirements
• Conventional Island and Balance of Plant: ISO 9001, GS-R-3, ASME NQA-
1, ASME VIII, ASME B31 series, etc

3. 22 March 2016 / 4 © 2013 – EON Consulting (Pty) Ltd
Conventional Island and Balance of Plant
• Low Pressure casings, pipe work, steel linings &
structures, ducting, fans & motors, gear boxes,
feedwater tanks & heaters and pumps, ….
• Steel structures, buildings, …
• Cranes, valves, piping, storage tanks, electrical
equipment and panels, generators, heat
exchangers, HVAC units, filters, switchgear,
transformers, cables, dryers, certain pressure
vessels, …….
• Services, design & engineering, project
management, commissioning, testing and
maintenance, …….
• - Medupi and Kusile
Made in RSA

4. 22 March 2016 / 5 © 2013 – EON Consulting (Pty) Ltd
South Africa - ASME Stamp holders
PP - Power Piping; U – ASME VIII, Div1 or Div 2 or Alt; NA - Field installation and shop assembly of all items
NPT - Parts, appurtenances, welded tubular products, and piping subassemblies; NS – Supports; S – Power boiler
Company Name State/Province Certificate Status
DB Thermal Nigel PP- 44112 Active
DB Thermal Nigel S- 44113 Active
DB Thermal Nigel U- 44114 Active
DB Thermal Nigel U2- 44115 Active
F.P. Installations (Pty) Ltd. KwaZulu Natal U- 44935 Active
GasCon Western Cape U2- 35516 Active
GasCon Western Cape U- 35515 Active
GEA Aircooled Systems (Pty) Ltd. Gauteng U- 34999 Active
H.G. Molenaar & Co. (Pty) Ltd. Western Cape U- 32564 Active
Intertek Industry Services (PTY) Ltd Gauteng AIA- AIA-70 Active
John Bean Technologies (Pty) Ltd Western Cape U- 45205 Active
Nuclear Manufacturing North West Province U- 26768 Active
Nuclear Manufacturing North West Province NPT- N-3807 Active
Nuclear Manufacturing North West Province N- N-4254 Active
Nuclear Manufacturing North West Province NA- N-3946 Active
Nuclear Manufacturing North West Province NS- N-3853 Active
Welfit Oddy Pty Ltd Eastern Cape U- 35782 Active

5. 22 March 2016 / 6 © 2013 – EON Consulting (Pty) Ltd
RSA fabrication framework:
Pressure Equipment Regulations
• Pressure Equipment Regulations - October 2009: SCOPE
– These Regulations shall apply to the design, manufacture, operation, repair,
modification, maintenance, inspection and testing of pressure equipment with a
design pressure equal to or greater than 50 kPa, in terms of the relevant health and
safety standard incorporated into these Regulations under section 44 of the Act.
– PER 3 (1) Any person who manufactures, imports, sells, offers or supplies any pressure equipment
described in these Regulations for use in the Republic shall ensure that such equipment complies with
these Regulations.
– PER 3 (3) All pressure equipment for use in the Republic shall be categorized and submitted to the
applicable conformance assessments of SANS 347 in addition to the requirements of the relevant
health and safety standard incorporated into these Regulations under section 44 of the Act.
– PER 7(3) (a) The chief inspector's approval of inspection bodies operating in the Republic shall be
subject to the submission of an accreditation certificate issued by the accreditation authority in
accordance with the requirements of SANS/ISO 17020 and SANS 10227; Provided that the chief
inspector may set additional requirements before granting approval;

6. 22 March 2016 / 7 © 2013 – EON Consulting (Pty) Ltd
PER – Incorporated Health and Safety Standards
• Incorporated Health and Safety Standard –
– “SANS 347" means the Standard Specification for categorization and conformity
assessment criteria for all pressure equipment, SANS 347, published by the South
African Bureau of Standards (Based on PED requirements)
– “SANS 10227" means the Standard Specification for the criteria for the operation of
inspection authorities performing inspection in terms of the Pressure Equipment
Regulations, SANS 10227, published by the South African Bureau of Standards;
• Approved Inspection Authority -
– IPE and CP hold SAQCC registration for knowledge, training and experience (renew
every 3 yrs)
– Technical Manager – holding tertiary qualifications and ECSA registration

7. 22 March 2016 / 10 © 2013 – EON Consulting (Pty) Ltd
RSA PER Regulatory Framework
Manufacturer
– NQA-1,
ISO9001,
ISO3834, plus
design code
Inspector of
Pressure
Equipment
Approved
Inspection
Authority
SAQCC (IPE
& CP)

8. South African Suppliers –
Quality Management readiness for
Nuclear
Understanding the nuclear regulatory
framework for nuclear requirements that
affect your quality management system

9. Nuclear
Quality
Management
System – key
documents

10. © 2013 – EON Consulting (Pty) Ltd
National Nuclear Regulator - rules
• RD 0034 sets the graded approach to the management systems applicable to
the classification of “Structures, Systems and Components”
• The Licensee has to establish the safety classification system for the nuclear
plant and assign accordingly.

