Technologies & Management Systems that Work: Current Best ...
Transcript of Technologies & Management Systems that Work: Current Best ...
![Page 1: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/1.jpg)
IAEA International Atomic Energy Agency
Technologies & Management Systems
that Work: Current Best Practice in
Nuclear New Build
John H. Moore
Nuclear Power Division [email protected]
Paris, France March 11, 2014 (OECD Workshop)
![Page 2: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/2.jpg)
IAEA International Atomic Energy Agency
Exciting Times!
![Page 3: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/3.jpg)
IAEA
Barakah-Unit 1, UAE
• The United Arab Emirates is the first country to start the construction
of its first nuclear power plant in 27 years, since construction was
started on China's first plant in 1985.
July 20 2012
Concrete
pouring
after approval
of PSAR.
Unit 2 followed
May 2013.
![Page 4: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/4.jpg)
IAEA
Sanmen, China
Jan 29, 2013
AP-1000
Containment
vessel top head
placement;
Sanmen, China
![Page 5: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/5.jpg)
IAEA
VC Summer Unit 2, USA
March 10/11, 2013
First concrete pour
of a new NPP in
North America in
three decades.
• Followed closely followed by concrete pours at
Vogtle Unit 3 (and later by Summer 3 and Vogtle4)
![Page 6: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/6.jpg)
IAEA
Other recent starts (2013 and 2014)
• Belarus;
• China (3);
• South Korea;
• Argentina.
![Page 7: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/7.jpg)
IAEA
Current status
0
2
4
6
8
10
12
14
16
18
Construction Starts
0
10
20
30
40
50
60
70
80
Europe-Western
Europe-Central &East
Asia-Middle East &South
Asia-Far East
America-North
America-Latin
Under Construction
Source: IAEA PRIS 05-Mar-2014
![Page 8: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/8.jpg)
IAEA
IAEA MANAGEMENT SYSTEM
GUIDANCE
Safety
Requirements Nuclear
Facility
Guidance
NPP
Guidance
![Page 9: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/9.jpg)
IAEA
IAEA GS-G-3.5 Mgmt System for Nuclear Installations -
Appendix V Construction
“Things to do:”
• Define roles and
interfaces;
• Grade requirements based
on safety significance;
• Have well defined
processes;
• Define handover and
responsibility transfer
processes;
• Plan activities;
![Page 10: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/10.jpg)
IAEA
IAEA GS-G-3.5 Mgmt System for Nuclear Installations -
Appendix V Construction
“Things to do”(continued):
• Have kick off meetings;
• Control design
information;
• Maintain cleanliness;
• Maintain control of
material;
• Prevent damage during
storage and handling;
• Verify construction work.
![Page 11: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/11.jpg)
IAEA
Verification of Construction Work
Need to have:
• Methods/schedules for verification that
specify levels of inspection & verification
required;
• Suppliers must verify all procurement
requirements have been satisfied;
• Construction activities should follow
inspection and test plans (ITPs) approved by
organization (Owner);
![Page 12: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/12.jpg)
IAEA
Verification of Construction Work
• ITPs should have appropriate hold / witness
points for owner to verify acceptability;
• Plan to be prepared to ensure design and
regulatory requirements met;
• Process required to verify construction
activities;
• Verification normally documented via check
sheets or similar means to record that SSCs
have been constructed and installed to
specified requirements.
![Page 13: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/13.jpg)
IAEA
Example quality issues (Sanman, China)
• RCP impeller :
Irregularities welded
without documentation;
• Squib Valve :
Manufacturer used
components and sub-
contractor without
proper equipment
qualification.
![Page 14: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/14.jpg)
IAEA
BEST PRACTICE
PUBLICATIONS
![Page 15: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/15.jpg)
IAEA
Project Management in NPP Construction
• Construction management
• Preparatory phase;
• Construction phase (after concrete
pouring);
• Commissioning phase;
• Main issues and lessons learned
• Selection of local suppliers;
• Bulk material management;
• Worker turnover;
• Construction equipment;
• Massive movements of people and
material;
• Public perception;
• Construction phase closure activities;
• Country specific lessons learned
![Page 16: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/16.jpg)
IAEA
Construction Technologies for New NPPs
• Goal: Achieving optimum construction schedule for future NPP construction projects.
• Content: • Comprehensive descriptions
of all construction methods;
• Advantages / disadvantages;
• Best practices;
• Lessons learned.
![Page 17: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/17.jpg)
IAEA
Some sample beneficial technologies
• Early engineering / front end
planning;
• Site construction management
support systems
• Modularization and open
top construction;
• Advanced welding;
• 4 season construction.
