IAEA Activities on Construction Technologies and … · · 2013-06-28IAEA Activities on...
Transcript of IAEA Activities on Construction Technologies and … · · 2013-06-28IAEA Activities on...
IAEA International Atomic Energy Agency
IAEA Activities on Construction
Technologies and Management
June 2013
Nuclear Power Division
IAEA
Overview of Current Status
2
437 In operation
373 GWe total net installed capacity
68 Under construction
PRIS Data April 2013
IAEA
Trend in construction starts
North America
Rabidly
changed the
No. of
Construction
Npps after F-A
(16- 4 -7)
16 4 7 3
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History of NPP construction
North America
A total number of Npps – not so
big change after F-A (65-67-66)
65 67 66 4
IAEA 5
Expansion centred in Asia
IAEA Reference: IAEA-PRIS
NPP Construction Data
IAEA International Atomic Energy Agency
Optimizing Construction Managemet
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Average Duration for Past NPP Construction 1969 to
1977 in USA
Since 1972,
rapidly
increase
construction
period
Why ??
Source : DOE NP2010 Construction Schedule Evaluation, DE-AT01-020NE23476
IAEA Reference: IAEA-PRIS
Full history of NPP construction
North America
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Construction Time Span
Categories 1970-1995
[month]
1996-Now
[month]
Median 80 83
Minimum 41 47
1 Quartile 67 61
3 Quartile 105.5 176
Maximum 283 302
Resource : Power Reactor Information System in the IAEA database
IAEA
Shortest Construction Period
• Construction Schedule for 1350 MWe unit
• From F/C to C/O : 62 49 Months
• Construction Schedule at 1000 MWe unit
• From F/C to C/O : 64 47 Months
• C/O: Commercial Operation
• F/C : First concrete pouring
IAEA
Construction Schedule for Gen III+ NPPs
Site preparation : 12~18 M
Construction : 36~42 M
Start-up : 6~ 7 M
Total : 60 M
Source : DOE NP2010 Construction Schedule Evaluation, DE-AT01-020NE23476
IAEA
Considerations Related to Schedule Assumptions
• Fundamental Project Assumptions
• First-of-a-Kind (FOAK) or Nth of a Kind (NOAK)
• Labour Resource Availability
• Cash Flow
• Labour Shift Structure
• Reference Location
• Labour Agreements
•Site-Specific Assumptions • Site Conditions
• Seismic Requirements
• Accessibility/Transportation
• Engineering & Procurement Assumptions • Engineering
• Procurement Relationships and Contracts
• Long-Lead Components
• Manufacturing Durations
• Construction Assumptions • Extent of Modular Approach
• Specialized Equipment
• Shift of Work Load
• Licensing and Permitting Assumptions • Licensing Environment
• Changes in the Licensing Process
IAEA International Atomic Energy Agency
Previous Experiences
IAEA
KEDO 1&2 (North Korea)
Bataan NPP (Philippines)
Westinghouse 2 Loop 600MWe
95% completed.
Cancelled following
government change.
Started but never
completed (international
partners pulled out).
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Cernavoda NPP, Romania Right: Unit 1 /2 (in operation) Left: Unit 3, 4 and 5 (in preservation)
IAEA Atucah II NPP (Argentina)
Installation of Moderator Tank, June 2009
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Dec 2012 Atucha II
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In 2003 Photos
Preservation Of Stored Components
Angra 3 Npp in Brazil
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Angra 3 Npp in Brazil
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Angra 3 Npp in Brazil
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Olkiluoto 3 at the end of April 2009
Source: TVO
Core thermal power
Net power output
Net efficiency
4300 MWth
1577 MWel
37 %
May 2005 : First Concrete for Reactor Building
May 2007 : RPV installed,
May 2008 : Start Hot Functional Tests
Aug. 2008 : First Fuel Loading
Nov. 2008 : First Criticality
April 2009 : Start Demo-Run
OL3 construction site in February
2012
IAEA CONFIDENTIAL © Teollisuuden Voima Oyj 23
OL3: 24.4.2013 Commercial operation no
earlier than 2015.
