npp construction activities - international atomic energy ... · pdf fileiaea international...

IAEA International Atomic Energy Agency

NPP Construction Activities

March 2013

John Moore

Nuclear Power Division

IAEA

Overview of Current Status

2

437 In operation

373 GWe total net installed capacity

67 Under construction

PRIS Data March 15, 2013

IAEA Reference: IAEA-PRIS

NPP Construction Data


Construction Starts

North America


History of NPP construction

North America


Full history of NPP construction

North America


First Nuclear Power Plant

IAEA

Budget Distribution in NPP Construction

Construction 24%

Procurement 30% Design & Licensing

6%

Interest 13%

CPI Increase 12%

Fuel 4%

Others 11%

DIRECT COSTS

(60%) INDIRECT COSTS

(40%)

TOTAL COST: Approx. 5 B$

IAEA Power Plant Engineering Page

9

Manpower and Duration

• Manpower : 4000/day, more than 80 Months

• Preparation : 40% and Implementation : 60%

IAEA

Material & Cost

• Rebar = 76,070 T

• Cable = about 4,000 km

• Instrumentation : 22500 devices

• Large bore piping = 120 km

• Cost : 5 Billion


Optimizing Construction Duration

IAEA

Average Duration for Past NPP Construction 1969 to

1977 in USA

Since 1972,

rapidly

increase

construction

period

Why ??

IAEA

Construction Time Span

Categories 1970-1995

[month]

1996-Now

[month]

1970-1995

[year]

1996-Now

[year]

Median 80 83 6.67 6.92

Minimum 41 47 3.42 4.08

1 Quartile 67 61 5.58 5.08

3 Quartile 105.5 176 8.79 14.67

Maximum 283 302 23.58 25.17

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

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

Needed Manpower for Construction

Personnel Description

Peak Personnel Average

Single Plant

Craft Labor 1600

Craft Supervision 80

Site Indirect Labor 160

Quality Control Inspectors

40

NSSS Vendor and Subcontractor Staffs

140

EPC Contractor's Managers, Engineers, and Schedulers

100

Owner's O&M Staff 200

Start-Up Personnel 60

Licensing Inspectors 20

Total 2400

Craft Description Craft

Percent (%)

Peak Personnel Average

Single Unit

Boilermakers 4 60

Carpenters 10 160

Electricians/I&C 18 290

Iron Workers 18 290

Insulators 2 30

Labourers 10 160

Masons 2 30

Millwrights 3 50

Operating Engineers

8 130

Painters 2 30

Pipefitters 17 270

Sheet metal Workers

3 50

Teamsters 3 50

Total Construction Labor

100 % 1600 * Ref : DOE NP2010 Construction Schedule Evaluation, DE-AT01-020NE23476

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, USA

• Finished the partially completed Unit 2.(PWR,

1100 Mwe)

• Unit 2 was about 80% complete, stopped in 1988. • Decrease in demand for electricity.

• Construction resumed on October 15, 2007, with the reactor expected

to begin operation in Oct. 2012(60 M)

• The project is expected to cost $2.5 billion USD

IAEA

USA Nuclear Industry

• Delayed Construction

• Watts Bar 2 - line in December 2015, with major budget

overrun possibly to $4.5 billion)

• Site preparation (Vogtle 3 & 4 and Summer 2 & 3

units – AP1000 reactor) : First nuclear concrete pour at

Vogtle-3 delayed by three months due to rebar – yield strength.

• Following a 30-year period in which few new

reactors were built, it is expected that 4-6 new

units may come on line by 2020.

• However, lower gas (shale gas) prices since 2009

have put the economic viability of some of these

projects in doubt.

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 4/2/2013 24

Angra 3 NPP, Brazil

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

December 2012, Areva

estimated full cost would be

about €8.5 billion, well over

previous estimate of €6.4

billion , with commercial

operation no earlier than 2015.

TVO and Areva are both

seeking compensation from

each other through the

International Court of

Arbitration.

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

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 : Dec 2015 (Total : 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

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

• 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


How can reduce construction

duration ?

