Future EQ Perspectives for Russian Global New-Build Projects · Lean Six Sigma Black Belt....

Future EQ Perspectives for Russian Global New-Build ProjectsNatalia AmosovaPrincipal ConsultantLean Six Sigma Black [email protected]+41 79 458 77 13

Prepared for 2020 Curtiss-Wright EQ Technical Meeting November 2020

Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 1November, 2020

The Water-Water Energy Reactor “VVER”Development and generations

November, 2020

+ Total number of 106 VVER‘s build since 1960

+ Three generations in operation:+ VVER-440+ VVER-1000+ VVER-1200 (AES-2006)

+ Generation III+ under construction:+ VVER-1300 (TOI)

+ New designs developed for future projects:+ MIR-1200+ VVER-1500+ VVER-1700+ VVER-600

Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 2

Rosatom Group

November, 2020

+ Russian government owned corporation, responsible for all nuclear applications

+ Consists of over 350 specialized companies throughout the whole fuel cycle, of which relevant for us:

+ Rosatom Overseas (RAOS) - vendor for VVER outside of Russia+ AtomEnergoProm (AEP) - designer of the plant+ AtomStroyExport (ASE) – main contractor for the international

NPP construction+ Titan-2 - main contractor for the international NPP

construction+ AtomEnergoMash (AEM) – Main equipment manufacturer

+ World leader in todays‘ newbuild portfolio+ 28 VVERs under construction (international and domestic)+ Total new-build portfolio >130 B. USD


The Overseas New-Build ProjectsOverview

November, 2020 Source: Rosatom

Rosatom Overseas (RAOS)Plant name Country Unit number Construction start Completion dateAkkuyu Turkey 1-4 2018 2023-2025Ostravets Belarus 1-2 2013 2020Busher Iran 2-3 2016 2025-2027El Dabaa Egypt 1-4 2017 2026-2028Hanhikivi Finland 1 2021 2028Kudankulam India 3-4 2017 2021

5-6 2020 2025Paks II Hungary 5 2021 2026

6 2022 2027Rooppur Bangladesh 1 2017 2023

2 2018 2024Tianwan China 7 2021 2026

8 2022 2027Suidapu China 3-4 2019 2028


25 UnderConstruction

22 UnderNegotiation

22 Potential Future Projects

Equipment Conformity Assessment in RussiaLaws and regulations relevant for equipment testing

5

НП-071-81

Safety classes 1, 2 and 3

Acceptance(Приемка)

Control(Контроль)

Tests(Испытания)

GOST R 50.06.01-2017

e.g. GOST R 50.05.05-2018

e.g. GOST R 15.309-98

Technical Document Review (Экспертиза технической

документации)e.g. GOST R 50.03.01-2017

Mandatory Product Certification(Обязательная сертификация

продукции)e.g. GOST 50.08.01-2017

November, 2020 Curtiss-Wright EQ Technical Meeting 2020 [email protected]

Scheme Test specimen tested in accredited labs QMS Audit Inspections during 3c Testing of test specimen - Testing of test specimen4c Testing of test specimen Analysis of workshop condition Testing of test specimen and Analysis of workshop condition5c Testing of test specimen QMS certification Testing of test specimen and QMS certification6c Testing of the whole LOT - -7c Testing of each test specimen - -

Conducted by certification body and consists of 5 steps:

1. Submission and review of request for certification*, selection of the certification scheme **2. Development of the certification plan3. Identification of test samples/specimen4. Certification tests and certification of manufacturer’s QMS5. Analysis of test results, decision if passed and granting of the certificate

* Request for certification has to include (among other documents) main parts drawings, calculations, manufacturing procedures, testing procedures ** Certification scheme

Mandatory Product Certification For all classes of safety related equipment

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Mandatory Review of the following documentation to ensure compliance to the specification and any other set requirements

+ Design+ Manufacturing+ Quality assurance and control (processes and procedures)+ Testing + Certificates

Technical Documentation ReviewMandatory before release for manufacturing or acceptance to procure foreign goods




Test Type Test Specimen PurposePreliminary Prototype Preliminary evaluation if prototype is compliant to TZ or TU draft (Proof the

readiness for acceptance)Acceptance Test specimen or lot representative specimen

(domestic)1.Compliance of technical parameters to ND, TZ, TU and KD2. Applicability of the design solution3. Production methods compliant to quality requirement4. Service and Maintenance friendliness5. Safe operation6. Lifetime

Acceptance Lot representative specimen (foreign) Compliance of the product to the approved technical requirements to the НП-071-18(May be also performed in a Rostechnadzor certified lab)

FAT Each product (if made at another company to be reflected in ITP)

Compliance to TU

Type Any from a lot or test specimen Improving or maintaining of product design in case of an impact to it due to changes in design or manufacturing process

Qualification Test specimen or lot representative specimen (min. 2) Check the quality if findings during FAT or periodical testingManufacturing is transferred to another OEM or designed by another organization

New LOT is being manufactured after more than 3 yearsLot representative specimen Check compliance if requirements to the product were updated

Comparative Lot representative specimen (conducted by the customer)

Comparison of most relevant technical characteristics of products from different suppliers under same test conditions

Periodical Lot representative specimen Confirmation of stable quality of manufacturingCertification Test specimen according to the certification plan

(performed by a Rosatom certified lab). May not be combine with any acceptance tests

Compliance of product properties to national and international regulatory documentation requirements.

