experiences of local participation in npp construction · pdf fileexperiences of local...

Experiences of Local Participation in NPP

Construction in Pakistan

Muhammad Tahir Khaleeq

Pakistan Atomic Energy Commission

Highlights

Introduction

Current Status of Nuclear Power

Process of Localization for Nuclear Power

Plant Construction

Capabilities and Experiences of PAEC

Capabilities and Experiences of Local

Industries

Human Resource Development for Nuclear

Power Plants

Introduction

• All seven projects of Nuclear Power Plants Construction so

far have been turnkey projects but some local participation in

these projects resulted in enhancement of capabilities and

experiences of PAEC and local industries.

• For the sustainable nuclear power program, Pakistan

increases the indigenization level in NPP construction by

utilizing the experience already gained for greater self-

reliance and participation of local industries.

• The local effort to address the aging, obsolescence of

equipment and the life extension of the Karachi Nuclear

Power Plant (KANUPP) beyond its designed life resulted in

a good experience in local involvement for NPP construction

Introduction

• Our aim of indigenization and self-reliance not only for more

participation in construction of future nuclear power plants but

also for providing support to the operating plants by

manufacturing spare parts and replacement components as

well as by rendering technical service in fuel management,

in-service inspection, etc.

• In the long term, the indigenization program will raise the

technical know-how level of domestic industry.

• The presentation highlights the local involvement in NPP

construction and capabilities and experiences gained for

sustainable local involvement for future NPP Projects.

Nuclear Power

Plants

Type

Capacity

(MWe)

Year of

Commissioning

In Operation

KANUPP (K-1) PHWR 137 1972

CHASNUPP-1 (C-2) PWR 325 2000


Under-construction



KANUPP-2 (K-2) PWR 1100 2021

KANUPP-3 (K-3) PWR 1100 2021

Current Status of Nuclear Power

• A Contract is signed with the vendor of NPP. A clause of

local participation is included in the contract.

• The basis of localization is the capability in different areas

of nuclear power plants construction, including civil

construction, manufacturing of equipment (mechanical,

electrical, etc.), operation and maintenance etc. Presently,

the percentage of local participation for civil construction

and manufacturing of equipment is very low (<1%). The

local participation in operation and maintenance is 100%.

• Local manufacturers/suppliers are introduced to the vendor.

Vendor make sub-contract with the manufacturer directly or

through PAEC

Process of Localization for

Nuclear Power Plant Construction

• Overall survey is conducted to see capabilities of the local

manufacturers/suppliers and selected manufacturers/suppliers

are introduced to the vendor.

• PAEC arranges dialogue directly between vendor and potential

manufacturers/suppliers

• The local industries are selected on the basis of their previous

experience with PAEC for supply/manufacturing of equipment for

nuclear power plants or already participated in the construction of

nuclear power plants in Pakistan or have experience of

manufacturing/supply of equipment for thermal power plants.

Qualification of local manufacturers/suppliers is checked on the

basis of vender’s lay down standards.


Nuclear Power Plant Construction … (2/3)

• Procedure of limited tenders is used for national

involvement. Those industries/companies are involved in

tendering process that have been short listed on the basis

of our last experience or their capability and experience for

the particular task.

• The vendor arranges contacts and visits of our local

manufacturers/suppliers to his qualified manufacturers/

suppliers for transfer of technical knowhow and up-

gradation of their facilities


Nuclear Power Plant Construction … (3/3)

Scope of Engineering and Technical Support

• Equipment Design and Manufacturing

• Inspections (ISI, PSI, NDT)

• Testing and Qualification

• Installation

• Technical Studies

• Ageing management

Capabilities and Experiences of PAEC

Design and Development

• PAEC has developed the capabilities in the areas of

nuclear design, in-core fuel management, thermo hydraulic

design, shielding design, safety analysis radiological

analysis for the preparation of basic and detailed design.

• PAEC has the capability to structure design of NI buildings.

• PAEC has the capability in structure design of Conventional

Island (CI) and BOP buildings. Reasonable capability exists

in the design of Process, Electrical and I&C systems.

Capabilities and Experiences of PAEC (2/9)

Mechanical Equipment Manufacturing

• PAEC has main mechanical equipment manufacturing

facilities. These have an appreciable capacity and

capability to manufacture mechanical equipment /

components for NPP.

• In addition to specialized machining capability, state of

the art welding machines are available. Adequate testing

facility quality assurance & quality control setups are also

available.


• HMC-3 currently has ASME U, U2, A, PP, S certificate

Authorization for stamps.

• HMC-3 is registered with the American National Board’s

Certificate for Repair (R) and has various API Certificates.

• HMC-3 is registered with the Pakistan Federal Boilers and

Pressure Vessel Safety Board and ISO 9001 Certified.

