Reactors & Services experience in design and construction · experience in design and construction. ... AREVA’s Reactors & Services experience in design and construction ... Building

AREVA Reactors & Services experience in design and construction

IAEA December 12, 2011 – p.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 EPRTM

time scheduling


The 5 Business Groups reflect AREVA’s Integrated Structure

> Mining

> Recycling

> Site Value

Development

> Logistics

> Cleanup

> Renewable

Energies

Nuclear operations

> Chemistry

> Enrichment

> Fuel

> New Builds

> Installed Base

> Equipment

> Nuclear Measurement

> Products & Technology

> Propulsion & Research

Reactors

International Commercial Organization

Engineering & Project Organization

The 5

Business

Groups

Reactors

& ServicesFront EndMining Back End Renewables

Functional Departments

Executive Board

Executive Committee

Reactors & Services Business GroupWorld leader in nuclear power


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 EPRTM reactors under construction


AREVA’s role in construction:OL3 example

AREVA

AREVA

SiemensHeit

kamp

AR

EVA

C

P

E

BoPCWBCITICWBNINSSS

I&C

NI CI

Leader/ PM

AREVA

Operator TVO

Bouy

gues

TV

O

OLKILUOTO 3AREVA is the leader of the consortium and responsible for the NI (EPC) with Bouygues as subcontractor for the Civil Works


AREVA EDFBouy-

gues

EDF

Alstom EDF Bouy-

guesEDF

C

P

E

BoPCWBCITICWBNINSSS

NI CI

AREVA

Operator

I&C

Leader /

PM

FLAMANVILLE 3AREVA provides the NSSS (EPC) and the I&C

AREVA’s role in construction:FA3 example


Operato

r

C

P

E

BoPCWBCITICWBNINSSS

NI CI

AREVACNPE

C

Ch

inese C

W

co

ntra

cto

r

CNPEC

Alstom CNPEC

Ch

inese C

W

co

ntra

cto

r

CNPEC

CNPEC CNPEC

AREVA

CGNPC

I&C

Leader / PM

TAISHAN 1&2AREVA is member of the consortium supplying the NI (EP)

AREVA’s role in construction:TSN example


The reference

in Safety

Answers varied

customer needs

with an adapted

product

portfolio

PWR 1650 MWeBWR 1250 MWe PWR 1100 MWe

AREVA’s reactor range

High Power OutputMedium Power Output

Pressurized Water ReactorsBoiling Water Reactor

DeployedMarket launch: 2010

Developed in partnership with MHI

AREVA can provide a range of Generation III+ Reactors

Final development stage


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

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

Minimal environmental impact

Reduced collective dose

Advanced severe accident management

Optimized level of redundancy, diversity of systems and incremental mitigation of abnormal events

Large commercial Airplane Crash resistance (APC)

BUSINESS PERFORMANCE ENVIRONMENTAL PROTECTION

OUTSTANDING SAFETY

The AREVA Reactor Range


The Path to Greatest Certainty

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 in Finland, France & ChinaLicensing under way in the USA & UK

The reference in safety and operational

performance1650 MWe PWR

The EPRTM Reactor


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


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

EPRTM Time scheduling

AIEA December 12, 2011

Fuel Building

Reactor Building

Nuclear Auxiliary

Building

Waste Building

Safeguard Buildings

Diesel Building

Diesel Building


EPRTM TIME SCHEDULING

1: - Definitions

2: Schedule construction process

3: Main critical paths

4: Conclusion


Time Schedule is a Plan, a Roadmap, a Communication Tool, a Contractual Document

Lead Time


Time ManagementHow to build a schedule

1. Start from WBS (avoid missing scope), andWork Package deliverables.

2. Create activity list and identify the contractualmilestones.

3. Create network diagram.

4. Identify sequence & interfaces betweenactivities.

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.

WBS &

Activity list

Create networkDefine the

logical links

Allocate resources &

estimate durations

Produce Gantt

charts

Identify critical

path and floats

R&O


WBS Work Breakdown Structure

WBS is the “backbone” of the project

Key Objective: Defining, Authorizing and Controlling the

Scope


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


1: Introduction - Definitions



4: Conclusion



STD Time Schedule Construction Process

System Design

Stage 1

Layout 3D

Model

CW Detail

DesignElectro-

Mechanical

Erection

Schedule

Equipment

Manufacturing

Piping, HVAC,

MCT DD

Electrical

I&C Detail

Design

Commissioning Documentation

System Test

Schedule

Overall

Commissioning

Sequence

CW Construction

Sequence

EPTSystem Design

Stage 2

System Design

Stage 3

Formwork and Reinforcement

Drawings

Layout Design Freeze

Flow DiagramsEquipment

Technical

File

Document

Delivery

Date

System

Meetings

Data Sheets

Equipment

Delivery

Date

Building,

Levels

Availability

Date

Erection Works on Main Critical

Path in Reactor Building

Process and

General

engineering

Functional and

safety

requirements

Procurement data base

LICENSING


Standard Time Schedule Organization in Primavera


Reactor building construction (extract)