IAEA

Site Construction

Management

support system

Modularization

with very large

crane

On-site

Work reduction)

Site Support

work efficiency

Open-top

&

parallel

construction

Work Leveling

(Peak Reduction)

Early and

Detailed

engineering

before on-site

work

Work

Efficiency

Strategies to Shorten Construction period

With Modularization Method

Construction Period = 38M (actual First ABWR)

Milestones S/C R/I M/C O/C P/S RPV H/T F/L C/O F/C

IAEA

40

100

’ 80 ’ 85 ’ 90 ’ 95 ’ 00 ’ 05

100

60

80

40

現地工数（出

力比

) (2

F -

1

=1

00

)

燃料装荷年度

Manhour Reduction with Early Engineering

Past

Design Start

Detailed engineering completed before construction start

Construction Start CO

Design/Engineering

Construction

Reduced Site Manpower to 40％

Man

ho

ur

‘80 ‘90 ‘00 ‘85 ‘95 ‘05

Current

Design Start Design Freeze

Design/Engineering

Construction

Early finish of Engineering

IAEA

Front-Loaded Construction Engineering

Basic Design

Detailed Design

Construction

Construction Engineering

Previous Design Process

Front-Loaded Construction Engineering

Basic Design

Detailed Design

Construction

Construction Engineering

Requirements from Construction Engineering Inputs from Plant Design

(BOQ, Composite Design, etc.)

Source : From Hitachi construction experiences

IAEA

建設工程

3D-model linked with Schedule

Construction Schedule with 6D

IAEA

Construction Schedule with 6D

3D-model by construction area

Quantities based

on 3D-model

Assign Labor

resource

Schedule loaded with Quantities and Resource

3D-model ＋ Quantities ＋ Resource ＋ Time ＝６D Database

• Develop detailed and precise Construction schedule by construction area based on Quantities and Labor resource

• Simulate the schedule with 3D-model

IAEA

RPV

Upper Condenser Module RCCV Lower Liner Module

Lower Condensor Unit RPV Pedestal Module Base Mat Module HPU Module

Stator Upper Drywell Module RCCV Top Slab

（420 ton）

（410 ton）（460 ton）（260 ton）

630 ton）（270 ton）

（650 ton）（900 ton）（550 ton）

（270 ton）

On-site Work Reduction - Modularization Method -

IAEA

Sep 27, 2010 Unit 1 CA01 lifting.

IAEA

Man P

ow

er

Construction Progress

(month)

Level-off

Manpower Peak

Based on previous ABWR (Conventional Method) (a

rb.)

Manpower Peak Reduction Effort

- Construction & Module Experience-

4

3

2

1

1 6 11 16 21 26 31 36 41 (month)

Manpower Distribution

Based on Latest ABWR

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

Four Season Construction

• Provides “Factory-like” environment for

construction during winter

• Secures environment for:

• Welding

• Concrete pouring & curing

• Protection from equipment

• Allows around the clock work

IAEA

Improvement of Work Productivity

during winter

Buildings with the All-Weather Structure (Steel and Temporary cover)

Four Season Construction

Movable Temporary Roof

70

75

80

85

90

95

100

冬期稼働率［％］

個別養生耐候工法全天候耐候工法


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

VC Summer Unit 2, USA

March 10/11, 2013

First concrete pour

of a new NPP in

North America in

three decades.

• Expected to be closely followed by concrete pour

at Vogtle Unit 2


IAEA Products and Services

IAEA

IAEA REVIEW SERVICES

59

Milestone 1 Milestone 2

NPP site

review

mission

Phase 1 Phase 2 Phase 3

INIR

mission

Milestone 3

INIR

mission

NPP construction

review mission

Pre-

OSART

mission

SCART

mission

EPREV

mission

ISSAS

mission

IPPAS

mission

INSSERV

mission

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 April 2013. Service available

now.

IAEA 61

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

Construction e-Learning Module

• Part of a series of modules targeted at newcomer

countries, at both senior leader and project team

member levels.

• Topics covered in the Construction Module:

• What makes nuclear construction unique

• Important considerations for projects and programmes

• How to achieve excellence

• Key site considerations

• Will be available by end of

Q2 2013.

IAEA

Thank you for your attention!

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