supply chain services for nuclear power plants: how to ... gehring... · supply chain services for...

Dr. Boris Gehring

Centurion, South Africa, March 2016

Supply Chain Services for

Nuclear Power Plants:

How to build and control the

supply chain

30/03/2016 Nuclear Services

Our heritage: 150 years of business success

Establishment of a Mannheim-based steam boiler

inspection association by 21 operators and owners

of steam boilers, with the objective of protecting

man, the environment and property against

technology-related risks

1866

First vehicle periodic technical inspection (PTI) 1910

1958 Development of a Bavaria-wide network of vehicle

inspection centres in the late 1950s

1926 Introduction of the “TÜV mark / stamp” in Germany

1964 First activities in South - Africa

TÜV SÜD continues to pursue a strategy of

internationalization and growth Today

2006 Expansion of services in ASEAN by acquiring

Singapore-based PSB Group

2009 Launch of Turkey-wide vehicle inspection by

TÜVTURK

TÜV SÜD AG Slide 2 30/03/2016 TÜV SÜD Corporate presentation

1960s Start Nuclear Inspection / Consultancy business

Global expertise. Local experience.

INTERNATIONAL

Euro 820 mio

10,600 staff

GERMANY

Euro 1,240 mio

11,400 staff

Legend:

Countries with TÜV SÜD offices

Regional headquarters

Note: Figures have been rounded off.

Global Headquarters

Munich, Germany


Problems with nuclear new build projects

TÜV SÜD AG Slide 4 TÜV SÜD Corporate presentation 30/03/2016

Source: Internet, May 2015

Nuclear new build projects today

TÜV SÜD AG Slide 5 TÜV SÜD Corporate presentation

HCP 3

• French /Chinese consortium building a NPP

in UK

SINOP

• Japanese / American consortium building a

NPP in Turkey based on French (RCC)

/American (ASME) design codes

30/03/2016

Challenge: Permanently changing requirements from different cultures and sources

Requirements management

OR

Expensive and long lasting complex, multi-national projects

Why delays?

Why cost overruns?

-Complex projects

-Supply-Chain is complex

-OEM, manufacturers, owners, operators on different locations

-High safety standards

-Changing requirements (Regulator...)

-Different understanding of codes / specifications / regulations


How to avoid cost overruns and delays?

-Solid project management

-Managing and controlling the Supply-Chain

-Quality control / Quality assurance (components and plant)

-”Translator” for all involved parties in codes / standards / regulations

needed

-Support in Know-how and staffing to manage the resources on the

side of the regulator, manufacturers, OEM



Utility owner: ENEC (Emirates Nuclear Energy Corporation) Type: APR 1400; Capacity: 5,600 MWe

EPC company: KEPCO (subcontractor: KHNP, KEPCO E&C, Hyundai E&C, Doosan Heavy Industry, Samsung C&T)

Completion plan: Unit 1 (May, 2017), Unit 2 (May, 2018), Unit 3 (May, 2019), Unit 4 (May, 2020)

QA/QC external

Code consultancy / Training

“Translator for local requirements and specification of the OEM

External Managing / consulting the supply - chain

Source : 2012 KEPCO E&C Sustainability Report, Google Map

Positive Example: UAE Barakah – Quality assurance for nuclear

power plant

Barakah Nuclear

Power Plant (BNPP)

Abu Dhabi

About 270 km

1st party to 3rd party conformity assessment

TÜV SÜD AG Folie 9 TÜV SÜD Corporate presentation 30/03/2016

Inspection

by

Supplier

Inspection by

Contractor

Inspection

by Contractor

Inspection

by Contractor

Licensee /

Owner

charges _______________________________________

Inspection

Entity

Independent

Inspection

Entity

Independent

Inspection

Entity

Nuclear

Safety

Authority

3rd

Par

ty

2nd

Par

ty

1st P

arty

Statutory

Inspection

Voluntary

Inspection

Ind

epen

den

cy a

nd

Tra

nsp

aren

cy

New build: Licensing for nuclear power plants: Requirements

licensing documents with respect to regulation compliance for:

Siting

Environmental impact analysis

Safety assessments

Hazard analyses

Quality assurance


Training Customised training programmes

Specialised expert workshops

Assessment & consulting services for authorities

Supervisory structures has to be created / optimized / adapted to new build NPP

Developing a licensing procedure

Conducting feasibility studies

Quality management system

Certification System for components

Nuclear new build projects today / UK – Horizon BWR



Actual situation: Generic design assessment process (GDA)

Independent Nuclear consultant

Design review / approval

Safety Case / reliability Study

Environmental Impact Study

Hazard Analyses

► Certification system

► Hazard identification

► Siting support

► Design review

► Quality assurance

► Compliance of specification

► Plant Security & Fire Protection

► Radiation Protection

► Decommissioning &

Radioactive Waste Management

TÜV SÜD AG Folie 13 30/03/2016 TÜV SÜD Corporate presentation

UK Regulator / ONR scope of requirements Technical Consultant

New Build: Design and construction of nuclear power plants

What does it mean?

