INSTITUTE FOR PLASMA RESEARCH
Doc Ref :
Date :
Status
IPR Ref :
Project Code :
In Work
Issue
IPR PL
Dr. S. Pradhan
01
Project:
Manufacturing of Superconducting Central Solenoid coil for SST-1
Document Type:
Quality Assurance Plan
Document Title:
Quality Assurance Plan for Superconducting Central Solenoid Coil
Summary:
The Quality Assurance Plan for manufacturing of superconducting central solenoid Coil is
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documented. All the required qualifications and expectation from suppliers is specified in
given document.
Name (s)
Prepared by :
Reviewed by :
Approved by :
Circulation
H.Patel,
T.Parikh,M.Ghate
P.Santra, U.Prasad
S.Pradhan
Signature(s)
Date
Change Control
Issue Number
Issue 1
Quality Assurance Plan
Status
IN work
Date
Project – Superconducting CS Coil
Changes Make
IPR
Table of Contents
Definitions............................................................................................................................................... 3
Acronyms ................................................................................................................................................ 3
1. Introduction ......................................................................................................................................... 4
2. Purpose of Quality Assurance Plan..................................................................................................... 4
3. Scope of Quality Assurance Plan ........................................................................................................ 4
4. General Requirements ......................................................................................................................... 4
4.1. Quality System ............................................................................................................................. 4
4.2. Inspection & Review.................................................................................................................... 4
4.3. Documents ................................................................................................................................... 5
4.4. Procurement ................................................................................................................................. 5
4.5. Identification & Traceability........................................................................................................ 5
4.6. Non-conformance & Deviations .................................................................................................. 5
4.7. Competence.................................................................................................................................. 5
4.8. Records ........................................................................................................................................ 6
5.Before Implementation ........................................................................................................................ 6
5.1. Supplier ........................................................................................................................................ 6
5.2. Sub-suppliers................................................................................................................................ 6
6.During Implementation ........................................................................................................................ 6
7.On Completion ..................................................................................................................................... 6
Quality Assurance Plan
Project – Superconducting CS Coil
IPR
Definitions
1. Document: any written, pictorial, or electronic information describing, defining, specifying,
reporting, or certifying activities, requirements, procedures, or results. A document is not
considered to be a quality assurance record until it satisfies the definition of a record as
defined below.
2. Suppliers: This term refers to an organization awarded a contract to supply of in-kind goods
and services to the IPR, on the basis of defined specifications.
3. Sub-Suppliers: This term refers to an organization awarded a contract to supply of in-kind
goods and services to the Suppliers, on the basis of defined specifications.
4. Non-Conformance: a deficiency in characteristic, documentation, or procedure that renders
the quality of an item or activity unacceptable or indeterminate.
5. Record: a completed document that furnishes evidence of the quality of items and/ or
activities affecting quality. Records may also include specially processed documents such as
radiographs, photographs, negatives, or microforms.
Acronyms
1. IPR: Institute For Plasma Research
2. CAD: Computer Aided Design
3.
CS: Central Solenoid Coil
4.
QAP: Quality Assurance Plan
5. NCR: Non-Conformities
6. IRN: Inspection Release Note
Quality Assurance Plan
Project – Superconducting CS Coil
IPR
1. Introduction
The project “Manufacturing of superconducting CS coil” is initiated under up-gradation activities
of SST-1 tokomak. Under this task, CAD models on the basis of feasibility report, detailed reports for
various R & D trials, cabling, conducting, fabrication of cryostat, 80K thermal shield and winding
technology will be delivered for following components of New CS coil as mentioned below
•
•
•
•
•
The Cryostat and its 80K shield
The Coil Winding Pack including its conductor and insulation
Heat Treatment Furnace
The Special Purpose Winding Machine
The Vacuum Pressure Impregnation Facility
2. Purpose of Quality Assurance Plan
QAP document establishes the direction and infrastructure necessary to assess & control the
quality of processes & components used during the manufacturing and testing of New
superconducting CS coil.
