AREVA Reactors & Services experience in design and construction

Transcription

1 AREVA Reactors & Services experience in design and construction

2 AREVA s Reactors & Services experience in design and construction Organization Reactor models Main aspects to be considered to establish a NPP construction planning : Example of the EPR TM time scheduling IAEA December 12, 2011 p.2

3 The 5 Business Groups reflect AREVA s Integrated Structure Executive Board Nuclear operations Executive Committee Functional Departments The 5 Business Groups Reactors Mining Front End & Services Back End Renewables > Mining > Chemistry > Enrichment > Fuel > New Builds > Installed Base > Equipment > Nuclear Measurement > Products & Technology > Propulsion & Research Reactors > Recycling > Site Value Development > Logistics > Cleanup > Renewable Energies Engineering & Project Organization International Commercial Organization IAEA December 12, 2011 p.3

4 Reactors & Services Business Group World leader in nuclear power

5 Reactors & Services Activities Gathering all activities related to the design, manufacturing, construction, maintenance and control for all types of nuclear reactors Providing Products and Services for New Builds as well as for Existing Plants Composed of 6 Business Units, backed by dedicated marketing and sales teams More than 12,000 employees worldwide 102 Nuclear Power Plants supplied or under construction 4 EPR TM reactors under construction IAEA December 12, 2011 p.5

6 AREVA s role in construction: OL3 example OLKILUOTO 3 AREVA is the leader of the consortium and responsible for the NI (EPC) with Bouygues as subcontractor for the Civil Works NSSS NI BNI CW TI CI BCI CW BoP E P C AREVA Bouy gues Siemens Heit kamp AR EVA TV O I&C AREVA Leader/ PM AREVA Operator TVO IAEA December 12, 2011 p.6

7 AREVA s role in construction: FA3 example FLAMANVILLE 3 AREVA provides the NSSS (EPC) and the I&C NI CI NSSS BNI CW TI BCI CW BoP E P AREVA EDF Alstom EDF Bouygues Bouygues EDF C I&C Leader / PM Operator AREVA EDF IAEA December 12, 2011 p.7

8 AREVA s role in construction: TSN example TAISHAN 1&2 AREVA is member of the consortium supplying the NI (EP) NI CI NSSS BNI CW TI BCI CW BoP E P C AREVA CNPEC CNPE C Chinese CW contractor Alstom CNPEC CNPEC Chinese CW contractor CNPEC I&C AREVA Leader / PM Operato r CNPEC CGNPC IAEA December 12, 2011 p.8

9 AREVA can provide a range of Generation III+ Reactors AREVA s reactor range The reference in Safety Answers varied customer needs with an adapted product portfolio BWR 1250 MWe Medium Power Output PWR 1100 MWe Developed in partnership with MHI PWR 1650 MWe High Power Output Boiling Water Reactor Pressurized Water Reactors Final development stage Market launch: 2010 Deployed IAEA December 12, 2011 p.9

10 The AREVA Reactor Range BUSINESS PERFORMANCE OUTSTANDING SAFETY ENVIRONMENTAL PROTECTION GEN III+ KEY BENEFITS Maximized availability: design target >92% Short outages High thermal efficiency Minimized global power generation costs Low O&M costs Fuel cycle flexibility MOX fuel Advanced severe accident management Optimized level of redundancy, diversity of systems and incremental mitigation of abnormal events Large commercial Airplane Crash resistance (APC) Minimal environmental impact Reduced collective dose ENERGY SUPPLY CERTAINTY Gen III+ evolutionary designs AREVA integrated supply chain strategy for critical components Proven Digital Safety I&C technology Maximized standardization for simplified licensing IAEA December 12, 2011 p.10

11 The EPR TM Reactor 1650 MWe PWR The reference in safety and operational performance Generation III+ PWR 4-Loop 4590 MWth SG pressure 77bar at 100% power 4x100% redundancy of active safeguard systems Backup in case of total loss of safety function High power output (1650 MWe) Evolutionary design (Konvoi/N4) Low global power generation costs Outstanding safety level Maximized benefit from size effect Minimal environmental impact Construction The Path to in Greatest Finland, Certainty France & China Licensing under way in the USA & UK IAEA December 12, 2011 p.11

12 Nuclear Safety at the Heart of our Activities 1/2 In the aftermath of the earthquake and tsunami in Japan, AREVA is involved in many actions aiming at increasing existing and future reactors safety worldwide AREVA team is supporting utilities in preparation for safety reassessments of their nuclear power plants with the AREVA safety alliance portfolio of solutions IAEA December 12, 2011 p.12

