Challenges & Successes of Candu Energy (former AECL) in Nuclear Construction: Case Study of China and Romania

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Dwight Nicholson
6 years ago
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IAEA Workshop on Construction Technologies for Nuclear

12 16 December, 2011 Challenges & Successes of Candu

Study of China and Romania Azhar Khan Manager, Design

1 IAEA Workshop on Construction Technologies for Nuclear Power Plants: A Comprehensive Approach Paris, France December, 2011 Challenges & Successes of Candu Energy (former AECL) in Nuclear Construction: Case Study of China and Romania Azhar Khan Manager, Design & Layout Candu Energy Canada Official Use Only À Usage Exclusif

2 Scope of Presentation Qinshan CANDU Nuclear Power Plant Salient contract details and construction responsibilities Site Quality Assurance (QA) Major construction contracts Challenges Important construction decisions Major issues during construction Localization Major achievements Reasons for success of project Future CANDU Projects in China 1 Official Use Only À Usage Exclusif

3 Scope of Presentation (Cont d) Cernavoda Nuclear Power Plant Unit 1 and 2 Salient contract details and construction responsibilities Challenges Important construction decisions Localization Major achievements Reasons for success of project Future CANDU projects in Romania 2 Official Use Only À Usage Exclusif

4 3 Official Use Only À Usage Exclusif Qinshan Nuclear Power Plant

5 4 Official Use Only À Usage Exclusif Qinshan Nuclear Power Plant

6 Qinshan Nuclear Power Plant Qinshan III CANDU NPP: 2 Unit 728 MWe by AECL and TQNPC International Project with financing from China, Canada, Japan and USA Qinshan, Zhejiang Province, PR of China Contract effective: 1997 Feb 12 First Concrete: 1998 June 8 In Service: Unit 1 Planned: 2003 Feb 12 Actual: 2002 Dec 31 Days Ahead of Schedule: 43 Unit 2 Planned: 2003 Nov 12 Actual: 2003 Jul 24 Days Ahead of Schedule: Official Use Only À Usage Exclusif

7 Qinshan Nuclear Power Plant Major Participants 6 Official Use Only À Usage Exclusif

8 Salient Contract Details and Construction Responsibilities In-Service Unit 1: 72 months from start of excavation (February 12, February 12, 2003): Unit 2: 9 months later Contract was between Third Qinshan Nuclear Power Company(TQNPC)-AECL TQNPC Responsibilities: Site Preparation Prepare Permanent Site Facilities Manage Balance of Plant (BOP) construction AECL as General Contractor and was completely responsible for: Overall Project Management Manage Nuclear Steam Plant (NSP) Construction at Site Site Quality Assurance 7 Official Use Only À Usage Exclusif

9 Salient Contract Details and Construction Responsibilities Bechtel was responsible for BOP Engineering and provided technical assistance at site for BOP construction Hitachi was responsible for T/G Contract and Accessories Construction contractors were responsible for: NSP construction BOP construction Responsible for preparing Level 3 Schedules Quality Control of all construction activities Major Contractors: CNI-23 Construction Company Huaxing (HXCC) Construction Company CNI-22 Construction Company Zhejiang Thermal Power Company (ZTPC) TQNPC was responsible for all payments 8 Official Use Only À Usage Exclusif

10 Site Quality Assurance (QA) AECL - Quality a priority AECL set QA requirements for all construction AECL initiated non-conformance reporting culture: Non-Conformance Report (NCR) process to control work, including Stop Work Orders for major NCRs Field Change Request Process to control design changes at site TQNPC had own Quality Surveillance Team AECL had own Quality Surveillance Branch Construction Contractors responsible for Quality Control 9 Official Use Only À Usage Exclusif

11 Major Construction Contracts Site Excavation (HXCC) NSP Civil Construction (HXCC) NSP Mechanical/Electrical Installation (CNI-23) BOP Civil Construction (CNI-22) BOP Mechanical/Electrical Installation (ZTPC) (Zhejiang Thermal Power Co.) Piping Fabrication (CNI-23) Supply of Concrete (CNI-22) 10 Official Use Only À Usage Exclusif