![Page 18: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/18.jpg)
IAEA
Early Engineering
Basic Design
Detailed Design
Construction
Construction Engineering
Previous Design Process
Front-Loaded Construction Engineering
Basic Design
Detailed Design
Construction
Construction Engineering
Requirements from Construction Engineering Inputs from Plant Design
(BOQ, Composite Design, etc.)
Source : From Hitachi construction experience
Reduce Site Manpower by 40%
![Page 19: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/19.jpg)
IAEA
Issues with a Gen 3+ project
• 18000 design changes by end of 2013;
• Lead time for nuclear side design change
approvals from one month to six months;
• Engineering completion behind schedule;
• Insufficient support for regulatory review
from off-shore team.
Should improve for “nth of a kind”
![Page 20: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/20.jpg)
IAEA
建設工程
3D-model linked to schedule
Site construction management support
![Page 21: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/21.jpg)
IAEA
“6D” construction schedules
3D-model by construction area
Quantities based
on 3D-model
Assign labour
resource
Schedule loaded with quantities and resources
3D model + Quantities + Resources + Time = 6D database
• Develop detailed construction schedule by area based on quantities and labour resources;
• Simulate schedule with 3D-model.
![Page 22: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/22.jpg)
IAEA
RPV
Upper Condenser Module RCCV Lower Liner Module
Lower Condensor Unit RPV Pedestal Module Base Mat Module HPU Module
Stator Upper Drywell Module RCCV Top Slab
(420 ton)
(410 ton) (460 ton) (260 ton)
630 ton) (270 ton)
(650 ton) (900 ton) (550 ton)
(270 ton)
Modularization
![Page 23: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/23.jpg)
IAEA
Sep 27, 2010 Unit 1 CA01 lifting.
![Page 24: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/24.jpg)
IAEA
Man P
ow
er
Construction Progress
(month)
Level-off
Manpower Peak
Based on previous ABWR (Conventional Method) (a
rb.)
Manpower Peak Reduction Effort
- Construction & Module Experience-
4
3
2
1
1 6 11 16 21 26 31 36 41 (month)
Manpower Distribution
Based on Latest ABWR
![Page 25: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/25.jpg)
IAEA
Advanced Welding Techniques
• Quality welding is crucial and time consuming;
• Advanced Techniques • Metal Arc Welding;
• Gas Tungsten Arc Welding;
• Submerged Arc Welding;
• Automatic welding equipment is very effective; • Maintains high quality;
• Improves work environment in narrow spaces.
![Page 26: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/26.jpg)
IAEA
Automatic Welding Machine
Automatic Welding Machine for RCCV Liner
Automatic Welding for Large Bore Piping
Automatic Welding for Small Bore Piping (CRD piping)
![Page 27: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/27.jpg)
IAEA
Four season construction
• Provides “factory-like” environment for
construction during winter;
• Secures environment for:
• Welding;
• Concrete pouring & curing;
• Protection from equipment;
• Allows around the clock work.
![Page 28: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/28.jpg)
IAEA
Improvement of Work Productivity
during winter
Buildings with the All-Weather Structure (Steel and Temporary cover)
Movable Temporary Roof
70
75
80
85
90
95
100
冬期稼働率[%]
個別養生耐候工法 全天候耐候工法
Four season construction
![Page 29: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/29.jpg)
IAEA
CONSTRUCTION READINESS
REVIEW SERVICE
![Page 30: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/30.jpg)
IAEA
IAEA REVIEW SERVICES
30
Milestone 1 Milestone 2
NPP site
review
mission
Phase 1 Phase 2 Phase 3
INIR
mission
Milestone 3
INIR
mission
NPP construction
review mission
Pre-
OSART
mission
SCART
mission
EPREV
mission
ISSAS
mission
IPPAS
mission
INSSERV
mission
![Page 31: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/31.jpg)
IAEA
Construction Readiness Reviews
• Focus is on a specific NPP
construction project (new
build or refurbishment), not
the overall programme.
• Must have design chosen
and construction
preparations underway at a
very detailed level.
• Guidelines finalized and
published. Service available
now!
![Page 32: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/32.jpg)
IAEA
INIR
mission
IAEA REVIEW SERVICES
32
Milestone 1 Milestone 2
NPP site
review
mission
Phase 1 (commit to
programme)
Phase 2 (invite bids)
Phase 3 (commission
and operate)
INIR
mission
Milestone 3
INIR
mission
NPP construction
review mission
Pre-
OSART
SCART
mission
EPREV
mission
ISSAS
mission
IPPAS
mission
INSSERV
mission
Stage 1
Construction
Preparation.
