Modularization : Challenges and Opportunities. World First AP1000 Unit

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1 Modularization : Challenges and Opportunities Modularization Construction Experiences of World First AP1000 Unit cnfdxl@163.com

2 Contents 1 Retrospect on Sanmen AP1000 Modularization Construction 2 Modularization Construction Experiences of World First AP1000 Unit 3 Challenges and Proposals

3 Overview 1) Sanmen1# is the world first AP1000 unit. 2) Features:. Passive safety system;. Modularization ation construction; ction 3)parties. Owner: SMNPC, SDNPC. Designer: WEC consortium. project Management : JPMO(WEC,SHAW,SNPEC). Constructor: CNF, CNI22, CNI24

4 Overall Schedule Sanmen Unit1 ATP+0 ATP+71 Unit2 Haiyang Unit1 Unit2 4month 6month 5month

5 Milestones Schedule of Sanmen 1#Unit

6 2 Retrospect on SanmenAP1000 NPP et ospect o Sa e 000 Construction

7 1#NI excavation started on #NI Basemat Construction

8 The dental concrete started on Aug,24,2008 1#NI Basemat Construction

9 On Sep. 18, 2008, lower mudmat concrete of 1#NI finished. 1#NI Basemat Construction

10 On Oct. 15, 2008, upper mudmat concrete of 1#NI finished. 1#NI Basemat Construction

11 O J b t f 1# NI On Jan. 12, 2009, basement of 1# NI rebar finished. 1#NI Basemat Construction

12 On Jan. 22, 2009, first equipment module KB10 was set. 1#NI Basemat Construction

13 On Feb. 19,2009, stay in place form installation finished. 1#NI Basemat Construction

14 1#NI Basemat Construction On Feb. 28, 2009, the embedded piping installation was finished and ready for FCD.

15 1#NI FCD on Mar. 29, #NI FCD

16 Night Shift 1#NI FCD

17 1#NI FCD On Mar. 31, 2009, monolithic concrete placement of more than 5000 m 3 was achieved. It took 47 hours for 1#Unit.

18 AP1000 ModularizationConstruction Process Modularization Construction Flowchart Module Assembly shop Fabrication Module Transportation Module Lifting engineering Set

19 shop Fabrication of Structural Module

20 In August of 2008, CA assembly area was available. Construction Progress Show CA20 Assembly

21 Construction Progress Show CA20 Assembly By the end of 2008, the first batch of sub modules of CA20 delivered on site.

22 Sub modules Fitting up Construction Progress Show CA20 Assembly CA20 Floor

23 Construction Progress Show CA20 Assembly Sub modules Welding

24 Construction Progress Show CA20 Assembly 1 2 The assembled subassemblies overturn and erected, ready for integrated assembly 3 4

25 Construction Progress Show CA20 Assembly Integrated assembly of structural module

26 Construction Progress Show CA20 Transportation and Lifting The structural module transported from assembly area to NI through heavy haul road Two 25 axes hydraulic trailers

27 CA20 module, about 1000T, lifted and set in NI on Jun. 29, 2009 Construction Progress Show CA20 Transportation and Lifting

28 on Oct. 23, 2008, CV assembly area was available CVBH Assembly and Lifting

29 CVBH Assembly CVBH Assembly and Lifting

30 CVBH Welding CVBH Assembly and Lifting

31 CVBH welding finished and ready for transportation CVBH Assembly and Lifting

32 CVBH Assembly and Lifting CVBH Lifting 1#CVBH was set at NI on Dec. 21, 2009

33 CV Shell Assembly & Transport

34 1#NI CV1# ring was CV Shell Lifting Set on Mar,18,2010 1#NI CV2# ring was set on

35 CV Shell Lifting 1#NI CV3# ring was set on #NI CV4# ring was set on

36 shop Fabrication of Equipment Module

37 Equipment Module KB11 Lifting Construction Progress Show Equipment Module Lifting KB12 Lifting

38 R151 Lifting Construction Progress Show Equipment Module Lifting R161 Lifting

39 2 Modularization Construction Experiences of World First AP1000 Unit 1) A detailed, intergrated schedule shall be prepared prior to project construction and implemented to ensure continuous, smooth construction on site.. Detailed design must be preliminarily completed to meet the requirements of material procurement and module fabrication.

40 2 Modularization Construction ti Experiences of World First AP1000 Unit 2)Much longer duration is required to use heavy load equipments for lifting and transportation t ti Equipment AP1000 Other PWR Heavy load Crane 2600T/3200T, for the 800T, interval utilization whole construction period Medium Crane Two 400T N/A Hydraulic Transporter 1000T, 400T 400T

41 2 Construction Experiences of World First AP1000 Unit 3) Module fabrication shall be started prior to FCD to meet site construction, The installation i of bulk material ilshall hllbe started right after FCD is finished. then:. The procurement ofbulk material and equipment shall be started at an earlier time.. award oftheconstruction contract shall satisfythe the construction requirements.

42 2 Construction Experiences of World First AP1000 Unit 4) The parallel/intercrossed construction for civil and erection needs more close coordinate, and the civil and erection work shall be performed at the sametimeand and together withoutside module fabrication.. Logic relation.. Lifting and transportation passage.