13 Nuclear Safety at the Heart of our Activities 2/2 EPR safety systems would have resisted the seismic event and the tsunami EPR is licensed to resist to a 0.25g-0.3g peak ground acceleration Seismic Margin Assessments lead to a 95% probability that a 0.6g peak ground acceleration wouldn t have impacted EPR s capabilities to mitigate the risk of severe accident No deterioration of diesel nor safeguard buildings due to dynamic impact of wave - Doors would have resisted to a 3-4m wave on the platform No deterioration of diesel nor safeguard buildings due to temporary flooding - Leak-tightness is ensured In similar seismic conditions as of Fukushima earthquake, the EPR wouldn t have endured damages impairing the adequate operation of its safety systems IAEA December 12, 2011 p.13

14 EPR TM Time scheduling Reactor Building Fuel Building Safeguard Buildings Nuclear Auxiliary Building Diesel Building Waste Building AIEA December 12, 2011 Diesel Building

15 EPR TM TIME SCHEDULING 1: - Definitions 2: Schedule construction process 3: Main critical paths 4: Conclusion IAEA December 12, 2011 p.15

16 Time Schedule is a Plan, a Roadmap, a Communication Tool, a Contractual Document Lead Time IAEA December 12, 2011 p.16

17 Time Management How to build a schedule 1. Start from WBS (avoid missing scope), and Work Package deliverables. 2. Create activity list and identify the contractual milestones. 3. Create network diagram. 4. Identify sequence & interfaces between activities. 5. Allocate resources and estimate durations. 6. Define intermediate and internal milestones. 7. Identify critical path 8. Produce the schedule. 9. Identify risks and opportunities 10. Iterations - optimise the schedule. 11. Gain approval. Establish baseline. Create network WBS & Activity list Define the logical links Allocate resources & estimate durations Identify critical path and floats Produce Gantt charts R&O IAEA December 12, 2011 p.17

18 WBS Work Breakdown Structure WBS is the backbone of the project Key Objective: Defining, Authorizing and Controlling the Scope IAEA December 12, 2011 p.18

19 Standard WBS The standard WBS for the Consortium and Nuclear Island scope is broken down by disciplines and coded as follows: CS = Consortium NI0 = Project Management NI1 = Engineering NI2 = Procurement NI3 = Erection NI4 = Commissioning IAEA December 12, 2011 p.19

20 EPR TM TIME SCHEDULING 1: Introduction - Definitions 2: Schedule construction process 3: Main critical paths 4: Conclusion IAEA December 12, 2011 p.20

21 STD Time Schedule Construction Process LICENSING Process and General engineering Layout 3D Model CW Detail Design Layout Design Freeze CW Construction Sequence Formwork and Reinforcement Drawings Building, Levels Availability Date Erection Works on Main Critical Path in Reactor Building Electro- Mechanical Erection Schedule Functional and safety requirements System Design Stage 1 Flow Diagrams Data Sheets Equipment Technical File Equipment Manufacturing Procurement data base Piping, HVAC, MCT DD Equipment Delivery Date Document Delivery Date Overall Commissioning Sequence System Design Stage 2 System Meetings Electrical I&C Detail Design EPT System Design Stage 3 Commissioning Documentation System Test Schedule IAEA December 12, 2011 p.21

22 IAEA December 12, 2011 p.22 Standard Time Schedule Organization in Primavera

23 IAEA December 12, 2011 p.23 Reactor building construction (extract)

24 IAEA December 12, 2011 p.24 Civil & piping resource loading in the Generic Time Schedule

25 Civil reinforcement installation curve IAEA December 12, 2011 p.25

26 Procurement schedule data base IAEA December 12, 2011 p.26

27 ENGINEERING TYPICAL SEQUENCE System Engineering Stage 1 Sequence on the critical path IAEA December 12, 2011 p.27

28 ENGINEERING TYPICAL SEQUENCE Building Engineering Level of detail Sequence - based on design milestones Building Engineering Successors P & Ids inputs from Systems D1 Last Inputs from Equipment suppliers Layout Engineering & Review CW Basic Design D2 Civil Work Preparation, Civil Work Construction (per level) Civil Work Finishing works, Civil Work Steel Structure installation CW Detail Design CW Steel structures & Finishing Works Detail Design Piping Detail Design & Isometrics HVAC Detail Design Electrical Detail Design Piping Prefabrication Piping Installation (per erection area) HVAC Installation (per level) Electrical cable trays Installation (per level) IAEA December 12, 2011 p.28

29 ENGINEERING TYPICAL SEQUENCE Civil Work Design Typical Sequence BD DD IAEA December 12, 2011 p.29

30 EPR TM TIME SCHEDULING 1: Introduction - Definitions 2: Schedule construction process 3: Main critical paths 4: Conclusion IAEA December 12, 2011 p.30