• PNRA has issued necessary certification / license to HMC-3

to manufacture equipment of safety class 2 and 3 in relation

to those components that were manufactured for C-2 and

these are currently being manufactured for C-3 and C-4.


• License for Nuclear Safety Class-I equipment and ASME

STAMPING for the manufacturing of Nuclear Equipment (N-

Stamp) have been acquired and currently these equipment

for C-3 and C-4 are being manufactured.

• Some 61 mechanical components for C-1 and some 97

types of equipment for C-2 have been manufactured. It has

also installed a number of vessels at site and has done

piping fabrication and installation at various sites. In order

to ensure that equipment manufactured is quality assured,

a quality assurance set-up is available.


Equipment for Chashma Nuclear Power Plants

Storage / Process Tanks

Instrumentation and Control (I&C) Equipment

• PAEC has existing facilities consist of fabrication and

testing of some reactor instruments and systems on small

scale.

• Some new systems including Internals Vibration Monitoring

Systems and Loose Part Monitoring System have been

locally developed and installed in C-1. Thermal Fatigue

Monitoring System has been installed in C-2.

• Few other systems like nuclear power monitoring systems

and some other systems for C-1 and KANUPP has been

designed and developed.

• Full scope training simulators have also been developed

for C-1 and C-2 another is being developed for C-3/C-4.


Commissioning

• In case of C-1, Participation of PAEC engineers was limited

to witness or observation only. PAEC engineers were not

allowed to do any hands on work:

• In case of C-2, about 120 qualified personnel took part in

the commissioning including preparation of commissioning

procedures, thus provided ample opportunities for learning.

The responsibility of commissioning of C-2 was on CZEC.


NDT Services for NPPs

• Control-point participation as NDT experts during fabrication

of vital components of C-1/ C-2/ C-3 / C-4

• Participation in RFOs of C-1

• Participation as observer in PSI of C-1/C-2

• Participation in RFO of C-2

• Inspection services provided to NPPs other than scheduled

shut-downs

• Training and qualification of NDT manpower

• Flow Accelerated Corrosion (FAC) studies carried out

for C-1 / C-2


Capabilities and Experiences

of Local Industries

Mechanical Equipment Manufacturing

Local manufacturing capability of following mechanical components

are available.

• Nuclear Safety class 2 and 3 vessels and fittings

• Non Nuclear class vessels and heat exchangers

• Hoisting facilities

• Steel structures

• Special tools

• Non nuclear class pumps

• Non nuclear class air conditioners

• Non-1E class low voltage motor

• Non-1E class cables/medium voltage electrical cubicles

• Non-1E class immersed type step down transformers


Industries ….. (2/5)

• Some reputed industries may be entrusted for the

manufacturing of NPP equipment.

• To achieve the objective some organizations can be

encouraged to enter into technology transfer arrangements

with the counterpart foreign organizations to undertake

local design and manufacture.

Electrical Equipment Manufacturing

• Local industry is already manufacturing electrical equipment

in different categories for conventional power plants.

• Capabilities of local industry can therefore be utilized for

manufacturing of most types of non safety related electrical

equipments for NPP.

• Local manufacturers are not in a position to manufacture

safety related electrical equipment due to lack of fabrication

facilities and equipment qualification programs.



Civil Construction

• Most of the civil works of a nuclear power plant can be

carried out by high profile local construction companies.

The construction materials are available in the country. The

structural design of buildings is carried out by many

departments, depending upon the type of structure.

• The construction of Conventional Island (CI) can be

undertaken by many construction companies, including

M/s. Habib Rafiq, M/s. Descon Ltd, M/s. Interhom and

M/s. Paragon.



• These companies toke part in C-2 and currently

participating in construction of C-3 and C-2.

• The local construction companies is also being involved

in construction of K-2 and K-3 Nuclear Power Plants.

• The construction is supervised by PAEC civil engineers

and overall QA work is also the responsibility of PAEC.



• Pakistan Institute of Engineering and Applied Sciences (PIEAS)

–Masters and Ph.D Programs in Engineering and Sciences

• Karachi Institute of Nuclear Power Engineering (KINPOE)

–Masters, Post-Graduate and Post-Diploma Programs in

Nuclear Power Technology

• CHASNUPP Centre of Nuclear Training (CHASCENT)

–Post-Graduate and Post-Diploma Programs

–Training for Licensing of PWR Operations Shift Supervisors

using a Full Scope Training Simulator

• National Centre for Non-Destructive Testing (NCNDT)

• Pakistan Welding Institute (PWI)

Human Resource Development

for Nuclear Power Plants

experiences of local participation in npp construction · pdf fileexperiences of local...

Documents