Assessment & consulting services for authorities and manufacturers

Evaluation of plant and reactor core designs

Deterministic and probabilistic safety analysis

Review of structural design against human-induced and natural events

Evaluation of the supply-Chain

Prequalification of components

Evaluation of quality assurance concepts

Evaluation of radiation protection concept

Evaluation of operating manuals and procedures


Training

Customised training programmes


New build: Commissioning for nuclear power plants


OEM, Manufacturers and operators: handling the Supply-Chain

Quality Assurance / Quality control on components manufactured

Understanding of the regulation

Preparation of licensing documentation

Establishment of a quality management system

Risk analyses e.g. FMEA, HAZOP or RAM-studies

Qualification of nuclear components


Construction of EPR at Olkiluoto: design review

of :

Emergency diesel generators

Safety related valves

Heat exchangers and vessels

Piping components and systems

All safety related HVAC components

Component support structures

Scope of our work:

Design review (e.g. seismic calculations, FEM analysis, GIPs and FIPs)

Construction inspection at the manufacturer (e.g. functional test, compliance with construction plan)

For SC3, SC4 and EYT components according to YVL 1.3

Commissioning inspection from 2015

30/03/2016

NPP Olkiluoto 3, Finland (EPR)

Finnland: Projekt Hanhikivi 1 – Consultant for Fenovioma

TÜV SÜD AG Folie 17 TÜV SÜD Corporate presentation 30/03/2016

WWER-1200

Manufacturer:

ROSATOM

In operation: 2024

National Regulator:

-Rule setting / Regulatory body

-Supervision of the supply-chain itself (class 1 components)

-Supervision of the supply-chain: approving 2nd parties to do

the inspection / acceptance tests for class 1-3 components

-Approval of the site and plant

Regulatory background in Finland

STUK Decision 1/T412154/2012:

TÜV SÜD Industrie Service GmbH is an

Approved Inspection Organisation for

conformity evaluation and approval of design &

manufacture of mechanical devices and structures

for the OL3 project according to

YVL 1.3 (previous YVL guides)

Validity: for NPPs under construction and in

operation, but only until the current YVL guides

have to be applied to all NPPs, which will be

decided by STUK - expected in 2015

Status: approved on 29th March, 2012

STUK Letter 8/0010/2014

STUK invites the authorised inspection organisations

to apply for approval according to the new YVL E.1,

which has replaced the YVL 1.3

Validity: for new build NPPs at the moment, for

NPPs in operation and under construction after a

forthcoming STUK decision

Status: Approval expected in week 42/2015

Our Role in Finland

STUK Decision 1/T4121117/2015:

TÜV SÜD Industrie Service GmbH is an

Approved Testing Organisation for testing of

mechanical equipment and structures in safety

classes 1 to 3 and EYT according to YVL 1.3

Validity: for FORTUM‘s Loviisa 1 and 2

until 15th July, 2020

Status: approved on 15th July, 2015

Our Role in Finland

YVL inspections

according to YVL 1.3:

• Design review and construction inspection for SC3, 4 and EYT components (pumps, valves, pressure vessels, EDG and SBO diesel equipment, HVAC)

• Commissioning inspections are expected from III/2016 on

• Combined experience of 42 years (man years) in the Finnish inspection business since 2004 / total turnover about 7,8 million EURO

Our Field of Activities in Finland

Our Field of Activities in Finland

Expert‘s opinions, case studies, review and

supervision for all Finnish utilities:

• TVO: evaluation of specifications and procedures

(project specifications OL3 / configuration managment)

• FENNOVOIMA: review of PSAR Chapter 2

(geography, geology, meteorology and seismology)

• FORTUM: plant and system case studies (moisture separator reheater / HP turbine, APROS

validation, supercritical pressure calculation)

• Combined experience of 6 years (man years) / total turnover about 0,5 million EURO

New Build: Support the OEM / manufacturers / owners / operators

of nuclear power plants


Training

Customised training programmes


Owner’s engineer

Code consultancy for the OEM, manufacturers

Alignment of specification and regulation

Qualification of Manufacturers / Vendor qualification

Support for the preparation of deterministic and probabilistic safety analysis

Risk analysis e.g. FMEA, HAZOP or RAM-studies

Prequalification of components

Certification of components

Support of setting up quality assurance concepts, protection concepts, operating manuals

HSE

Type , Acceptance and Commissioning testing

Manufacturing supervision

Concrete testing

ShinKori 1&2

TÜV SÜD AG Slide 24

Quality control

30/03/2016 TÜV SÜD Corporate presentation

-QA/ QC

-Owners Engineer

-Supply-Chain

-code consultancy

Renewal of HP turbine and moisture separator reheater


Modernisation of Loviisa:

Renewal of several components

Review of transient behavior

Analyses of operational transients and

accidents (e.g. loss of coolant)

Scope of our work:

Performing thermohydraulic analyses with APROS for different plant configurations (two turbine shaft lines)

Validation of model and results

Interpretation of results, recommendations for future work

APROS model and analysis instructions submitted by FORTUM

30/03/2016

NPP Loviisa, Finland (VVER 440)

TÜV SÜD – Accreditations

Accreditations

DIN EN ISO/IEC 17020: 2012 (DAkkS)

DIN EN ISO/IEC 17025: 2005 (DAkkS)

ISO 9001: 2008

ISO 14001: 2004

KOLAS


Our expertise standards

IAEA

ASME

NUREG

KTA (Germany)

SAPs (UK)

KEPIC (Korea)

PNAE (Russia)

RCC (France)

YVL (Finland)

What South Africa needs for NPP New Build

Global support Code consultancy and “Translation of Specification / Regulation”.

Owners

Engineering

Expediting / Commissioning: check the supply-Chain independently, make

sure that the components are in line with regulation / specification (of the

OEM)

Ensure

transparency

Safety analysis and transparent approval process with stringent quality

control of manufacturing and construction.

Build up of a

supply-Chain Code consultancy, quality manuals, quality control and certification services

Enabling the local industry to manufacture for New Build (also international).


Contact us today!

TÜV SÜD AG

Industry Service

[email protected]

T: +49 89 5791 2400

M: +49 173 6589 001

Dr. Boris Gehring

Head of Power & Systems Business Unit

Head of Nuclear Energy Business Unit


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