An Introduction to Engineering Design in the Nuclear Industry

Transcription

1 An Introduction to Engineering Design in the Nuclear Industry Nuclear Supply Chain Event 28 th April 2016 Part 2: The Design Process Rob Barrand Lead Process Engineer

2 Overview Contents The Staged Design Process. The FEL Process. Safety And Environmental Assessment.

3 Why a staged design process Compliance with Site License Requirements Reduces risk and uncertainty with design New and unique processes R&D needs to be carried out to underpin FOAK facilities. Scope clearly defined. Safety and environmental assessment Cost Nuclear safety dominates criticality, dose, shielding Need to secure discharge and disposal routes Control and quantify to manage escalations Decommissioning and liabilities

4 Overview 4 stages to manufacture: Design Strategy Concept Design Preliminary Design Detailed Design

5 Design Strategy Identifies point of entry / number of design stages. Who are key stakeholders? (external approvals, areas of specialist input). Identifies design checklists & key deliverables. Design strategy Concept Design (design package) Preliminary Design (design package) Detailed Design (design package) Risks and assumptions (live document). Capital projects formal report to support business case. Procurement package Handover to manufacturer

6 Concept Design Results in a package which identifies feasible technologies, develops a functional specification / basis of design and identifies key safety and environmental issues. Typically includes: Functional specification & basis of design report. Scheme diagram. Technology assessment. Location statement. Draft hazard and environmental statement. Concept design review, approved by the Design Authority.

7 Preliminary Design Results in a package which provides frozen design data, preliminary layouts, approximate service requirements and the first level of detailed safety and environmental reviews. Typically includes: Performance specification, with system description and operating envelope included. General Arrangement for installation. Data sheets for key items. Drawings indicating key safety systems and process control (EFDs / PFDs / MFDs). HAZOP I report and Environmental Statement. Preliminary design review, approved by the Design Authority.

8 Detailed Design Results in a fully detailed frozen design package for build. All functional safety and environmental design requirements are incorporated in the package. The manufacturer will typically only need to produce shop or site working documents for use by those engaged in the construction. Typically includes: Full 'for build' design package. Detailed design review in meeting record format, approved by the Design Authority. Closed out HAZOP II and safety memorandum for PMP or equivalent authorisation process. Full installation method statements. Design documents and drawings at for build status.

9 Procurement NNL use a risk based graded approach (1-4) to define quality requirements as part of any procurement package: Grade 1 Grade 2 Grade 3 Grade 4 Risk HH H M L Quality Plan Y Y Y/N N Inspection H H M L Approvals prior to manufacture Y Y N N Documentation H M L L

10 Manufacture to Operation Design, Supply & Install (DSI) contracts: Manufacture Stage 2 Inactive Plant Commissioning (IPC) Includes Stage 1 Commissioning at manufacturers works Stage 1 Works Commissioning and Testing (WCT) Installation Stage 3 Inactive Safety Commissioning (ISC) active plant inactive plant Working on-site for installation Stage 4 Active Plant Commissioning (APC) Handover point of DSI contract Stage 5 Active Safety Commissioning (ASC) Handover point of turnkey contract

11 Manufacture to Operation Turn Key contracts Manufacture Stage 2 Inactive Plant Commissioning (IPC) Commissioning for inactive plant Stage 2 on site, to demonstrate the operation of the plant in as close to actual operating conditions as is possible Stage 3 - safety systems perform as designed, people (including maintainers and operators) are all in place and at a state of readiness sufficient to move to operations, functional testing of plant / equipment has been completed. Stage 1 Works Commissioning and Testing (WCT) Installation Handover point for DSI contract Stage 3 Inactive Safety Commissioning (ISC) active plant Stage 4 Active Plant Commissioning (APC) Stage 5 Active Safety Commissioning (ASC) inactive plant Handover point for turnkey contract

12 Manufacture to Operation Turn Key contracts Manufacture Stage 2 Inactive Plant Commissioning (IPC) Commissioning for active plant Stage 4 - demonstrate the performance of the plant and equipment on real feedstock(s). Tests will ramp up the plant in a controlled manner to confirm that the plant/equipment functions as expected utilizing active materials. Stage 5 - confirms the safety performance of the plant under active conditions. Stage 1 Works Commissioning and Testing (WCT) Installation Handover point for DSI contract Stage 3 Inactive Safety Commissioning (ISC) active plant Stage 4 Active Plant Commissioning (APC) Stage 5 Active Safety Commissioning (ASC) inactive plant Handover point for turnkey contract

13 The FEL / Gated Process (with acknowledgement to Sellafield Ltd) Front End Loading is a Stage and Gate approach, which operates from the approval of the client specification to the decision to sanction project completion. FEL is a way of progressively removing risk in projects so that when a project is sanctioned the level of risk that remains and is known is acceptable to the business. FEL is used by Sellafield Ltd for all capital projects, as part of its Business Investment Delivery process. Technology Readiness Levels (TRLs) used to assess maturity. Sellafield Ltd also require that any work undertaken by external design frameworks (DSAs) also follow the FEL process. Embedded with FEL, are the generic design stages.

14 The FEL / Gated Process (with acknowledgement to Sellafield Ltd) Stages in FEL FEL 0 FEL 1 FEL 2 FEL 3 FEL 0 is the evaluation stage of the project and answers the question 'Should the project be carried out?' Design Strategy FEL 1 is referred to as the appraisal stage and focuses on understanding the problem, defining the constraints and determining whether the project is feasible. Concept Design FEL 2 - During this stage the options are developed to allow for the selection of a single option Preliminary Design FEL 3 - During this stage the single option is developed to allow the specification of that option to be sanctioned and implemented Detailed Design

15 The FEL / Gated Process (with acknowledgement to Sellafield Ltd)

16 Safety And Environmental Assessment Background Safety and environment activities are aligned to support staged design process. The nature of the safety assessments vary depending on the type of facility and the scale of the project. Simple systems - a single PMP More complicated a series of linked PMPs or formal safety cases related to individual implementation stages and coordinated In facilities where PMPs are not required e.g. inactive facilities, there is still a requirement to demonstrate that the proposed design meets the relevant legislative requirements and that the item can be safely operated in the intended location.

17 The Design Process Key Messages More emphasis on risk; technical, commercial & safety. There will be a wider range of people involved in the design, researchers, safety analysts, operators. Your design may be driven by factors outside of your area of expertise; safety factors, scientific knowledge of the system. Design will take longer and have more hold points for a nuclear related project, than a non-nuclear one.