1. Date: 04/05/2015 NucSIG Event – 9 th June 2010 Poor Supplier Quality Performance, Electrical Switchgear Paul Murphy CEng, CQP, MCQI Management Systems Manager Dounreay Site Restoration Ltd

2. Date: 04/05/2015 Project – New Fuel Cycle Area Ventilation System Electrical Installation IAW Site’s Electrical Supply Policy: Progressively standardise the Site’s Electrical Distribution System & Components. Major worldwide Supplier selected. No significant problems prior to 2009.

3. Date: 04/05/2015 Supply Chain  Local Contractor installing new FCA Ventilation System.  Electrical Supplier providing assembled Switch Boards.  Electrical Supplier’s European Subsidiary supplying Assembled Circuit Breakers.  Various Sub Suppliers proving sub components.

4. Date: 04/05/2015 Procurement Controls Applied Adequate Specification Vendor assessment Large Reputable Established Company (not the cheapest!) ISO 9001 Certification Good previous performance Sample Witness of Factory Acceptance Tests Goods Inwards Checks & Storage Change Control 

5. Date: 04/05/2015 2 off 415v Switch Boards for New FCA Vent System.

6. Date: 04/05/2015 Moulded Casing Circuit Breakers were an ‘improved’ design using new sub components from new sub component suppliers. The Boards and Breakers had multiple defects indicating multiple Supplier Quality Failures

7. Date: 04/05/2015 Broken Door Handles & Safety Latches Safety Interlock Negated: –Padlocked Breaker Access Door could be opened.

8. Date: 04/05/2015 Broken Door Handles & Safety Latches Safety Interlock Negated: –Door could be opened when the breaker was closed.

9. Date: 04/05/2015 Breaker Mechanisms Out of Tolerance Hook Springs meant that two units failed to reset after tripping

10. Date: 04/05/2015 Base Unit Boss – Broken & Glued!

11. Date: 04/05/2015 Broken Boss Might have been caused by a Twisted Racking Shaft

12. Date: 04/05/2015 Or out of Tolerance Latch Guide …. smear of glue on the shaft caused glued repair to break as shaft rotated.

13. Date: 04/05/2015 Watch your Fingers – Live Bus Bars!

14. Date: 04/05/2015 Consequences for DSRL  Project Delays / Costs - loss of fee.  Ventilation failure in service can result in evacuation of Fuel Cycle Area & Contamination of Facilities (£100k +).  Regulator interest.  Loss of confidence in spares.  Reassess future contracts, cost of re-tendering, objective of standardising questioned.

15. Date: 04/05/2015 Causes and Resolution  Causes – Multiple quality Failures –Redesign; Metal Components replaced with Plastic. –New Sub Component Suppliers could not meet tolerances. –Inadequate Quality Planning:  Sub Component Inspection; new suppliers.  Factory Acceptance Testing.  Incomplete and incorrect Quality Documents & Test Records. –Attitude of Supplier’s management and workforce (e.g.: cost over quality:- plastic components and lack of adequate inspection. Glued repair, mechanical problems obvious but tolerated / misunderstood, etc.).  Resolution –Design changed back to metal components. –Designed to accommodate greater tolerances. –Adequate and appropriate inspection throughout. –Tool box talks.

16. Date: 04/05/2015 Epilogue –Supplier Open, Helpful and Cooperative. –Remedial actions satisfactory  Rework and repair.  Previously installed units checked and found OK –Corrective Actions Implemented. February 2010 - Interlock Problems with the next set of Breaker Units. HOWEVER!

17. Date: 04/05/2015 Shutter Prevents ‘Closed ’ Withdrawal / Insertion

18. Date: 04/05/2015 Retracts to allow withdrawal when Breaker is Open

19. Date: 04/05/2015 But sometimes the Shutter doesn’t fully retract when open

20. Date: 04/05/2015 Or doesn’t drop down when Breaker is Closed!

21. Date: 04/05/2015 The Worrying Bit 1995 Wylfa Judgement  Establishes that Nuclear Site Licensees have absolute responsibility for conformity of purchased items used on their sites.  Licensees must demonstrate that they have taken all reasonable actions to ensure conformity. Do We?

22. Date: 04/05/2015 What are Other Industries doing?  Consider the copies of AS9100C handed out.  Please Read the Forward.  AS9100C overlays (BOLD) ISO 9001 with specific additional / clarified requirements for aviation space and defence. (Similar standards for medical devices, etc.)  What additional requirements in Section 7.4, ‘Purchasing’ might have helped us avoid the supplier assurance problems discussed? DO WE THINK THAT THE NUCLEAR INDUSTRY SHOULD HAVE SOMETHING SIMILAR?