Poland Nuclear Program EPR Flamanville 3

Transcription

1 Poland Nuclear Program EPR Flamanville 3 Project Organization Design & Manufacturing activities On Site activities What We Are Learning from New Construction Experience September 29 th, 2010 Gilles Zask 1POLAND - PPL Executive NUCLEAR Leadership PROGRAM presentation FLAMANVILLE - OE process 3 SEPTEMBER - October 15th, 29th, MEETING in WARSAW

2 Project Organization

3 EDF - Architect Engineer Engineering organization for Flamanville 3 Owner (Level 0) Architect Engineer Level 1 EEDFDF EDF NSSS I&C BNI BOP/BCI TG and Auxiliaries Detailed Design Level 2 AREVA NP AREVA NP SIEMENS SOFINEL 55% EDF,45% ANP EDF Engineering - sub-contractors ALSTOM Suppliers Level 3 Supply & Construction Contracts (calls for bids) Limited number of contracts 150 vs. 700 for N4 projects

4 EDF: OVERALL ENGINEERING AND PROJECT MANAGEMENT EDF acting as Architect Engineer : Project Management (schedule, cost, quality, interface management, Risk analysis ) Cost optimisation for equipment taking into account investment and maintenance costs (feedback of experience from operation) Technical specifications and surveillance of main contracts (NSSS, I&C, CI, BNI design) Definition of technical references and overall operation Definition of contract allotment and contract management Licensing process Construction on site and commissioning management

5 18 Critical Paths are monitored through monthly indicators (Engineering, procurement, manufacturing, site work, ) 1. Licensing 2. Systems engineering 3. Civil Work Design 4. Lay-Out Design 13.Site Construction 5. CI Engineering and contracts 14.Water discharge structure 6. BOP Engineering and contracts 15.Procurement 7. NSSS Engineering 16.In-Service Inspection 8. Main Components Manufacturing 17.Component Qualification 9. Overall Operation and Safety Studies 18.Operations Team Staffing & Training 10.Full Scope Simulator 11.I&C 12.Industrial Information System

6 Design and manufacturing activities

7 Engineering and full scope simulator Phase 1 : in operation since 2008, validation of I/A operation Phase 2 implemented in CNEN, Septen & Flamanville Man Machine Interface validation tests has been proceeded Results of this tests under analysis between engineering and operating staffs Training and qualification of operators in progress Phase 3 : final development phases and in factory tests delivery scheduled in october 2010

8 Standard I&C and Protection System Functional acceptance tests in progress at Vitry s platform for for the batches of cabinets. First cabinets already installed and commissioned in CI for Auxiliary Transformer energization Protection system(txs) under acceptance tests, with some difficulties; risk to jeopardize V2 developments Safety Authority Assessment further to EDF documentation issued as answer to ASN letter from 15 October 2009

9 Main NSSS components manufacturing Forgings: All main forging are now completed, but some delays in manufacturing. Reactor vessel : primary nozzles welding is in progress. SG : in progress, Pressurizer : Fabrication pending on agreement of the safety authority required by the new French regulation on pressure vessels/components. Reactor coolant pipe : in progress, fabrication pending on SA agreement.

10 CI / BOP Design & Manufacturing Generator : Tests on july 2010 Turbine : HP cylinder finished BP cylinder on july 2010 HP Heater : Delivered and installed MFW Tank Elements delivered on site HMP Rotor MFW Tank HMP barrel

11 Licensing Objective for license application Final Safety Report and Tech Spec scheduled 1 year before fuel loading A very tight schedule to be adapted and discussed with ASN taking into account the general progress of the project

12 On site activities

13 Reactor building Outer containment : 9 th lift concreted, Inner containment : 4 rd lift concreted Dome : liner being assembled on prefabrication area Internal structures : +1,50m heavy slab concreted Installation of excore instrumentation in the reactor pit

14 Fuel building and SAB HK Fuel Building 5th and 6th APC lift being proceeded Floor level -3,40m (int) acheived and 0,00m (ext) under construction HL Safeguard Building External levels under 0,00m weather proof HL 2 3 ext : Last APC lift concreted +8,10m external floor under construction Monorails assembly in low levels HL 1 4 8,10m external floor done Walls from +8,10 to +12,00 being proceeded 0,00m internal floor under construction painting in progress at 9,60m