Types of Tests for Safety-Related ProductsTests performed at different project stages

8November, 2020 Curtiss-Wright EQ Technical Meeting 2020 [email protected]

No. Acceptance Test Scope 1 Control of the results of the preliminary test2 Visual control3 Material density and hardness tests, test, weld seams shell test, stability and tightness test of the assembled product4 Leak test of weld joints, interfaces and joints5 Functional test6 Lifetime test*7 Seismic resistance test, incl. natural frequency up to 20hz8 Vibration resistance test9 Vacuum tightness test (for equipment working with under pressure)10 Total mass check11 SB LOCA, LB LOCA, BDBE, DBE, steam leakage outside containment12 Shut off valves leak tightness13 Stroke limits indication tests14 Thermal stress resilience15 Blackout “stay in place” test for shut-off / control valves16 External leak tests when actuator shutoff fails17 Multiple hydraulic tests resilience18 Defectiveness (Disassembly and examination)

*There are two classes of cycling tests for major valves, tests may be performed on 50% smaller test specimen and may not exceed testing capabilities of domestic labs. Tests will be conducted only if required by customer.

Acceptance Tests for Main Valves

9November, 2020 Curtiss-Wright EQ Technical Meeting 2020 [email protected]

+ Rosatom established the procedures for and provides accreditation of any test lab, which perform conformity assessments of safety related equipment

+ Rosatom trains and certifies experts who are entitled to perform accreditations of test labs

+ Rosatom maintains a list of all accredited test labs

+ Rosatom announces first-time and recurring accreditation audits every year

+ All information (list of accredited labs and their accreditation scope, list of accreditation experts, list of first-time and recurring test lab accreditation audits) is posted on Rosatom.ru

+ Today there are 55 accredited test labs

+ Every lab has an accredited scope, which specifies which tests and according to what norms the lab is accredited for

Authorized Test LabsMandatory for labs working under or with the Rosatom system


Source: Stroyventmash

November, 2020

Main Testing LabsJSC "NPO CKTI"

Curtiss-Wright EQ Technical Meeting 2020 [email protected]

Located in St- Petersburg, Russia

Founded in 1927

Provides tests of valves, heat exchangers and other equipment for NPP

Performs experimental research of thermohydraulic processes and hydrodynamicstability at a large-scale model of natural circulation circuit for LNPP-2 (LeningradNuclear Power Plant 2) of afterheat removal passive system through the steamgenerator(ARPS PG).

Sources: specmont.ru, hiddenside.ru; iocenter.ru

November, 2020

Main Testing LabsJSC “SNIIP" Testing Lab subdevision “CMI”


Located in Moscow, Russia

Founded in 1952, now part of Atomenergomash

Performance of Tests (Acceptance, Certification, Periodic,Comparative) of special valves, elements of safety systems,equipment and components for NPP’s and other industries;

Performance of tests for electrical equipment for NPP‘s

Sources: atomic-energy.ru; vestnik-aem.ru, yablor.ru

November, 2020

Main Testing LabsAO “NIZ NPP”


Located in Koshyra, Russia

Founded in 1987, now part of Rosatom

Performance of Tests (Acceptance, Certification, Periodic, Comparative) ofspecial valves, elements of safety systems, equipment and components forNPP’s and other industries;

Provision of services and technical support for the operation of valves of NPP’s;

Creation and maintenance of a database of special valves for NPP’s

Design, assembly, commissioning and acceptance tests of valves for NPP’s

Source: presentation of NIZ NPP from the year 2008 : niaes.ru

Major Changes and ChancesThe system is adapting to international practices…

November, 2020

Acceptance(Приемка)

Control(Контроль)

Tests(Испытания)

GOST R 50.06.01-2017

e.g. GOST R 50.05.05-2018

e.g. GOST R 15.309-98





Now a „type test“ from a western EQ Lab may be accepted (after review)*

Inspection and Test Plan

May be performed in an ILAC and Rosatom accredited test lab according to Russian test plan

Irrelevant for Overseas Projects

* New since Feb 2020


Reasons for the Changes… Explanation and background

November, 2020

+ Despite of a governmental directive for Russia-source based equipment strategy, Russia still imports western safety-related equipment

-> Reduction of costs through acceptance of „western“ qualification tests instead of Russian „acceptance test“

+ The Hanhikivi project is in Finland and sets the requirements according to YVL guides which is closer to the „western“ EQ requirements

-> Russian suppliers should benefit from the need to perform only one kind of EQ test and meet Russian and international requirements at the same time

+ Strategy of Rosatom to expand further into western Europe and global markets-> Before Hanhikivi project, the Russian regulatory system was more or less completely accepted by the overseas importer nation-> Big investments were made into VVER-TOI in order to fulfill international design requirements

VVER-1000 ReactorCurtiss-Wright EQ Technical Meeting 2020 - [email protected] 15

Perspective and OutlookBusiness Opportunities

November, 2020

+ As of today essentially no Russian OEM has performed EQ according to IEEE, QME-1, RCC-M, RCC-E

+ Partial or full EQ programs will have to be performed on the Russian equipment, which is subject to export to „non-Russian“ regulatory system countries

+ Several VVER types are planned to be built, which will mean new equipment will have to be integrated and qualified as well

+ Western equipment OEM‘s can use their western EQ but may be required to do some additional tests

+ Unique chance to participate in a Russian VVER-1200 new-build project according to Finnish regulation with (likely) no need to comply to Russian rules and requirements – not only as an OEM but also as a test-lab


Conclusion

+ Today we are facing the very beginning of the transition of the Russian EQ/Conformity Assessment landscape towards more globally recognized ways of working

+ The VVER is the leader among todays‘ nuclear new-build technology – in order to expand further, these reactors will require equipment, which is compliant with EQ programs understood to U.S. and European service suppliers

+ A new service and equipment supply chain is being built for Western VVER projects

November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 17

November, 2020 18

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Future EQ Perspectives for Russian Global New-Build Projects · Lean Six Sigma Black Belt....

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