12 Challenges Site: Very restricted site; small peninsula on which plant was placed Required considerable reclamation from sea to locate full plant Required considerable detailed planning in early stages of construction Very high silt content in water, divers of no use Cultural differences/sensitivities: AECL, Chinese, Bechtel, Hitachi Experience: Young Chinese commissioning staff with first time on CANDU station Construction contractors had no previous CANDU construction experience, but had significant experience of nuclear power plant construction Work to Canadian quality standards not previously performed in China 11 Official Use Only À Usage Exclusif

13 12 Official Use Only À Usage Exclusif Challenges (Cont d)

14 Challenges (Cont d) Complex execution model: Owner manages BOP construction AECL manages NSP contractors - Owner pays First time use of open top construction and modularization on a CANDU 6 Maximization of localization 13 Official Use Only À Usage Exclusif

15 Important Construction Decisions Dedicated Concrete Batch Plant and concrete testing laboratory at Site Confirmation of major concrete design mixes completed months prior to First Concrete Establishing Welding Procedures and Welder Training Program very early in Construction Phase AECL Sole Source for Procurement of NSP Material Localization of HVAC, Electrical Conduits, Cable Trays Open Top Method of Construction Upgrading of Very Heavy Lift (VHL) Crane for Open Top Method of Construction Maximize parallel works between Civil / Mechanical / Electrical Construction 14 Official Use Only À Usage Exclusif

16 Major Issues during Construction Coordination between Construction Contractors Hot Weather Concreting Structural Steel, Unavailability of Heavier Sections Lack of Structural Steel Shop Drawing Detailers in China 15 Official Use Only À Usage Exclusif

17 Localization General Upgrading of Very Heavy Lift Crane with crane with manufactories supervision Civil Execution-100% localized Structural steel with fabrication and erection with expatriate supervision Concrete with expatriate supervision Architectural works -100% localized Mechanical/Piping Installation of piping with expatriate supervision Welding Installation of heavy equipment with expatriate supervision Piping fabrication Very heavy lifts with 100% local effort All HVAC materials and fabrications Fabrication of steel tanks/vessels in BOP Electrical Cable tray fabrication Conduit fabrication Fuel Fabrication 100 % localized due to use of natural uranium fuel 16 Official Use Only À Usage Exclusif

18 Major Achievements Shortest construction of any NPP in China from 1 st concrete to In-Service (54 months) Shortest duration to construct perimeter wall (14 days) Best integrated leak rate of all CANDU 6 nuclear power plants 70 heavy lifts of equipment with the VHL crane Steam generator installed in 8 hours Fuel channels installed in 64 days Excellent performance of Chinese contractors with experience (50% less NCRs for Unit 2 in comparison with Unit 1) 17 Official Use Only À Usage Exclusif

19 Qinshan Success Unit 1 Declared in service 43 days early. Unit 1 Criticality Sept. 20th, 2002, ahead of schedule Open Top and on site modularization methods resulted in effective execution. Large Civil Modules Fabrication/Installation near work face Unit 2 Criticality April 29th, 2003, 52 days ahead of schedule Great success with 3D CADDS as a production tool and use of electronic data management system Training of Contractor to Western Construction Methods Buy in by contractors of Quality philosophy of doing it right the first time. (It made economic sense) Aggressive QA & QS programs praised by Chinese Regulator 18 Official Use Only À Usage Exclusif

20 Reasons for Success of the Project Client/Owner was fully 100% behind completion of project and gave full support to AECL and its sub-contractors Excellent teamwork between all participants AECL had available manpower resources with extensive experience of construction management and engineering expertise on overseas projects Use of Open Top Method of Construction Use of Modularization 19 Official Use Only À Usage Exclusif

21 Future CANDU Projects in China China in the last 10 years has matured as a developer of nuclear power plants and can easily achieve 90% localization on future CANDU nuclear power plants in both supply of equipment and construction. 20 Official Use Only À Usage Exclusif

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28 CANDU Construction in China Ahead of Schedule Under Budget 27 Official Use Only À Usage Exclusif

29 28 Official Use Only À Usage Exclusif CANDU Construction in China Ahead of Schedule Under Budget