3. Scope of Quality Assurance Plan
The scope of this document is to define the Quality assurance plan for the Manufacturing of
New superconducting CS coil. This Quality Assurance Plan has been established to comply with all
the activities associated with “Manufacturing of New superconducting CS coil” mentioned in
•
•
•
•
Contract documents for the procurement of materials (SS316Ln tubes, Copper strands, etc.)
Contract documents for Cabling for SST-1 CS CICC employing Nb3Sn superconducting
strands
Contract documents for manufacturing
for SST-1 CS CICC employing Nb3Sn
superconducting strands
Contract documents for the manufacturing of winding pack including heat treatment of CICC,
insulation of CICC, and its VPI & winding machine.
4. General Requirements
4.1. Quality System
•
The supplier providing equipment or services to IPR will have an adequate & currently
operational quality system and organization capable of meeting the technical requirements of
the contract.
4.2. Inspection & Review
•
•
•
Reviews & inspection of the supplier's quality assurance arrangements will be carried out by
IPR or the appointed representative. These activities may be extended to cover sub-suppliers.
In respect of any deficiencies revealed, the supplier will implement corrective actions in
accordance with an agreed timescale & procedures.
IPR will be informed of the Supplier's reviews & inspection activities relating to the contract
including those involving sub-suppliers.
The supplier will provide IPR with access to documentation, personnel and their sub
supplier's premises during all stages of the contract for purpose of review & inspection.
Quality Assurance Plan
Project – Superconducting CS Coil
IPR
•
IPR reserves the right to verify the quality program and entire product characteristics
during manufacturing to assure the indented and specified quality of the product.
4.3. Documents
•
A system for control of documents and data to assure appropriate review and approval for use
will be established and implemented by all industries associated for fabrication of new
superconducting CS coil related activities using appropriate guidance documents. These
systems may include procedures to be used to implement quality program requirements to
ensure that all activities affecting quality are planned, controlled, and documented.
•
Types of documents subject to controls include, but are not limited to:
−
−
−
Management plans
Quality assurance plans
Technical documents (i.e., design drawings, safety documentation, technical specifications,
etc.).
−
These document control systems shall assure only correct and current information is available for the
performance of New CS coil activities.
4.4. Procurement
•
All the material used in manufacturing of New CS coil should satisfied IPR requirements. All
the necessary test, test certificate and related documents need to be supplied an approved by
IPR.
4.5. Identification & Traceability
•
The supplier shall maintain the identification & traceability of plant, equipment, materials &
documentation supplied as part of the works and make sure that every item has unique
identification.
4.6. Non-conformance & Deviations
•
All items & services that do not meet the requirements of the contract or technical
specification must be recorded as non-conformities (NCR).
•
If the NCR doesn’t satisfy a requirement of the contractor or technical specification the
supplier must stop the work & immediately inform IPR.A repaired item is considered to be
not acceptable if such repairs are undertaken without prior approval from IPR. IPR will
review proposed corrections and notify the supplier of the agreed actions to be taken. These
NCRs are to be provided as records.
•
If NCR satisfy a requirement of the contract or technical specification the supplier may take
action to resolve the NCR within their own quality management system. In such cases the
supplier must note the details of the non conformity and corrections as a Non-conformance
Report & send a copy to IPR for information immediately.
•
Requests to deviate from specified requirements or to change the requirements of the contract
or technical specification must be submitted in writing to IPR.
4.7. Competence
•
Personnel engaged by the supplier shall have appropriate authority & be suitably trained and
qualified to meet the requirements of safety regulations, applicable codes, standards &
specifications.
Quality Assurance Plan
Project – Superconducting CS Coil
IPR
4.8. Records
•
All the records for this project will be submitted in electronic as well as hard copies in
English. All the records should be reviewed and retained for an agreed retention period.
5.Before Implementation
5.1. Supplier
•
•
•
When required by the contract, the supplier must prepare a contract specific 'Quality Plan' and
submit this to IPR for approval as per the format (Appendix 1-3).
