Copy No.: ____ _

PROCEDURE FOR QA SURVEILLANCE

PK21 0010021 K00004AP Rev.3

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K-2/K-3

PAEC

September 2014

KARACHI NUCLEAR POWER PROJECT - 2 (K-2/K-3) PAKISTAN ATOMIC ENERGY COMMISSION

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KARACHI NUCLEAR POWER PROJECT - 2 (K-2/K-3)

QA ASSESSMENT

PROCEDURE FOR QA SURVEILLANCE PK21 0010021 K00004AP

Rev.3

Prepared by

Farhan Kanm , SE

Reviewed by

~ '''" ~~ \"' \ QA ~~q~:q/1 1

Sami Ullah Siddiqui, ss

M. Orner Iqbal, H(QAD)

~q [ l~ ApprovJ by

Azfar Minhaj , GM (K-2/K-3)

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2 15

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Rev. Page No.(s)

KARACHI NUCLEAR POWER PROJECT - 2 (K-2/K-3)

QA ASSESSMENT

PROCEDURE FOR QA SURVEILLANCE

September 2014

July 201 3

Nov. 2008

April2008

Date

PK21 0010021 K00004AP Rev.3

REVISION CONTROL SHEET

Updated according

Syed Saifuddin M. Orner Iqbal, to Management

Rizvi , DCE H (QAD) System for Azfar Minhaj ,

Sami Ullah Design and GM(K-2/K-3) Siddiqui , SS Construction

Phase of K-2/K-3.

-Updated according to Management

Syed Saifuddin Muhammad System for Azfar Minhaj, Rizvi, DCE Younus, Siting and PD(K-2) M. Orner Iqbal, SE H (S&QA) Construction phase of K-2 Project. - Revision due

Procedure has S.M. Nafeesuddin,

Abdul Bari , been updated Zulfiqar Al i,

PE SM/M/H(QAD)

according to PO (K-2) Jahangir Zafar, SE latest

requirements .

M. Suhail Akhtar, Abdul Bari , First Issue

Qamrul Hoda, SE SM/M/H(QAD) DG (K-2)

Reviewed by QA Reviewed by Reason for Approved by

Modification

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· 11 Procedure for QA Surveillance

TABLE OF CONTENTS

PK210010021K00004AP Rev. 3

1 PURPOSE ....... -............................................................................................. 4

2 SCOPE ......................................................................................................... 4

3 DEFINITIONS .......... _ ..................................................................................... 4

4 RESPONSIBILITIES .. .................................................................................. 6

4.1 ORIGINATOR ....... .. .. .... ... .. ....... .... .. .. .............................. ... ............................ .. 6

4.2 MODIFIER ..... ..... ... ........ ..... .... .. ... ... ...... .... ....... ..... .... ........ .............. ... .. .. .... ... .. .. 6

4.3 REVIEWER ...... .... .. ......... .... ... .. .. .. ... ..... ...... ........... ..... ............... ......... .. ... .. ... .. .. 6

4.4 QA REVIEWER ... .... ... ......... .. ......... ... ...... ......... ..... .. ..... .. ... ... ... ....... ... ... ..... .... _ .. . 6

4.5 APPROVAL .. .. .... .. ......... .. ..... ... ...... ............ .. ... ... ...... ... ... .. .... .... ...................... ... 6

4.6 TRAINING AND QUALIFICATION ... ...... ... ...... .. .... ........ ............ .. ............. ... .... 6

4.7 DOCUMENT CONTROL ...... .. .... .. ..... ...... ..... ..... ....... .. ............ .. .... .... .... ..... ..... . 7

4.8 EFFECTIVENESS AND IMPLEMENTATION ...... ...... .. .. ... .. .... ...... ...... .... ... .... 7

5 REFERENCES ............................................................................................. 7

6 DETAILS ......................................................... -............................................. 7

6.1 ELEMENTS FOR QA SURVEILLANCE .............. ... .... ... ..... ......... ...... .. ..... .. ... . 8

6.2 QA SURVEILLANCE TEAM .. ................ .... .... .. .. .. .. .......... ... .... .. .... .. .... .. ... .. .. .. .. 8