15 Nuclear auxiliaries, diesels and waste buildings HN Nuclear Auxiliary Building 0.00m floor in progress TES tank and APG demineralizer installed HQ Waste treatment Building A : raft concreted and walls between and 0.00m being concreted B : -3,90m floor under construction HD Diesel Buildings south : 0.00m floor concreted and walls from 0.00 to +8.10m being concreted Diesels foundation blocks concreted north : embankment done (underground levels are achieved, buried under the heavy track)

16 Turbine hall Condenser tube bundles under installation ADG tank 3/3 parts delivered on site LP 3 and 6, HP 6 and 7 heater installed BP3

17 Water pumping station and outfall structure HP(Pumping station) HP1 waterway area superstructures under construction HP2 volute area : walls from -16,40 to -12,00m under construction HC (Outfall structure) -8,90m floor under construction

18 CI electrical building and operation building CI electrical building Equipments required for TA energization installed and tests achieved (electrical board, control cabinets ) Operation building Erection in progress Cabling, HVAC erection in lower zones

19 Outlet channel End of digging Dismantling for tunneler and treatment plant Next step : channel sea pit connexion

20 Staffing and industrial safety ~ hours on site since beginning. Estimation for the complete construction : hours Site staffing # 2900 people Frequency accident rate (number of accidents with work stop for hours) in 2009 : 29 Since the beginning of 2010 : 18 Safety goals are improving action plans are maintained (benchmarking, best practice, sub-contractor management, dedicated staffing) EDF/ENEL POLAND NUCLEAR 06 Novembre PROGRAM 2009 FLAMANVILLE 3 SEPTEMBER 29th, 2010 MEETING in WARSAW

21 The graph below reflects the updated staff mobilization plan for Civil works, Evolution de l'effectif chantier 2500 Effectif prévisionnel agrégé 2000 Effectif réalisé J A SON D J F MAM J J A SOND J F MAM J J A SON D J F MAM J J A SON D J F MAM J J A SON D J FMAM J J A SON D J F MAM J J A SON D

22 Feedback Operating Experience

23 OE Process General Principles To be competitive, achieve quality construction the first time, and accomplish industrial safety goals, projects must: Establish a continuous improvement culture across organizations Implement a process which quickly defines, assesses applicability and implements Construction Lessons learned Avoid repetition of problems encountered on in-progress EPR Projects Topics Engineering (Drawings, specifications and procedures), construction, contracts, organization, procurement, etc.. all facets of the project. Customers All EPR Projects

24 Process Elements and Key Attributes Procedure Simple & non-bureaucratic Database Robust & accessible Real time project integration Speed Living, dynamic and immediate implementation, quick capture, dedicated resources, and actionable recommendations Communication Frequent updates organization-wide

25 OE Results Overview 114 reports in progress (64) or completed (50) Reports in each of the following areas: Construction Engineering Studies Contracts Procurement Organization 25 POLAND - PPL Executive NUCLEAR Leadership PROGRAM presentation FLAMANVILLE - OE process 3 SEPTEMBER - October 15th, 29th, MEETING in WARSAW

26 OE Results Construction Liner, Anchor plates, External containment (APC), Quantity of rebar in containment, Welding difficulties, Studies Construction codes (ETC-C) Fire zoning, Seismic qualification, ECWS hydraulic transient phenomena, Contracts Alstom contract, climatic conditions, and hazards Bouygues interfaces, Procurement Pipes control, Organization Project interfaces, Control procedures, POLAND 26 - PPL Executive NUCLEAR Leadership PROGRAM presentation FLAMANVILLE - OE process 3 SEPTEMBER - October 15th, 29th, MEETING in WARSAW

27 OE Results Early Examples Containment Liner RIS/EVU piping A single concrete pour for the NI base mat Manufacturing- contractual difficulties Anchor Plates Use of technical galleries Reactor Building gusset adaptation (re-design) Containment pre-stressing system Concrete reinforcement bar densities Concrete ventilation duct coatings Etc. 27 POLAND - PPL Executive NUCLEAR Leadership PROGRAM presentation FLAMANVILLE - OE process 3 SEPTEMBER - October 15th, 29th, MEETING in WARSAW

28 Thank you for your attention