IAEA
Major Concrete Dismantling and Demolishing
Project in Belene - Site Preparation
Dismantling and Demolishing
•Reinforced Concrete 150 298 m3
•Steel Structures 8 760 t
•Excavation works 150 923 m3
•Planned Duration 18 months • Mobilization 2 months
• D&D 14 months
• Demobilization 2 months
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… and 10 months
after …
Site opening on
31.07.2008
Major Concrete Dismantling and Demolishing
Project in Belene - Site Preparation
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USA NPP Construction Experience
0
20
40
60
80
100
120
140
160
180
200
St.L
ucie 2
Pal
o Ver
de 1
Gra
nd Gulf
1
Wolf
Cre
ek 1
Sea
brook
1
Susq
uehhan
na
Sum
mer
1
Byro
n 1
San
Onofr
e 2
Wate
rford
3
LaSal
le
Com
anch
e Pea
k 1
Per
ry 1
McG
uire
Shore
ham 1
Mid
land 2
Cata
wba 1
Watts
Bar 1
Harr
is 1
Wash
ingto
n Nucle
ar 2
Enric
o Fer
mi 2
Limer
ick 1
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Watts Bar Unit 2 – Delayed NPP
• Completed
partially Unit 2.
(PWR, 1100 Mwe)
• Unit 2 was about
80% completed,
stopped in 1988.
• Resumed on
October 15, 2007,
• Operation in Oct.
2012(60 M)
• $2.5 billion USD
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Watts Bar Cost/Schedule Overruns
• Need additional $1.5 B to $2 B(2.5B $4~ 4.5 B$)
• Completion : Oct. 2012 Dec 2015 (60 M 99M)
• EPC : Bechtel
• Root causes: • Leadership - Organization and management capabilities misaligned
with unique project characteristics
• Estimate - Lack of rigorous understanding of work to be done led to
low initial estimates and impeded planning
• Execution - Management did not execute a robust execution plan or
fully utilize available capabilities
• Oversight - Inadequate oversight and project assurance
IAEA International Atomic Energy Agency
IAEA Activities on Construction
IAEA
Construction Technologies for
New NPPs
• Goal: Achieving an Optimum Construction schedule for future NPP construction projects.
• Content: • Comprehensive descriptions
of all construction methods
• Advantages and disadvantages
• Best practices
• Lessons learned
IAEA
Construction
Management
• Construction management
• Preparatory Phase
• Construction phase (after
concrete pouring)
• Commissioning phase
• Main issues and lessons
learned
• Selection of local suppliers
• Bulk material management
• Worker turnover
• Construction equipment
• Massive movements of people
and material
• Public perception
• Construction phase closure
activities
• Country specific lessons
learned
IAEA
E- Learning Module on Construction
Topics covered in the
Construction Module: • What makes nuclear
construction unique
• Important
considerations for
projects and
programmes
• How to achieve
excellence
• Key site considerations
IAEA
Construction Readiness
Review Guidelines
1. Project Management Review
2. Engineering Readiness
3. Procurement / Material / Supply Chain
Readiness
4. Quality Management and Records
Programme Review
5. Human Resources & Training Review
6. Construction Readiness Review
7. Construction Installation Completion
Assurance/ System Handover
8. Targeted Area Review (including Project
Delays and Corrective Actions)
9. Technical Visits
IAEA
Construction Methods
• Open Top Installation
• Modularization
• Advanced Welding
Techniques
• Steel Plate Reinforced
Concrete Structures
• All Weather Construction &
Round the Clock Work
• Concrete Composition
Technologies
• Excavation Techniques
• Cable Installation
• Area Completion Schedule
Management
• Application of Computer
Systems for Information
Management and Control
IAEA
Open-top Construction
• Integrating the construction of the building walls/slabs with the modules, equipment/mechanical and electrical commodities installation.
• Reduces temporary openings, the material handling costs of bulk commodities
• Require Very Heavy Lift Cranes
SG Installation in Qinshan, China
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Sep 27, 2010 Unit 1 CA01 lifting, Sanmen Unit 1.