All the documents required in the contract must be reviewed by IPR prior to their use e.g.
Time schedules, drawings, procurement specifications, special process specifications, test
specifications & any document necessary for the effective implementation of quality
assurance requirements. Once approved, no changes must be made without prior agreement
and formal approval.
The supplier must prepare a 'control plan' for all the contracts. The plan must list all the
activities in order of sequence ranging from verification, manufacture, test & assembly and
any other activity associated with quality. This document is to be agreed & approved by IPR.
5.2. Sub-suppliers
•
•
•
The supplier must inform all activities to be performed by a sub-supplier.
The supplier must ensure that each of their sub-suppliers has an adequate and operational
quality organization or failing this, they will undertake all the necessary actions to establish
and maintain the quality in the sub-supplier's premises.
The requirements of this specification apply to sub-suppliers. The supplier will be responsible
for disseminating these requirements where appropriate. Where the supply chain extends
beyond direct sub-suppliers to the supplier, it is the responsibility of the supplier to ensure
adequate requirements are in place throughout the supply chain.
6.During Implementation
•
•
•
•
•
•
Approved control plan & other relevant documents are must be followed by supplier during
the execution without exception unless agreed otherwise by IPR.
All the activities & operations will be carried out in controlled conditions using only those
documents approved by IPR & must be directly accessible to those performing the work.
A suitable document management system must be implemented to ensure that only current
issues of the relevant documents are held at each work or process location,
Documents related to the contract must be accessible in order to verify the implementation of
the quality assurance requirements at the supplier's/sub-supplier's works.
All the equipment’s used for the inspection & testing shall be maintained & calibrated in
accordance with maker's instructions and national standards. Evidence must be provided if
requested by IPR.
The supplier will compile the quality documentation as work proceeds and the documentation
must be made available for review by IPR on request.
7.On Completion
•
On completion of the work the supplier must check that documentation required by the
contract is complete in all respects.
Quality Assurance Plan
Project – Superconducting CS Coil
IPR
•
•
•
•
•
•
Document shall include but not limited to operation manuals, instruction manuals &
maintenance manuals where relevant.
Before delivery the supplier will complete an Inspection Release Note (IRN) as per attached
format. It is the supplier's responsibility to request information from IPR to complete section I
of the form.IRN confirms that all necessary tests and inspections have been completed
satisfactory and that all necessary documents required by the contract are complete in all
respects. Equipment may not be accepted on IPR site if section I is not signed by IPR.
IPR shall check the condition of equipment and the completeness of all relevant functional
tests before signing & dating section I of IRN for release.
IRN with section I completed & signed by IPR, together with the equipment and document
package will be sent by supplier to IPR.
Section II of IRN will be completed on the acceptance by IPR.
A copy of IRN will be sent to supplier to indicate that the equipment and document package
is accepted by IPR.
Quality Assurance Plan
Project – Superconducting CS Coil
IPR
Appendix
1. Quality Plan Guidance
a) Organisation
- Chart showing organisational and functional responsibilities involved, including the Contract
Liaison Officer, the Quality Manager, relevant supervisory staff, all personnel authorised to
sign relevant documents.
b) Quality Manual
- Chart showing the QA Organisation;
- Chart showing the procedure for approval of design, Code/Specification compliance, Procurement,
manufacture, etc.
c) Sub-Suppliers
- List of all sub-suppliers to be employed on the Contract;
- Supplier/Vendor appraisal.
d) Design Control
- Provision of a Code of Design Practice and Procedures;
- Identification and control of design interfaces;
- Preparation and maintenance of drawings, specifications, procedures and instructions;
- Consideration of statutory requirements including those for health and safety;
- Design reviews.
e) Procurement
- Procurement specifications, purchase orders, material certification, inspection and verification
of purchased material;
- Critical procurement delivery times should be indicated.
f) Control of Documentation
- Availability of appropriate documents;
- Written procedures describing how functions are controlled, extent of control and responsibilities.
g) Quality Control in Manufacture, Assembly and Installation
- Written work instructions and procedures;
- Clean conditions with details of working conditions, controls;
- Special processes, i.e. welding, brazing, soldering, cleaning, heat treatment; etc.