31 SITE PREPARATION / WORKS TO BE DONE BY THE CUSTOMER BEFORE CONTRACT DATE START SITE INVESTIGATION GEOLOGICAL PRELIMINARY REPORT 1 CONTRACT DATE OFF-SHORE INVESTIGATION (GEOLOGICAL, GEOTECHNICAL, SEISMIC) GEOLOGICAL ON- SHORE & OFF- SHORE MODEL On shore and off-shore site investigation can be done in parallel ON-SHORE GEOLOGICAL INVESTIGATION DEFINITION OF GEOLOGICAL OFF-SHORE CAMPAIGN OFF SHORE INVESTIGATION ENQUIRY SUBCONTRACTOR MOBILIZATION OFF-SHORE SEISMIC REFRACTION OFF-SHORE SEISMIC REFRACTION REPORT BATHYMETRY GEOLOGICAL INVESTIGATION (CORE DRILLING) GEOLOGICAL OFF-SHORE REPORT PRELIMINARY GEOLOGICAL MODEL ADDITIONAL GEOLOGICAL OFF-SHORE INVESTIGATION GLOBAL GEOLOGICAL MODEL SEISMIC DATA SITE DATA PRELIMINARY PLOT PLAN CUSTOMER ANALYSIS SITE SURVEY GENERAL LAYOUT & SPECIFICATIONS PRELIMINARY MASTERPLAN & COSTS COMPARISON ADDITIONAL GEOLOGICAL ON-SHORE INVESTIGATION SEISMIC REFRACTION REPORT GEOLOGICAL ON-SHORE REPORT ANALYSIS & DEFINITION OF SEISMIC REFRACTION SEISMIC REFRACTION MOBILIZATION & EXECUTION OF TESTS SECOND GEOLOGICAL INVESTIGATION SEISMIC REFRACTION ENQUIRY GEOLOGICAL ON-SHORE REPORT ANALYSIS & DEFINITION OF SEISMIC REFRACTION Overall estimated duration: 18 months Th Bo R ord du b inv ava IAEA December 12, 2011 p.31

32 Standard Time Schedule: Lead Time (before FCD) IMS installation Start work AREVA Eng. D0 D2 CW Prepa Conceptual design/ 3D model Prepa CW Basic design CW Detail design Plot plan finalization/ Concept D0 D2 CW Prepa Engineering mobilisation Process Eng. CW Basic design 1rst FR issue (RIS/JN) CW Detail design Final P&Ids System Eng stage 1 (RIS/JN) Drainage,.., pre-stressing galleries Start galleries construction Reactor base mat 1st Concrete date The first safety related concrete is with the Galleries Engineering Earthwork drwgs Site access Contractors site establishment Routing all disciplines Quarry research, Concrete design & lab tests D1 Plant terracing & excavations work for NPP Mixing plant erection CW Basic design D2 Compliance tests CW Detail design CW Prepa Start Reactor Building construction from -6,15 to slab -2,30 Terracing Concrete PSAR studies, redaction and edition RPV, SG1&3 Eng. Activities + RFQ Notification to EFF - JSW Order to JSW 1st Ingot pouring PSAR Licensing Forging + documentation for manufacturing + transport Start Manufacturing Activities Licensing Critical Procurement 1st other RFQ (Special valves) IAEA December 12, 2011 p.32

33 Construction main critical paths through Reactor & Fuel buildings Civil Work Electromech. Inst. Test & Commissioning Critical path IAEA December 12, 2011 p.33

34 EPR TM TIME SCHEDULING 1: Introduction - Definitions 2: Schedule construction process 3: Main critical paths 4: Conclusion IAEA December 12, 2011 p.34

35 The value of Experience Standardization of early engineering activities System activities: Input data for other disciplines ready earlier and better defined P&ID : Important input for layout in order to validate Civil Works (CW) interfaces DSE stage 2 : important input for I&C NSSS engineering standardized and streamlined -60% OL3 Taishan 14-36% 9 P&ID First issue (months) -33% System Description Stage 2 - First issue (months) % Piping isometrics Nb of revisions OL3 Taishan Number of engineering hours for NSSS completion (for Taishan: estimate) IAEA December 12, 2011 p.35

36 The value of experience Illustration, from OL3 to TSN: first main milestones Construction duration (# months) Dome lifting Slab +1,5m Start of inner containment Gusset pouring 1 st concrete OL TSN1 IAEA December 12, 2011 p.36

37 EXPERIENCE GAINED Schedule maturity mainly based on ongoing projects Learning Curve Next Projects with EPR Taishan 1&2 TAISHAN Flamanville 3 Olkiluoto 3 FLAMANVILLE 3 OLKILUOTO 3 TIME Thanks to this Continuous Improvement process: AREVA can manage the configuration of the EPR to the benefit of our customers on future bids and projects IAEA December 12, 2011 p.37