Stage 2
Construction
Execution.
![Page 33: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/33.jpg)
IAEA
Construction readiness reviews
• Areas Reviewed: • Project Management;
• Engineering Readiness;
• Procurement / Material / Supply Chain Readiness;
• Quality Management and Records;
• Human Resources and Training;
• Construction Readiness;
• Construction Installation Completion Assurance;
• Targeted Reviews (as requested by customer).
![Page 34: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/34.jpg)
IAEA
Project management area
• Scope control;
• Front end planning;
• Project scheduling;
• Estmating;
• Metrics;
• Alignment;
• Community support;
• Roles & responsibilities;
• Risk management;
• Project oversight;
• Contract &
procurement
strategies;
• Change control;
• Delay/suspension
provisions.
![Page 35: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/35.jpg)
IAEA
Engineering readiness area
• Documentation;
• Feedback
incorporation;
• Design change
process;
• Planning;
• Configuration mgmt,
controlled docs &
records;
• Computer & cyber
security;
• Review of previous
work (if delayed
project);
• Eng. Programmes;
• Eng. quality (Ph2 review).
![Page 36: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/36.jpg)
IAEA
Procurement / material / supply chain readiness
• Equip./material availability;
• Procurement procedures and plans;
• Packaging, warehousing, & transport;
• Material inspection;
• Risk management;
• Quality assurance / quality surveillance.
![Page 37: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/37.jpg)
IAEA
Quality management and records
• Quality assurance & controls;
• Independent assessments;
• Non-conformance / corrective action
programmes;
• Construction experience;
• Quality surveillance and construction
inspection;
• Controlled documentation and records.
![Page 38: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/38.jpg)
IAEA
Human resources and training
• Hiring, development, and training;
• Personnel qualification;
• Human performance;
• Health and safety training;
• Personnel availability;
• First line supervision and management.
![Page 39: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/39.jpg)
IAEA
Construction readiness
• Site infrastructure
requirements;
• Regulatory requirements;
• Tools availability;
• Construction sequencing;
• Security and safeguards
requirements;
• Construction execution
plans and procedures;
• Safety management;
• Environmental
management;
• New construction
practices /
technologies.
![Page 40: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/40.jpg)
IAEA
Construction completion assurance
• Process defined;
• Walkdown processes;
• Hold points;
• Open item tracking;
• Labelling and control of boundaries;
• Inaccessible items;
• Interim maintenance during construction.
![Page 41: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/41.jpg)
IAEA
Targeted reviews (upon request)
• Completed activities and expenditures;
• Detailed as-experienced schedule review;
• Variance review;
• Significant events of interest;
• Corrective action review;
• Other areas.
![Page 42: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/42.jpg)
IAEA
E-LEARNING
![Page 43: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/43.jpg)
IAEA
Construction e-learning module
• Part of a series targeted at newcomer countries, at both
senior leader and project team member levels.
• Topics covered in Construction Module:
• What makes nuclear construction unique;
• Important considerations for projects and programmes;
• How to achieve excellence;
• Key site considerations.
• Now available !
![Page 44: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/44.jpg)
IAEA
SOME LESSONS LEARNED
![Page 45: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/45.jpg)
IAEA
Elements needed for successful NPP
• Health, environment and safety • Communicate with regulator and public as early as possible and as
much as possible;
• Quality • Quality surveillance of sub-contractors (engineering, construction
etc.) should start early;
• Cover both domestic and foreign vendors;
• Schedule • Level 2 for management; monitor at level 3;
• Ensure sufficient resources, support contractors;
• Financial • Risk funding needed. Only 25 % NPP projects in China were completed
with planned budget.
![Page 46: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/46.jpg)
IAEA
Project management lessons
• Clearly define roles of Owner and EPC
contractor ;
• Set up PM organization early;
• Ensure Owner has appropriate contingency
funding and risk allocated for unforeseens;
• Perform surveillance of quality during
manufacturing;
• Need strong site centred PM for EPC and
Suppliers;
![Page 47: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/47.jpg)
IAEA
Project management lessons (cont.’d)
• Off-site team should support fully, but not
manage site team;
• Include incentives for on/off site team;
• Authorized to proceed (ATP) for long lead
items equally important with first concrete
pour date (FCD); • Lead time typically 3 years between ATP and FCD in
recommended (China).
![Page 48: Technologies & Management Systems that Work: Current Best ...](https://reader036.fdocuments.net/reader036/viewer/2022062906/58a1a0211a28ab784d8c3c0a/html5/thumbnails/48.jpg)
IAEA
Thank you for your attention!
Follow IAEA Nuclear Energy on Twitter @IAEANE