11. © 2013 – EON Consulting (Pty) Ltd
Integrated Management System - Levels
• The IMS-structure of this RD consists of three levels:
• Level 1 (Direct influence on the safety performance of the nuclear installation): The
licensee as well as suppliers assigned responsible for products of high importance to
nuclear safety must additional to the Quality Management System (QMS) implement a
Safety Management System as part of an Integrated Management System (see section
6.3).
• Level 2 (Products important to nuclear safety): A QMS is required for organisations
providing products important to nuclear safety which is compliant with /3/ or any equivalent
international accepted QM standard. Accreditations according to accepted nuclear QM
standards (e.g. /5/) would be considered as a basis if provided for the organisation. In
addition QM processes, design codes and standards have to be applied that are specific to
nuclear installations. The safety and quality classification of the SSC and the application of
the nuclear codes and standards require additional QM and SSC related QA measures.
• Level 3 (All products of the Nuclear Installation): The implementation of an appropriate
QMS is mandatory as a basis for all organisations involved in the products related to an
application for or operation of a nuclear installation. The QMS requirements of the applied
QM standard should include the consideration of the Quality Assurance (QA) measures
specified for the particular products of the organisation. The determination of QM/QA
requirements and the associated QM/QA system for products with no importance to nuclear
safety rests with the licensee.
Safety
Culture
+
ASME
NQA-1
+
IAEA GS-R-
3
+
ISO9001
+
Licensee
determined

12. © 2013 – EON Consulting (Pty) Ltd
Quality Management System standards
• The NNR default position for the Level 3
and 2 quality management systems is ISO
9001 compliance plus applicable nuclear
and design code quality requirements,
namely -
– /3/ ISO 9000:2000 Series including ISO
9001:2000
– /4/ IAEA Safety Standard GS-R-3: The
Management System for Facilities and Activities
– /5/ ASME NQA 1:2008: Quality Assurance
Requirements For Nuclear Facility Applications
• Noting there is a great portion of a nuclear
plant that is not classified as Level 1.

13. Safety Culture Enhancement
Programmes to support the Quality
Management Systems
Principles of Safety Culture programmes

14. © 2013 – EON Consulting (Pty) Ltd
Nuclear Safety Culture
• The test is - Human Behaviour
• Strong Leadership sets direction

15. © 2013 – EON Consulting (Pty) Ltd
NNR Safety Culture Requirements: RD0034
• Para 6.2: “The NNR requires that an appropriate level of SC be adopted within
each organisation involved in processes with high nuclear safety importance.
The NNR considers the following aspects as important to reach an appropriate
Safety Culture within all level 1 organisations:
–Individual Awareness / Questioning Attitude
–Knowledge, Authority and Competence
–Example Function of Management (Safety Leadership)
–Commitment to Safety
–Acceptance of Authorities
–Acceptance of Rules
–Motivation to reach goals
–Safety Promoting Work Environment (Including Housekeeping)
–Open Communication (Including with Authorities)
–Monitoring of safety culture performance
–Operational Experience Feedback”

16. © 2013 – EON Consulting (Pty) Ltd
Safety Culture Principles
• Safety Culture Principles for a Strong Safety Culture
1. Everyone is personally responsible for nuclear safety.
2. Leaders demonstrate commitment to safety.
3. Trust permeates the organisation.
4. Decision-making reflects safety first.
5. Nuclear technology is recognised as special and unique.
6. A questioning attitude is cultivated.
7. Organisational learning is embraced.
8. Nuclear safety undergoes constant examination.
• Ref - IAEA INSAG Series No. 4: Safety Culture

17. © 2013 – EON Consulting (Pty) Ltd
Barberton Boiler

18. © 2013 – EON Consulting (Pty) Ltd
Case Studies: Barberton Boiler
• Failure by Management to provide proper
resources for the –
– Maintenance and Repair services
– Competent personnel to operate plant
– To hear the warnings

19. © 2013 – EON Consulting (Pty) Ltd
Injaka Bridge collapse

20. © 2013 – EON Consulting (Pty) Ltd
Case Study: Injaka Bridge
• Designer Management failure –
– Proper Oversight / Supervision of personnel
– Overloaded personnel
• Personnel failure –
– They are the Professionals and know best
– Failure to hear concerns / warnings
• Construction Management failure –
– Questioning attitude (Designer is responsible)
– Lack of oversight and validation

21. © 2013 – EON Consulting (Pty) Ltd
Where do you start as a Fabricator / Supplier
• Establishing an integrated management system embedding the –
–Compliance to ISO 9001
–Compliance to “Quality Plus” – design code quality requirements (ASME NQA-1, IAEA
GS-R-3)
–For Level 1 Suppliers –
–Compliance to Safety Management requirements
–Compliance to “Safety Plus” – design code safety requirements
–Implemented Safety Culture enhancement program (IAEA + INPO)

22. Questions and
discussions
@eon_consulting
info@eon.co.za
www.eonconsulting.co.za
+27 (0)11 564 2300
EON Consulting services include –
• Understanding the Regulatory framework
and requirements
• Development of management systems and
processes
• Establishment of a Safety Culture
programme
• ASME endorsed NQA-1 training
• Supplier evaluations and approval