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Consideration of Very Heavy Lift Crane
• A VHL crane needs to be applied taking account of the
following items:
• A VHL Crane could be one of long-lead items;
• A VHL Crane could be restricted by the transportation
limitation;
• A VHL Crane requires wider construction space; and
• A VHL Crane shall not affect to the existing safety-
related systems, structures, and components
including in case of the boom/jibs falling down to the
SSC.
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Modular Construction
Pros and Cons need to be evaluated based on the job site
conditions
Good Bad
Reduce Schedule (If Module is applied to CP)
Reduce Field Work and Leveled On-site Manpower
Increase Productivity and Quality under Factory Environment
More Safely and efficiently at Ground Level Work
Reusability of PPM Engineering to the Nth Plants
Increase Engineering for Module
Increase Temporary Support
Structure
Early Material Requirements
Additional Transportation Cost
(Large trailer truck, Barge)
Increase Lifting/Rigging
Requirements (Crane, Lifting
Jig)
Inspection of Modular
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Sanmen AP1000 #1 Nuclear Island Concrete Pouring
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Taishan EPR Concrete Pouring
Oct. 26, 2009, 9300m3, 86 hours,
Created a world record for pouring of the largest mass concrete
FCD: Oct 26th,2009, Dome: Oct 23rd,2011, 24 Months
IAEA
Advanced Welding Techniques
• Quality welding is crucial and time consuming
• Advanced Techniques • Metal Arc Welding,
• Gas Tungsten Arc Welding
• Submerged Arc Welding
• Automatic welding equipment is very effective • Maintaining high quality
• Improving the working environment in narrow spaces.
IAEA
Automatic Welding Machine
Automatic Welding Machine for RCCV Liner
Automatic Welding for Large Bore Piping
Automatic Welding for Small Bore Piping (CRD piping)
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Manual welding Vertical
Manual welding Horizontal
Automatic
welding
Horizontal
Automatic
welding
Vertical
Advanced Welding Techniques
IAEA
Small Bore piping bending
IAEA International Atomic Energy Agency
Lessons Learned
IAEA
Lessons Learned (Project Management)
• Circumstances in Europe and the USA are quite different from 1970’s • India, Japan and Korea seem to be different due to continuous
NPP construction.
• Safety requirements clearly should be understood to avoid surprises. • Understanding of regulatory practices is essential
• Vendors and sub-contractors have lost knowledge and skill • New type of competence is needed for new technologies.
• New advanced safety features are not easily implemented
• New sub-contractor networks from companies with proven skills
IAEA
Lessons Learned (Project Management)
• Do not underestimate the importance of proven experience • Organization of construction site organization,
• Resource requirements and timing,
• Sub-contractor location and management
• Competence of manufacturers and sub-contractors is not easy to judge solely through auditing
• Owner management of construction activities
IAEA
• Ensure before starting implementation. • Licensee’s capabilities
and resources
• Vendor’s capabilities and resources
• Design has been done to a detailed level (i.e. design is complete!),
• Qualified subcontractors are available
Past
Design Start
Construction Start CO
Design/Engineering
Construction
Current
Design Start Design Freeze
Design/Engineering
Construction
Early finish of Engineering
Lessons Learned (Design)
• Challenges from design changes
• Design standards and Material Substitution Management
• Localization and technical transfer
IAEA
Lessons Learned (Design)
• Inadequate completion of design and engineering work prior to start of construction • Delays start of construction activities at full speed
• Causes continuous pressures to all organizations
• Leads to attempts to reschedule manufacturing and construction steps,
• Leads to reduced quality due to time pressures
IAEA
Lessons Learned (Design)
• Inconsistency and different locations for designers • Different organisations in different places or even in
different countries
• Vendor’s standards versus international or imported country standards
• Metric system and British units
IAEA
Lessons Learned (Modularization)
• Difficulties during module
fabrication
• Procurement (Fabrication)
• Welding technology
• Challenges with modular
construction
• Assembling technology
• Lifting deformation control
• Transportation plans
• Installing, measuring and
positioning technology
Biggest module : Size: 21×14×21M
Weight: 850T
IAEA International Atomic Energy Agency
Exciting Times!
