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

IAEA

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


Optimizing Construction Managemet

IAEA

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

IAEA

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


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).

IAEA

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

IAEA

Dec 2012 Atucha II

IAEA

In 2003 Photos

Preservation Of Stored Components

Angra 3 Npp in Brazil

IAEA 6/27/2013 20


IAEA


IAEA

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

IAEA

… and 10 months

after …

Site opening on

31.07.2008

Major Concrete Dismantling and Demolishing

Project in Belene - Site Preparation

IAEA

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

IAEA

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

IAEA

http://www.timesfreepress.com/videos/2012/apr/06/6027/

IAEA

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 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

IAEA

Sep 27, 2010 Unit 1 CA01 lifting, Sanmen Unit 1.

IAEA

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.

IAEA

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

IAEA

Sanmen AP1000 #1 Nuclear Island Concrete Pouring

IAEA

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)

IAEA

Manual welding Vertical

Manual welding Horizontal

Automatic

welding

Horizontal

Automatic

welding

Vertical

Advanced Welding Techniques

IAEA

Small Bore piping bending


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


• 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


• 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


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

IAEA

Sanmen, China

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 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

http://southerncompany.com/what-doing/energy-innovation/nuclear-energy/gallery/new/








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

iaea activities on construction technologies and … · · 2013-06-28iaea activities on...

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