6.3 FERQUENCY OF QA SURVEILLANCE ... .... .. ..... ...................... .. .... .. .......... ... 9

6.3.1 PLANNED QA SURVEILLANCE .... .. ... ... ..... ...... ...... ...... .. .... .. .. ..... .... ... ............ 9

6.3.2 GENERAL QA SURVEILLANCE .. .. .... .. ... ............ ................ ... ... ............ .... ... 10

7 DOCUMENTS AND RECORDS ................................................................ 10

ANNEXURE-I QA SURVEILLANCE CHECKLIST .. .. .. .... .... .. ... ... .. ........ ..... ...... . , 12

ANNEXURE-II CONTENTS OF CONTROL POINT JOINT WITNESSING SUMMARY ... ... .. ..... ......... ... ..... .. ............................... ... 13

ANNEXURE-Ill LIST OF OBJECTIVE EVIDENCES ... .. .... ..... .. ..... ... ...... ... ..... ....... 14

ANNEXURE- IV CONTROL POINT WITNESSING REPORT .. .. ... ........ .. .......... .. . 15

ANNEXURE-V GENERAL SURVEILLANCE REPORT .......... ............ .. ...... ......... 16

ANNEXURE-VI COMMENTS SHEET .... .. .... ....... .. .. .. .. .......... .. .. .. ... ..... ...... ....... .. .... 17

DISTRIBUTION LIST ... ............ ... ... ...... .. .... .. ...... .... ... ............. ... ... .. .. .......... .. .. ...... ... .. 18

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I; , Procedure for QA Surveillance

1 PURPOSE

PK210010021K00004AP Rev. 3

The purpose of this procedure is to provide guidelines to the QA division and experts from other departments I establishments of PAEC for QA Surveillance. The experts will participate in QA Surveillance as QA Surveillance team members from time to time for any specific Control Point as well as general QA surveillance. This procedure will also provide guidelines to QA personnel to participate and record observations in a systematic and organized manner so as to assist in effective monitoring during design and construction phase of K-21K-3 Project.

2 SCOPE

The QA personnel and other members of QA Surveillance team will use this procedure for the planned I general QA Surveillance during design and construction phase of K-21K-3 Project.

3 DEFINITIONS

DC&CM

Document Control & Configuration Management

GM {K-2/K-3)

General Manager (K-21K-3)

H, W, R Points

Hold , Witness & Record Point

IAEA

International Atomic Energy Agency

K-2/K-3

Karachi Nuclear Power Project-2

P&HR

Planning and Human Resource Division

QAP

Quality Assurance Program

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f j • Procedure for QA Surveillance

QMS

Quality Management System

Q-Pian

Quality Plan

SD

Site Development Division

SON

System Deficiency Notice

SURVEILLANCE

PK210010021K00004AP Rev. 3

It is an act of inspection, monitoring to verify that activities are being performed as per specified requirements .

NON-CONFORMANCE

A deficiency in characteristic, documentation or procedure that renders the quality of an item or activity unacceptable or indeterminate

NCN

Non-Conformance Notice

NCR

Non-Conformance Report

PAEC

Pakistan Atomic Energy Commission

Planned QA Surveillance

The act of monitoring through witnessing of control points, selected in Q-Pians and surveillance test schedules, or verification regarding implementation of selected approved procedures.

General QA Surveillance

The surveillance carried out by QA personnel other than planned QA surveillance.

Responsibte Division

Division of K-2/K-3 under which the work is been carried out.

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M/H

Manager I Head

QAD Quality Assurance Division

TE

Technical Division

4 RESPONSIBILITIES

4.1 ORIGINATOR

PK210010021K00004AP Rev. 3

M/H (QAD) of K-2/K-3 or his designated person shall be responsible for preparation of this procedure.

4.2 MODIFIER

M/H (QAD) of K-2/K-3 or his designated person shall be responsible for modification/revision of this procedure after every five years or earlier, if required .

4.3 REVIEWER

A person(s) designated by M/H (QAD) shall be responsible for the internal review of this procedure. In addition, DG/GM/PD (K-2/K-3) may authorize relevant person(s) of K-2/K-3 Project or outside to carry out external review of this procedure.