IAEA
Barakah-Unit 1, UAE
• The United Arab Emirates is the first country to start the construction
of its first nuclear power plant in 27 years, since construction was
started on China's first plant in 1985.
July 20 2012
Concrete
pouring
after approval
of PSAR
IAEA
Sanmen, China
Jan 29, 2013
AP-1000
Containment
vessel top
head
placement;
Sanmen,
China
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Sanmen, China
IAEA
IAEA
VC Summer Unit 2, USA
March 10/11, 2013
First concrete pour
of a new NPP in
North America in
three decades.
IAEA
Vogtle Unit 3 Containment Vessel Bottom June
2013
http://southerncompany.com/what-doing/energy-
innovation/nuclear-energy/gallery/new/
IAEA International Atomic Energy Agency
IAEA Construction Readiness Review
Service
IAEA
Construction Readiness Review Guidelines
• Performed at Two stages
• Before starting first concrete pour – check of preparations
• After hot function test, before initial fuel loading
• Areas Reviewed: • Project Management
• Engineering Readiness
• Procurement / Material / Supply Chain Readiness
• Quality Management and Records
• Human Resources and Training
• Construction Readiness
• Construction Installation Completion Assurance
• Targeted Reviews (as requested by customer)
• Guidelines to be finalized August 2013. Service available
now.
IAEA 62
NPP Owner/Operator Establishment
Decision to
go nuclear
Contract signed
Pre-bidding Bidding and evaluation
Negotiations
Financial infra.
Promotion of national participation
Educational infrastructure
Insurance infra.
Legal infra.
OWNER ESTABLISHED
Regulatory body
COD
Site develop-ment
Construction
Erection
Start of construction
First reinforced concrete
Start of constr’n of RB interior
End of containment pressure test
End of primary loop pressure test
Start of first hot trial run
First criticality
Start of trial operation
Handover
Year -1 -3 -4 -5 -6 -2 1 3 4 5 6 2 0
Planning Project Implementation (Pre-project) Project Implementation (Execution)
Commissioning
Stage 1 Construction
Preparation
Stage 2 Construction
Execution.
IAEA
Causes of Project Failure
• Planning • Lack of clearly defined project goal
& objectives at the beginning
• Done with insufficient data
• Change • Cost increase & Schedule
modification
• Cost of executing a project changes exponentially with time
• Many changes late in the project can kill the project
• Scope change during the project
• Scheduling • Too short a time frame
• Overly optimistic deadlines
• Management Support • Lack of support and involvement
of top management
• Shortage of specialized skills and equipment
• Funding • Retracting funds during project
• Kiss of death to the project
• Cost Escalation • Project cost escalation beyond
initial estimates
• Resources
• Insufficient human resources - slows project down and burns out personnel
• Early Investment in the education of the contractors and fabricators must be prioritized
IAEA
Acknowledgements
• DOE NP 2010 Construction Schedule Evaluation, DE-AT01-
020NE23476
• M. Hanyu, Hitachi, ABWR Technology & Construction Experiences
/ Experience of ABWR Operation and Global Deployment, Vienna
(2009)
• Cai, Jiaxin, CNEC, NPP Nuclear Island Civil Construction
Management -Practical Experience & Achievements of CNEC,
Beijing (2012)
• IAEA Power Reactor Information System (PRIS), Vienna (2013)
• http://southerncompany.com/what-doing/energy-
innovation/nuclear-energy/gallery/new/
• Photos : Barakah, Sanmen, Vogtle, VC summer, Taishan, Atucha II,
Angra III, Okiluoto III, Belene
IAEA
When we find an Iceberg
If we simply see the Surface…
IAEA
We could be in a Big Problem
When we find an Iceberg
IAEA
Once mounted on a tiger’s back, it is
hard to control him
騎 虎 難 停