30 Conventional Construction of CANDU 6 Stations Conventional Construction Method

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32 Open Top Construction Method Strategically-placed Openings with Sliding Cover on the Temporary Roof for Heavy Lifting

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34 Open Top Construction Method Official Use Only À Usage Exclusif Skew Truss

35 Dousing Steel and Lower Dome Formwork Assembly Area at Site (Unit 2) Official Use Only À Usage Exclusif

36 Official Use Only À Usage Exclusif Qinshan Dousing System Module on Mobile Crane

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38 Qinshan - Dousing System Modules 37 Official Use Only À Usage Exclusif

39 Open Top Construction Method Lower Dome Formwork Being Lifted from Assembly Yard Official Use Only À Usage Exclusif

40 Cernavoda Nuclear Power Plant Situated off the River Danube in south east Romania Units 1 and 2 completed Unit 1 in service 1976 Unit 2 in service 2007 Unit 3 and 4 partially completed and presently being reviewed for completion 39 Official Use Only À Usage Exclusif

41 40 Official Use Only À Usage Exclusif Cernavoda - Site

42 41 Official Use Only À Usage Exclusif Cernavoda - Site

43 Unit 1 & Unit 2 Salient Contract Details and Construction Responsibilities NSP Engineering & Procurement was AECL responsibility BOP engineering/procurement was ANSALDO responsibility Unit 1 owner was RENEL now called SNN Unit 1 Construction management was responsibility of AECL and ANSALDO Unit 2 Owner is SNN Unit 2 Construction Management was responsibility of SNN, AECL and ANSALDO All construction was performed by Romanian contractors 42 Official Use Only À Usage Exclusif

44 Challenges Maximization of Localization Civil Works had been suspended for some time and exposed to natural conditions Very limited structural steel industry. Large sections produced in Romania with welded plates Mechanical Equipment had been installed for long time Electrical Unit 1-some electrical equipment installed for some time Human Resources Extensive turn over of staff 43 Official Use Only À Usage Exclusif

45 Important Construction Decisions Civil Thorough inspections performed, all deficiencies identified, repair methods evaluated Performed preliminary pressure test of reactor building to find leaks in the building Mechanical/piping Setting up of welding training program prior to start of mechanical construction process 44 Official Use Only À Usage Exclusif

46 Localization All construction performed by Romanian contractors with only some specialty foreign contractors Structural steel sections fabricated with plates welded to form required sections All civil materials with the exception of epoxy finishes fabricated by Romanian contractors Site engineering performed by Romanian with supervision by expatriate staff Large number of BOP equipment (tanks, pumps, motors, water treatment plant) provided by Romanian industry Fuel Fabrication; 100% localized due to use of natural uranium fuel Heavy Water Supply: 100% localized 45 Official Use Only À Usage Exclusif

47 Major Achievements Unit 1 completed on Schedule Unit 2 completed on schedule Extensive construction experiences gained by Romanian contractors Extensive analysis and design experience gained by Romanian engineers Extensive management experience gained by Romanian service staff 46 Official Use Only À Usage Exclusif

48 Reasons for Success of Project Both Owner and Project managers determined to bring project to successful closure Extensive Romanian experience that began project in the 1980s was available during project completion phase in 1990s and 2000s 47 Official Use Only À Usage Exclusif

49 Future CANDU Projects in Romania In civil engineering, extensive localization is feasible both with respect to construction and domestic industry In Mechanical/Piping engineering, extensive localization is feasible for construction but a review is required to estimate extent of domestic industry participation In Electrical, Control and Instrumentation engineering, extensive localization is feasible with respect to construction but a review is required to determine the extent of domestic industry participation In engineering, procurement and construction, extensive localization can be maintained and further expanded 48 Official Use Only À Usage Exclusif

50 New address: THANK YOU 49 Official Use Only À Usage Exclusif

51 Thank You Official Use Only À Usage Exclusif

Overview for a feasibility study

Overview for a feasibility study What, Why & Objectives of Feasibility Study? International Atomic Energy Agency Nuclear power option included within the national energy strategy MILESTONE 1 Ready to