- Control Plan which lists all operations on each component, sub-assembly, etc.
h) Inspection and Test
- Qualification of personnel; Test Procedures;
- Accuracy and suitability of test equipment.
i) Concessions and Non-Conformities
- Segregation procedures, analysis and remedial actions.
j) Audits
- Planned and documented audits to verify compliance with the Technical and Quality aspects of the Contract.
k) Inspection Release Note
- All documents required by the Contract
l) Packaging and Delivery
- Packaging and delivery specifications, provision for short and long term storage.
Quality Assurance Plan
Project – Superconducting CS Coil
IPR
2. Control Plan
Quality Control Plan for manufacturing of Prototype CICC-IPR proposal
Supplier Name
Document No:
Project title
Characteristics/ Items
1
Raw materials like tubes, filler
wire
2
Welder process Qualifications
at Each Stage
Welding Procedure
Specifications
(WPS and WPQR will be
prepared for each stage of
manufacturing of CICC such
as compaction and swaging.)
Procedure Qualification Report
a
b
c
Welder Performance
Qualification Report
3
Cable Insertion
4
Orbital welding of jacket tubes
Quality Assurance Plan
Contract No
0
SI. No
Revision No
Prepared By
Manufacturing of long length CICCs for SST-1 CS coil
pe
QAP/CS/CICC/
02
Date :
Accepted By :
Type of Check
Chemical Properties
Mechanical Properties
Dimensional Check & Co-relation
with MTC's.
Quantum/Freque
ncy of Check
Vendor
IPR
100% per 100%
heat per
size
Reference
Document
Acceptance
Criteria
Record
Format
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test
report
Agency
Vendor
P
IPR
W
Verification
100%
100%
ASME Sec.IX/
Approved
Drg./Tech. Spec.
ASME Sec.IX/
Approved
Drg./Tech. Spec.
Reports as pe
ASME
Sec.IX
P
H
100% Radiography & Physical
Testing at Laboratory
100%
100%
100%
P
H
visual inspection
100%
100%
Reports as pe
ASME
Sec.IX
Reports as pe
ASME
Sec.IX
--
H
100%
P
H
Visual Inspection
Mechanical and Metallurgical
Qualification
NDT inspection (RT/UT/Eddy
100%
100%
ASME Sec.IX/
Approved
Drg./Tech. Spec.
ASME Sec.IX/
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
P
Visual
ASME Sec.IX/
Approved
Drg./Tech. Spec.
ASME Sec.IX/
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
P
H
Project – Superconducting CS Coil
IPR
Test Cert. /
Check test
report
current testing)
5
Compaction of jacketed cables
6
Square swaging of jacketed
cables
7
Spooling
8
Visual Inspection
Mechanical and Metallurgical
Qualification
NDT inspection (RT/UT/Eddy
current testing)
Visual Inspection
Mechanical and Metallurgical
Qualification
NDT inspection (RT/UT/Eaddy
current testing)
Spool wise length as per IPR
requirements
SST-1 CS CICC (long length Overall dimensions
prototypes and samples)
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test
report
P
H
100%
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test
report
P
H
100%
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech.
Spec..
Approved
Drg./Tech. Spec.
Packing list
P
H
100%
Rand
om
Approved
Drg./Tech. Spec.
Leak testing in vacuum as well
as in sniffer mode
100%
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Flow test with GHe/GAr at RT
100%
100%-
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Surface condition
100%
W
R
R/W
H
P
Quality Assurance Plan
100%
Project – Superconducting CS Coil
Test Cert. /
Check test
report
Test Cert. /
Check test
report
P
H
P
H
Test Cert. /
P
H
Check test
report
100%Approved
Approved
Test Cert. /
P
H
Drg./Tech. Spec.
Drg./Tech. Spec.
