Advanced Construction Technologies and Further Evolution ......*1). The numbers above include those...

Ref. CNJ-OG-Ｇ056Rev.7.3All Rights Reserved Copyright © 2009, Hitachi-GE Nuclear Energy , Ltd.

Advanced Construction Technologies and Further Evolution Towards New Build NPP Projects

International Conference on Opportunities and Challenges forWater Cooled Reactors in the 21st Century

Hitachi-GE Nuclear Energy, Ltd.(HGNE)Junichi Kawahata


HGNE’s NPP Construction Experience

NETOUTPUT

TSURUGA - 1* HAMAOKA - 1*

10,000

15,000

(MWe)

1970 1975 1985357

HAMAOKA - 4*

KASHIWAZAKI・KARIWA - 5

SHIMANE - 2

HAMAOKA - 3*

FUKUSHIMA-II-4

FUKUSHIMA Ⅱ-2

FUKUSHIMA Ⅰ-4

TOKAI - 2*

HAMAOKA - 2*

0

5,000

1995 2005

460460540784

1100

840

SHIKA - 1

KASHIWAZAKI・KARIWA 4

1100

1100

1100

820

1100

540

1137

1100

20,000

Advanced BWR phaseImprovement and Standardization phaseDomestic Production Phase

SHIMANE - 1

FUKUSHIMA I-1*

Qinshan III

HGNE’s BWR plantsIn Operation ：20 unitsUnder Construction ：

1 unit

*) Collaborative Construction

Tsuruga

Shika Kashiwazaki kariwa

HamaokaTokai -II

Fukushima-I

Onagawa

Fukushima-II

Shimane

Oma

Lungmen- 1&2Oversea Projects

11HIGASHI-DORI-1

5 5 ABWRsABWRsContinuousContinuousConstructionConstructionExperienceExperience 1380

1358

KASHIWAZAKI・KARIWA 7*

KASHIWAZAKI・KARIWA 6*

HAMAOKA - 5*

SHIKA - 2

SHIMANE-3

825ONAGAWA - 3*

1356

1356

OMA-1


HGNE’s Construction Strategy

Integrated Engineering System

Modularizationwith

Large crane

On-site Work

Reduction

Open-top &

parallel construction

On-site Work

Leveling

Construction Support System

Improvement of On-site

Work Support Efficiency

22

Improvement of On-site Work

Efficiency

Detailedengineering

before on-site work

Engineering &Delivery ScheduleControl System


HGNE’s Construction Strategy22


Modularizationwith

Large crane

On-site Work

Reduction

Open-top &


On-site Work

Leveling





Efficiency

Detailedengineering

before on-site work



History of HGNE’s Module Application

18 27 28 32 3883

194

28

7745

247 235

317

150

322 309

196

76

0

50

100

150

200

250

300

350

400

APlant

Num

ber o

f Mod

ule:

unit

ModulesPipe Blocks

Note:*1). The numbers above include those of mechanical modules and of some large scale civil modules like base mat and top slab

modules on construction critical path in whole plant (N/I and T/I). Note that hundreds of pre-fabricated rebar modules are not included.

*2). For Plant F/G, HGNE’s scope was T/I for Plant F and N/I for Plant G. The numbers are the summation of them.*3). For Plant H, HGNE’s scope was T/I only

*1)

*2) *3)

1990 1995 2000 2005B C D E F/G H I J

0

20

40

60

80

100

Perio

d, S

ite M

anpo

wer

(%)Construction Period

Work Force at site

2-12-1




Modularizationwith

Large crane

On-site Work

Reduction

Open-top &


On-site Work

Leveling





Efficiency

Detailedengineering

before on-site work



Strategy-2: On-site Work Leveling Open-top & Parallel Construction2-22-2


Strategy-2: On-site Work Leveling Floor Packaging MethodConventional MethodConventional Method

Pres.Pres.TestTest1F

B2F Mech. Inst.Mech. Inst.

B1F

2F

B2FB1F

2FSystem Test

1F

System Test

Wor

k Fo

rce

Construction schedule

Floor Packaging Method

Construction schedule

Peak ReductionPeak ReductionPeak Reduction

Remaining Remaining WorkWork

Need to wait for all piping installation

Open Top Parallel Const.