4.4 QA REVIEWER

M/H (QAD) of K-2/K-3 Project shall be responsible to conduct QA review of this procedure.

4.5 APPROVAL

GM (K-2/K-3) shall approve this procedure.

4.6 TRAINING AND QUALIFICATION

M/H (TE) shall be responsible to arrange for the familiarization/ training of QAD and other personnel of different department regarding use & implementation of this procedure.

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Rev. 3

4. 7 DOCUMENT CONTROL

M/H (TE) shall be responsible for keeping records (hard and soft copies) distribution and issuance of the procedure.

4.8 EFFECTIVENESS AND IMPLEMENTATION

M/H (QAD) of K-2/K-3 Project shall be responsible for the effectiveness and implementation of this procedure.

5 REFERENCES

PK210010003K00004AP (Rev,1), "Guidelines to Prepare, Review and Approve Procedures for K-2 Project".

PK210010027K00004AP (Rev.O) , "Procedure for Coding and Filing of Documents".

PK21 0020001 K00004GN (Rev.O), "Management System for Design and Construction Phase of K-2/K-3 Project" .

PK210010024K00004AP (Rev.1), "Procedure for Review of QA Program I Manual of Main Contractor and Subcontractor".

PK210010032K00004AP (Rev.O), "Procedure for Control of Non-Conformance".

GS-R-3, "The Management System for Facilities and Activities".

GS-G-3.1 , "Application of Management System for Facilities and Activities" .

GS-G-3.5, "The Management System for Nuclear Installations".

IAEA Nuclear Energy Series No. NP-T-2.7, 2012 "Project Management in Nuclear Power Plant Construction"

PAK 912, Regulations on the Safety of Nuclear Power Plant Quality Assurance (Rev. 0)

PAK 1304, Quality Assurance in Siting

Interface Procedure b/w CZEC K-2/K-3 and PAEC K-2/K-3 for the Execution of QA Activities during the Course of Construction", PK210010031K00004AP, Rev. O

6 DETAILS

Surveillance of work performance is considered to be the best technique for

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. 1: Procedure for QA Surveillance PK210010021K00004AP

Rev. 3

assessing and reporting on a specific area, or on-going activity. It can be performed in a relatively short period of time with limited preparation and show product deficiencies and weaknesses in the QA program.

6.1 ELEMENTS FOR QA SURVEILLANCE

The QA personnel will cover the following elements related to equipment manufacturing and construction activities in the course of QA surveillance:

1. Hiring of Services/ Contractor and Procurement of items or equipments for data collection or other equipment manufacturing and construction activities should be according to Procedure for QA in Hiring of Services I Contractor and Procurement of Items (PK210010014K00004AP, Rev.2) ;

ii. Measurement of performance

a. Work related to equipment manufacturing and construction activities of K-2/K-3 project should be planned, performed and controlled and ensure that all activities relating to witness of the control point are being followed strictly in accordance with IAEA I PNRA Safety Standards for Nuclear Power Plants and designer speCifications, etc.;

b. Equipment manufacturing and construction work is to be performed in accordance with specified procedures and instructions listed in Section 5.4 and 5.5 of Management System for Design and Construction phase of K-2/K-3 Project (PK21 0020001 K00004GN. Rev.O);

c. The measuring and test equipment used for data acquisition throughout the equipment manufacturing and construction process should be of proper type, range, accuracy and precision. A procedure should be established for the calibration of these equipments to ensure that the accuracy is maintained within the prescribed limits and that the required reproducibility and tractability is present;

6.2 QA SURVEILLANCE TEAM

QA surveillance team may comprise of one or more than one person considering the surveillance requirements and availability of the group personnel.

M/H (QAD) may also request to arrange the services of properly qualified person from other Departments I Establishments of PAEC for participation as subject specialist in specific control points.

M/H (QAD) may also join the team considering his appointments and requirements.

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6.3 FERQUENCY OF QA SURVEILLANCE

PK210010021K00004AP Rev.3

OA surveillance for a particular activity will be conducted as per predefined frequency for specific task.

OA surveillance could be Planned or General.