Check test
report
Witness – IPR representative will be present during the particular operation or test
Review
Random witness
Hold – IPR representative will be present during the particular operation or test. All
the results will be discussed and reviewed. Only after approval from IPR, vendor
should go ahead for manufacturing stage.
Perform – Vendor will perform all the required operation and tests
IPR
Quality Control Plan for manufacturing of Final CICC-IPR proposal
Supplier Name
Document No:
Project title
Date :
Accepted By :
Characteristics/ Items
1
Raw materials like tubes, filler
wire
2
a
Welder process Qualifications
at Each Stage
Welding Procedure Specifications
b
(WPS and WPQR will be
prepared for each stage of
manufacturing of CICC such as
compaction and swaging.)
Procedure Qualification Report
c
Welder Performance
Qualification Report
3
Cable Insertion
Quality Assurance Plan
Contract No
0
SI. No
Revision No
Prepared By
Manufacturing of long length CICCs for SST-1 CS coil
QAP/CS/CICC/
02
Type of Check
Chemical Properties
Mechanical Properties
Dimensional Check & Corelation with MTC's.
Quantum/Frequen
cy of Check
Vendor
IPR
100% per
100%
heat per
size
Reference
Document
Acceptance
Criteria
Record Format
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test report
Agency
Vendor
P
IPR
W
Verification
100%
100%
ASME Sec.IX/
Approved
Drg./Tech. Spec.
ASME Sec.IX/
Approved
Drg./Tech. Spec.
Reports as pe
ASME Sec.IX
P
W
100% Radiography & Physical
Testing at Laboratory
100%
100%
ASME Sec.IX/
Approved
Drg./Tech. Spec.
ASME Sec.IX/
Approved
Drg./Tech. Spec.
Reports as pe
ASME Sec.IX
P
W
Visual
100%
100%
ASME Sec.IX/
Approved
Drg./Tech. Spec.
ASME Sec.IX/
Approved
Drg./Tech. Spec.
Reports as pe
ASME Sec.IX
P
W
visual inspection
100%
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
--
P
W
Project – Superconducting CS Coil
IPR
4
Orbital welding of jacket tubes
5
Compaction of jacketed cables
6
Square swaging of jacketed cables
7
Spooling
8
SST-1 CS CICC (Single
length of L1-215 m, L2- 235
m, L3-245 m, L4 - 260 m)
Visual Inspection
Mechanical and Metallurgical
Qualification
NDT inspection (RT/UT/Eddy
current testing)
Visual Inspection
Mechanical and Metallurgical
Qualification
NDT inspection (RT/UT/Eddy
current testing)
Visual Inspection
Mechanical and Metallurgical
Qualification
NDT inspection (RT/UT/Eaddy
current testing)
Spool wise length as per IPR
requirements
Overall dimensions
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test report
P
W
100%
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test report
P
W
100%
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test report
P
W
100%
100%
Approved
Drg./Tech. Spec.
Packing list
P
W
Rando
m
Approved
Drg./Tech. Spec.
Approved
Drg./Tech.
Spec..
Approved
Drg./Tech. Spec.
Test Cert. /
Check test report
100%
P
W
Leak testing in vacuum as
well as in sniffer mode
100%
100%
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test report
P
W
Flow test with GHe/GAr at
RT
100%
100%-
Approved
Drg./Tech. Spec.
Approved
Drg./Tech. Spec.
Test Cert. /
Check test report
P
W
Surface condition
100%
100%-
W
R
R/W
H
P
Quality Assurance Plan
100%
Project – Superconducting CS Coil
Approved
Approved
Test Cert. /
P
W
Drg./Tech. Spec. Drg./Tech. Spec. Check test report
Witness – IPR representative will be present during the particular operation or test
Review
Random witness
Hold – IPR representative will be present during the particular operation or test. All
the results will be discussed and reviewed. Only after approval from IPR, vendor
should go ahead for manufacturing stage.
Perform – Vendor will perform all the required operation and tests
IPR
3. Inspection Release Note
Quality Assurance Plan
Project – Superconducting CS Coil
IPR