DividedPressure Test

2-22-2

B2F：Completion of Construction 1F：Hydrostatic

Testing

2F：Peak Construction

Construction

Area Release

▼

－3 3 6 9 12 15 18 21 24 27 30FloorMonth

2F

1F

B2F

▼

Pressure Testing

Insulation & Painting

▼

◆

◆

Disassembly of Scaffoldings

Pre-Operation Test

◆

Earlier Floor Const. Completion

Wor

k Fo

rce


Strategy-2: On-site Work Leveling Track Record in Work Leveling

Site

Man

pow

er

Construction Time 1 6 11 16 21 26 31 36 41 month

Latest ABWR Completed

On-Site Manpower Leveled OffOnOn--Site Manpower Leveled OffSite Manpower Leveled Off

Peak ReductionPeak ReductionPeak Reduction First ABWR

2-22-2




Modularizationwith

Large crane

On-site Work

Reduction

Open-top &


On-site Work

Leveling





Efficiency

Detailedengineering

before on-site work



High-End IT Systems Applied for Construction

ModuleEngineering

Yard / CraneEngineering

ConstructionSchedule Planning

Index 3

Index 4

Index 5

Index 6

Index 7

Index 8

Index 1

Index 2

Effect 1Effect 2Effect 3Effect 4Effect 5Effect 6Effect 7Effect 8Effect 9Effect 10

Effect 1Effect 2Effect 3Effect 4Effect 5Effect 6Effect 7Effect 8Effect 9Effect 10

3D Module Design Module Evaluation, Improvement Indices

Feedback

Crane, Equipment Model

Simulation

Simulation

Schedule＋3D-CAD

2-32-3




Modularizationwith

Large crane

On-site Work

Reduction

Open-top &


On-site Work

Leveling



Work Support

Efficiency


Efficiency

Detailedengineering

before on-site work



Features

Just in TimeJust in Time

Construction Management

System

•Data Visualization•Process Standardization•Numerical Evaluation

Project Management Office

Drawing

Schedule

Product(Material)

Project Management PDCA

【Plan】

【Problem Prediction】

(ＨＧＮＥ)

Thermal Power Div.

Power & Industrial Div.

Hitachi Plant Tech.

Information &Telecom. Div.

AE Power

Integrated Managem

entBHK

another Subsidiaries

Installation

InspectionTesting

Schedule Control

Product(Material)Control

Document Control Data Data

Just in TimeJust in Time

【OperationPromotion 】

Construction SiteDesign Office

【Visualization】

Construction Management System Concept Integrated System from Design to Construction

・Business Process InnovationInstallation&InspectionProcess StandardizationZero Defect Cost

　　（Shorten Lead Time）Paperless BusinessUbiquitous Environment（using RFID）

Workforce Leveling・Information Sharing

Design Office - SiteHGNE - Corporate Firms

・Integrated Construction Mgt.Design-Procurement-Delivery-Construction

【Counter- measure】

2-42-4


Material Control

Material Control

Schedule Control

Schedule Control

Delivery Control

Delivery Control

Product

Schedule

DocumentDocument Control

Document Control

Work Instruction

WarehouseManagement

e.g.) Equipment (Target Date from Design to Site)

Construction Management System Delivery Schedule Control

-25 -18 -8

0-8-13-20

-3

Area ScheduleArea Schedule

Construction Management

System

Shipping Information

SiteSiteReceiveReceive

Requisition

Contract with Vendor

Fabrication Schedule

Material Order

Material Receiving

Fabrication Start

Shipping ListIssue

Carry-in Date ≒Delivery Date

2-42-4


Work Instruction & Work Record SystemWork Instruction & Work Record System

Construction Management System Work Instruction Function -(ex. Pipe Fit-Up Work)2-42-4


Input Actual Data using PDA& RFID

RFID Reader

Worker Worker IDID

ProductProduct IDID

Construction Management System Work Instruction Function -(ex. Pipe Fit-Up Work)

PDA:Personal Digital Assistance2-42-4


Construction Management System - Progress Evaluation Function -2-42-4

Progress Monitoring & Evaluation SystemProgress Monitoring & Evaluation System


Construction Management System - Creating Electric Construction manual -

ElectricalElectricalInstructionInstructionManual DBManual DB

Know-How

• Accumulating Real Construction Know-How• Easy and Steady Traceability• Further Enhancement of Construction Quality

2-42-4


Conclusion

• HGNE has continuously constructed 20 BWRs (4 ABWRs) over 35 yrs since 1970’s with NO delay in their planned Commercial Operating Dates (COD’s).

• During this period, various “Advanced Construction Technologies” have been developed based on its accumulated experiences and lessons learned, and they are proven to be effective for Nuclear Power Plants Constructions.

• HGNE is one of the very few companies which can complete NPP construction in “On-schedule” and “On-budget” manner in the world.

33

Advanced Construction Technologies and Further Evolution ......*1). The numbers above include those...

Documents

Transcript of Advanced Construction Technologies and Further Evolution ......*1). The numbers above include those...