6.3.1 PLANNED QA SURVEILLANCE

a) QA SURVEILLANCE ACTIVITIES AT K-2/K-3 SITE

Main contractor I responsible division of K-21K-3 will inform QAD in writing at least two weeks before the start of any activity and provide approved OMS I OAP I OAM, Working Program along with 0-Pian of the activity. M/H (OAD) will assign one or more OA personnel to review the documents according to the "Procedure for Review of OA Program I Manual of Main Contractor and Subcontractor", PK21 001 0024K00004AP (Rev.1 ).

The assign OA personnel will mark their Hold I Witness I Record points on 0-Pian with the consultation of MIH (OAD). The final 0-Pian with selected control points will be returned to responsible division I main contractor by MIH (OAD) before the start of activity arid will prepare the OA Surveillance Checklist (ANNEXU-RE-i).

Before Start of the activity responsible division of K-21K-3 I main contractor will arrange the Entrance meeting so the schedule I plan for work execution will be agreed and properly communicated.

Responsible division of K-2/K-3 I main contractor will inform OAD for its selected activity (as per 0-Pian) 24 hrs prior to the commencement of selected activity.

The OA surveillance team will closely observe each and every process including pre-requisites, tests, testing arrangement and set-ups, adequacy of testing and installation of equipment and other related activities.

The QA surveillance team will ensure that all the activities relating to the witness of the control point are being performed strictly in accordance with Specified requirements mentioned in the relevant Designer's Specification and or other applicable documents such as PSAR, OOAP I OMS, related codes and standards, etc.

All the results I observations recorded during witnessing of control point will be properly documented in the Control Point Witnessing Summary (ANNEXURE­II) along with list of Objective Evidences (ANNEXURE-Ill).

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The report will be supported with filled checklist (based on Applicable Designer's Specifications and I or relevant Codes & Standards) , appropriate sketches & photographs (if necessary). Assign QA personnel I team leader is responsible for the preparation of Control Point Witnessing Report (ANNEXURE-IV). The report will be submitted to M/H (QAD).

Any non-conformance observed during witnessing of the control point will be properly recorded in the Control Point Witnessing Report and System Deficiency Notice I Non-Conformance Notice I Non-Conformance Report will be issued according to Procedure Control for Non-Conformance (PK200010010032K00004AP, Rev.O). Follow-up shall be maintained till satisfactory closure of the Non-Conformance.

b) QA SURVEILLANCE ACTIVITIES OTHER THAN K-2/K-3 SITE

For the QA inspection and surveillance activities other than K-2/K-3 site will be carried out as per "Interface Procedure b/w CZEC K-2/K-3 and PAEC K-2/K-3 for the Execution of QA Activities during the Course of Construction", PK210010031K00004AP, Rev. 0.

6.3.2 GENERAL QA SURVEILLANCE

Any Non-Conformance observed during General QA surveillance will be immediately communicated to M/H (QAD) for initiating NCR/NCN/SDN/CAR as per Procedure Control for Non-Conformance (PK200010010032K00004AP, Rev.O) further necessary action . The relevant section/ division will provide their written response to OAD within one week for site and two weeks for manufacturing related issues. All QA surveillance reports will be maintained and properly filed in folders by QAD. All the observations recorded (on the specific format of report attached at ANNEXURE-V) during this General QA surveillance duties will be submitted to the M/H (QAD).

For General QA Surveillance following should be considered :

i. Checklist ii. Team or single person iii . Graded approach iv. Issues to be raised (NCN, NCR, SON)

7 DOCUMENTS AND RECORDS

All the following records generated as a result of implementation of this procedure will be kept by QAD.

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Procedure for QA Surveillance

i. Q-Pian(s) ii. Control Point Witnessing Report iii. General Surveillance Report iv. Control Point Witnessing Summary v. List of Objective Evidences vi. Any non-conformance (Permanent record)

PK210010021K00004AP Rev. 3

Comment(s) on this procedure can be offered by any K-2/K-3 person on the 'Comments Sheet' attached at ANNEXURE-VI. Comments sheet shall be kept as record till the next revi$ion of this procedure.