43 Typical Construction Logic Figure CA01 set CA04 set CA05 set Concrete placement for layer 4 Concrete placement for layer 2 Concrete placement for layer3 Concrete placement for layer1

44 On Apr. 28, 2009, CR10 module was set. CV Internal Structure Construction

45 CV Internal Structure Construction On Aug 1, 2009, exterior foundation layer A was poured.

46 On Aug. 1,2009,CVBH was set. CV Internal Structure Construction

47 On Jan 12, 2010,interior structure layer1 was poured. CV Internal Structure Construction

48 On Jan 26, 2010, the lifting of CA04 module was successfully performed. CV Internal Structure Construction

49 CV Internal Structure Construction On Feb. 10,2010, interior structure layer2 was poured.

50 CV Internal Structure Construction On Feb. 28,2010, CA05 module was set. On Mar. 11, 2011,interior structure layer3 was poured.

51 CV Internal Structure Construction

52 CV Internal Structure Construction CA01 Lifting

53 CV Internal Structure Construction On Mar. 27, 2010, CA01 module was successfully set.

54 2 Construction Experiences of World First AP1000 Unit 5) The stick installation is changed into the modularization construction, which makes the work at shop(module fabrication) easier, while the site work (module transportation, assembly, lifting, erection)more difficult. Structure module assembly:. overhead position welding required;. Irregular shaped assembly structure, hard to locatethethe CG;. Integral outline dimension is hard to control due to fabrication and assembly deviation accumulation.

55 2 Construction Experiences of AP1000 First Unit 6) Flexible site module adjustment The actually delivered KB15 module is not completed, and the unfinished parts inside module, such as piping, will be installed on site. Integrated KB15 module in 3D Model

56 2 Construction Experiences of World First AP1000 Unit 7) Weather Protective Measures. Temporary cover;. Hard and soft cover for individual;. Paint after permanent coverd. The assemblyfor temporary top cover is ongoing. Main truss Annular truss

57 3 Challenges and Proposals 1) Increase of Construction Cost:. The fees for lifting&transportation equipment are increased..more manpower resources: due to the parallel construction of civil and erection, the construction period for these two disciplines has been extended, which caused that the manmonth input has been increased.

58 3 Challenges and Proposals 1)Increase of Construction Costs:.Lower labor efficiency : The construction logic is strictly required, if any deviation of schedule hdl on any link, such as design, equipment and material supply, the progress for major structure will be slowly, and even local suspension willbe caused, so that the laborefficiency becomelower and lower.. Heavy haul road, module assembly field and facilities shall be added.

59 3 Challenges and Proposals 1) Increase of Construction Costs large quantity for temporary steel structure CVBH Temporary Steel Structure Support Structural Module Temporary Steel Structure Support

60 3 Challenges and Proposals 1) Increase of Construction Costs large quantity for temporary steel structure CVTH Temporary Steel Structure CVTH Temporary Steel Structure Supports

61 3 Challenges and Proposals 2) Increaseof difficulty of Finished Products Protection Outdoor Installation of Equipment Module

62 3 challenges and Proposals 3) Large Difficulty for Management of Intercrossed Construction Intercrossed d construction for structural module and embedded bdddpiping, civil RV cavity structural module CA04 Embedded piping Embedded cable conduit CB65 structural module

63 3 challenges and Proposals 3) Large Difficulty for Management of Intercrossed Construction

64 3)Big Difficulty for Management of Intercrossed Construction. The layout tfor each building of AP1000 is compact, the Open Top method shall be adopted, so that the layout of site cranes, location of tower cranes and operation managementare are critical.

65 3 Challenges and Proposals 4) Increase of Construction Difficulty : The deformation control during structural module fabrication, assembly and installation is greatly difficult. The connection after setting of equipment module, such as site piping, is very difficult to be performed. The location precision is high, and as the precision requirements for multi location and multi points need to be met, alignment is very difficult to be performed.

66 Pipe terminal of R155 module Pipe terminal of R151 module Site connection issues after these two modules are set: as the accumulated deviations for module fabrication and installation, the pipe position is difficult to be aligned.

67 3 Challenges and Proposals 5) Prior to design finalization, the detailed constructability &maintenance evaluation and optimization must be performed:. Module lifting and transportation passage.. The decoration after module set is very difficult to be performed, so that the final decoration must be finished before modulesetting.

68 Install equipment module by Open Top Method Lifting of equipment module Equipment module set

69 3 Challenges and Proposals. Installation space, equipment module internal space is small, so that cable layout and maintenance is very difficult to be performed. The distance between floor module and cable tray is very short, so that the cable layout and maintenance is very difficult to be performed.

70 3 Challenges and Proposals 5) Prior to design finalization, the detailed constructability&mainenance evaluation and optimization must be performed:.operation space while installation (scaffolding, welding and NDE)..Evaluation for module transportation and lifting passage.

71 3 Challenges and Proposals 5) Prior to design finalization, the detailed constructability& maintenance evaluation and optimization i i must be performed: The evaluation of maintainability is also vey important:. The evaluation of maintainability is also vey important: equipment moved in through Open Top Method and the operation space and passage moveout of equipment components during maintenance must be considered.

72 3 Challenges and Proposals 6) Prior to design finalization, the detailed economy evaluation and optimization i must be performed:. Whether moduleshall be adoptedornot or not, bigorsmallsize size shall be used.. Considering the costs for integrated link (design, fabrication and site construction).

73 Conclusion The most valuable contribution for modularization is that the construction period (FCD~CO) reduced, so as to reduce the investment, however, partial works need to be performed in advance (change from after FCD to before FCD) and with good planning and organization & implementation, otherwise, the stick installation method is better.

74 Thanks! net sanmen.com ap1000.com

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