Civil & piping resource loading in the Generic Time Schedule


Civil reinforcement installation curve


Procurement schedule data base


ENGINEERING TYPICAL SEQUENCESystem Engineering – Stage 1

Sequence on the critical path


ENGINEERING TYPICAL SEQUENCE Building Engineering Level of detail

Sequence - based on design milestones

Building Engineering Successors

Civil Work Preparation,

Civil Work Construction (per level)

Civil Work Finishing works,

Civil Work Steel Structure installation

Piping Prefabrication

Piping Installation (per erection area)

HVAC Installation (per level)

Electrical cable trays Installation (per level)

CW Basic Design

Layout Engineering & Review

D2

CW Detail Design

D1

CW Steel structures & Finishing Works Detail Design

Piping Detail Design & Isometrics

HVAC Detail Design

Electrical Detail Design

P & Ids inputs from Systems

Last Inputs from Equipment suppliers


ENGINEERING TYPICAL SEQUENCE Civil Work Design Typical Sequence

DD

BD





4: Conclusion



SITE PREPARATION / WORKS TO BE DONE BY THE CUSTOMER BEFORE CONTRACT DATE

START SITE INVESTIGATIONCONTRACT DATE

GEOLOGICAL PRELIMINARY REPORT

DEFINITION OF GEOLOGICAL OFF-SHORE CAMPAIGN

OFF SHORE INVESTIGATION ENQUIRY

SUBCONTRACTOR MOBILIZATION

OFF-SHORE SEISMIC REFRACTION

OFF-SHORE SEISMIC REFRACTION REPORT

GEOLOGICAL INVESTIGATION (CORE DRILLING)

GEOLOGICAL OFF-SHORE REPORT

BATHYMETRYADDITIONAL GEOLOGICAL OFF-SHORE INVESTIGATION

PRELIMINARY GEOLOGICAL MODEL

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

On shore and off-shore

site investigation can be

done in parallel

This sequence has

been built with

Bouygues during the

RSA call for bid in

order to estimate the

duration between the

beginning of site

investigation and the

availability of site data.

1-9 -8 -7 -6

ON-SHORE

GEOLOGICAL

INVESTIGATION

GEOLOGICAL ON-

SHORE & OFF-

SHORE MODEL

OFF-SHORE

INVESTIGATION

(GEOLOGICAL,

GEOTECHNICAL,

SEISMIC)

-19 -1-18 -17 -16 -15 -14 -13 -12 -3 -2-11 -10 -5 -4

Overall estimated

duration: 18 months


Standard Time Schedule: Lead Time (before FCD)

IMS installation

Start work – AREVA Eng.D0

D0

D1

D2

D2

D2

Earthwork

drwgs

Contractors site establishment

Plant terracing & excavations work for NPP

Mixing plant erection

Quarry research, Concrete design & lab tests Compliance tests

Plot plan finalization/ Concept

Site access

CW Prepa

CW Prepa

CW Prepa

CW Basic design

CW Basic design

CW Basic design

CW Detail design

CW Detail design

CW Detail designConceptual design/ 3D model Prepa

Final P&Ids

System Eng stage 1 (RIS/JN)

Routing all disciplines

1rst FR issue (RIS/JN)

Process Eng.

Engineering mobilisation

Start galleries construction

Start Reactor Building

construction from -6,15

to slab -2,30

Drainage,.., pre-stressing galleries1st Concrete date

Reactor base mat

1st Ingot pouring

RPV, SG1&3 Eng.

Activities + RFQ

Start Manufacturing Activities

PSAR LicensingPSAR studies, redaction and edition

Forging + documentation for manufacturing + transport

Order to JSWNotification

to EFF - JSW

1st other RFQ

(Special valves)

The first safety related

concrete is with the Galleries

Critical

Procurement

Terracing

Concrete

Engin

eerin

g

Licensing


Construction main critical pathsthrough Reactor & Fuel buildings

Civil Work

Electromech. Inst.

Test & Commissioning

Critical path





4: Conclusion



The value of ExperienceStandardization of early engineering activities

P&ID : Important input for layout in order to

validate Civil Works (CW) interfaces

DSE stage 2 : important input for I&C

14

30

109

20

3

P&ID First issue

(months)

OL3

Taishan

-36%

-33%

-70%

System Description

Stage 2 - First issue

(months)

NSSS engineering standardized

and streamlined

System activities:

Input data for other disciplines ready earlier

and better defined

Number of engineering hours

for NSSS completion

(for Taishan: estimate)

Piping isometrics

Nb of revisions

OL3 Taishan

-60%


Construction duration (# months)

The value of experienceIllustration, from OL3 to TSN: first main milestones

126

4

17

127

10

TSN1OL3

Slab +1,5m

Start of inner

containment

Gusset

pouring

1st concrete

Dome lifting

24

47

126

4

17

127

10

TSN1OL3

Slab +1,5m

Start of inner

containment

Gusset

pouring

1st concrete

Dome lifting

24

47


Learning Curve

OLKILUOTO 3

FLAMANVILLE 3

Next Projects with EPR™

Olkiluoto 3

Flamanville 3

Taishan 1&2

TIME

EX

PE

RIE

NC

E G

AIN

ED

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

TAISHAN

Schedule maturity mainly based

on ongoing projects

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