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Code:

Sr.#

Prepared by:

Procedure for QA Surveillance

QA SURVEILLANCE CHECKLIST QUALITY ASSURANCE DIVISION

K-2/K-3 PROJECT

Check Contents

Checked by:

----

Title of Activity:

Q-Pian:

Reference

Approved by:

PK210010021K00004AP Rev. 3

ANNEXURE-I PK210010021K00004AP

Rev. 3

Remarks

*use extra sheet if required -

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Procedure for QA Surveillance

PK21 001 0021 K00004AP Rev. 3

ANNEXURE-II PK210010021K00004AP

Rev. 3

CONTENTS OF CONTROL POINT JOINT WITNESS SUMMARY

i. Summary Code (right corner)

ii. Title of Summary

iii. Date and Time

iv. Witness Place

v. Witness Period

vi. Q-Pian

vii. Control Point Title (R, W & H)

viii. Entrance Meeting

ix. Details of Documents I Records Examined

x. Brief Description

xi. Observations

xii. Conclusion

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LIST OF OBJECTIVE EVIDENCES Equipment/Part:

QUALITY ASSURANCE DIVISION Karachi Nuclear Power Project-2 (K-2/K-3) Organization:

DOCUMENTS EXAMINED DURING CONTROL POINT WITNESSING Sr.No TITLE OF DOCUMENS

Prepared by: Reviewed by :

CODE

PK210010021K00004AP Rev. 3

ANNEXURE-Ill PK210010021K00004AP

Rev. 3

Code:

Date:

No. of Pages:

ATTACHMENT REMARKS

Approved by T earn Leader:

*use extra sheet if required

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CONTROL POINT WITNESSING REPORT QUALITY ASSURANCE DIVISION

KARACHI NUCLEAR POWER PROJECT -2 (K-2/K-3)

1 CONTROL POINT IDENTIFICATION:

Q-PLAN No: WITNESS DATE:

2 TEAM MEMBERS S.No. NAME & DESIGNATION DEPARTMENT

1.

2.

3.

PK21 0010021 K00004AP Rev. 3

ANNEXURE-IV PK210010021K00004AP

Rev 3

CODE:

DATE:

I No. of Pages:

I SPECIALITY

3 APPLICABLE DOCUMENTS (Procedures, Specifications, Code, Drawings, etc.)

i. iv. ii. v. iii. vi. 4 BRIEF SUMMARY OF CONTROL POINT WITNESSED

5 OBSERVATIONS I REMARKS

Team Leader

6 REVIEWED BY RELEVANT SECTION

Section lncharge

7 APPROVED by M/ H (QAD)

M/H (QAD)

*use extra sheet if required

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SURVIELLANCE REPORT QUALITY ASSURANCE DIVISION

KARACHI NUCLEAR POWER PROJECT-2 (K-21K-3)

PK210010021K00004AP Rev. 3

ANNEXURE-V PK210010021K00004AP

Rev 3

CODE:

DATE:

1 DESCRIPTION OF GENERAURANDOM SURVEILLANCE:

Q-PLAN No: VISIT DATE: AREA:

EQUIPMENT: SYSTEM: LOCATION:

2 TEAM MEMBERS S.No. NAME DESIGNATION

1.

2.

3.

3 APPLICABLE DOCUMENTS (Procedures, Specifications, Code, Drawings, etc.)

i. iv. ii. v. iii. vi. 4 BRIEF SUMMARY OF GENERAL I RANDOM SURVEILLANCE

5 OBSERVATIONS I REMARKS

Team Leader

6 REVIEWED BY RELEVANT SECTION

Section lncharge

7 APPROVED by Ml H (QAD)

M/H (QAD)

*use extra sheet if required

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Rev. 3

ANNEXURE-VI

tf'"~·~> KARACHI NUCLEAR POWER PROJECT - 2 (K-2/K-3)

COMMENTS SHEET

Procedure Title Procedure for QA Surveillance

Code & Revision PK210010021K00004AP, Rev. 3

S.No. Date Section Page Comments

Name, Designation

M/H (Concerned Division)

M/H (TE)

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DISTRIBUTION LlST

1. GM (K-2/K-3)

2. Manager (SD)

3. Head (P&HR)

4. Head (QAD)

5. Head (Safety)

6. Head (Commissioning)

7. Head (Technical)

8. Author(s)

9. Reviewer(s)

1 O.lncharge DC&CM (Original)

PK210010021K00004AP Rev. 3

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