Challenges of Engineering and Constructing the Next Generation of Nuclear Plants

All Rights Reserved, Copyright © 2006 Hitachi, Ltd. 1

Challenges of Engineering and Constructing the Next Generation of

Nuclear Plants

Jack TuohyDirector, Strategic PlanningHitachi Power Systems America, Ltd.

Hideo (Hede) YonemuraVice President &General Manager(Construction Management)Hitachi-GE Nuclear Energy, Ltd.

MITFebruary 2008


What has changed?

• Energy Policy Act of 2005: Incentives to deployment

• Coal seen as high risk due to uncertainty in C tax

• Nuclear Power viewed as a clean energy solution (C free)

• Operating Plants: Extraordinary operating record

• New build infrastructure is gone


Current Capability in US

• Engineering/Design

• Procurement

• Manufacturing

• Construction

(Maybe not where we would like it)


Current Capability in the US

Remember back

• New Regulations: Developed in parallel with design, manufacturing and construction activities

• New codes and standards: ASME Section III, IEEE Class 1E,… did not exist

• Design Drawings: Pencil on Mylar

• Document reviews: Hard copies for everyone (The copier was overburdened)

• Typewriters (Proof reading again and again, and again)

• Incorporation of comments: Cut and Paste (literally)

• Composite drawings (Crude Interference detector)

• Slide Rules (I still have mine)

• Great leadership

(Better than when we built the first wave in the 60s and 70s)


How to meet the challenge

• Use modern tools

• Maximize effectiveness of experienced personnel still in the industry

• Tap into retired labor pool of experience

• Get help from Overseas Programs that did not experience a discontinuity in deployment of new nuclear units


PO

WE

R

* COOPERATION CONSTRUCTION

TSURUGA-1*

10,000

15,000

(MWe)

1970 1975 1985357

0

5,000

1995 2005

460460540784

1100

840

1100

1100

1100

820

1100

5401137

1100

1356

1356

20,000

825

1380

1358

Advanced BWR phaseImprovement and Standardization

phaseDomestic Production Phase

KASHIWAZAKI-KARIWA 7*

KASHIWAZAKI-KARIWA 6*

KASHIWAZAKI-KARIWA 4

HAMAOKA - 4*SHIKA - 1

KASHIWAZAKI-KARIWA - 5

SHIMANE - 2

HAMAOKA - 3*

FUKUSHIMA II - 4

FUKUSHIMA II - 2

HAMAOKA - 2*

TOKAI - 2*FUKUSHIMA -4Ⅰ

HAMAOKA - 1*

SHIMANE - 1

FUKUSHIMA I -1*

ONAGAWA - 3*

HAMAOKA - 5*

SHIKA - 2

Construction Start

1358SHIMANE - 3

OMA – 1*

MWe

Commercial Operation

2010

1373• 30 years of continuous experience • Continuous workforce development • Additional ABWR orders in the pipeline

Hitachi BWR Construction Experience


•Hitachi Plant Integrated CAE System provides optimized design, visualization, and information management throughout the plant lifetime.

Engineering CAE/CAD System/Database

Basic DesignBasic DesignDetail DesignDetail Design

ManufacturingManufacturingConstructionConstruction

MaintenanceMaintenance

Japanese model – Vertical Integration


Reactor Pressure Vessel and Internals

Reactor Pressure Vessel

Core Shroud

Steam Dryer

Steam Separator


Tower CraneLarge C/C

Advanced Construction Technologies

Modularization

1990

1975

1980

・ 1st Generation

・ 2nd Generation

・ 4th Generation

Introduction of Open-top method using Tower Crane

Introduction of Large Crawler Crane for Module Placement

Advanced Construction Technologies (RFID)

1985

2000

・ 3rd GenerationExpanded use of Open-top Method & introduction of Parallel Construction


27 32

83

196

235

0

50

100

150

200

250

1990 1994 1997 2006 CurrentProjectPlant Commercial Operation

Nu

mb

er o

f M

od

ule

s

Modular construction is becoming more sophisticated and more extensively employed

Start ModularizationLarge Crawler Crane

Dedicated Module Factory

1980 1990 2000

Mil

esto

nes


Displace Critical Path Activities Shorten Activity Durations Reduce and Level-off Site labor Reduce Construction Cost Improve Safety and Quality Shorten overall schedule

Advantages of Modularization


Poor accessibility

Large Platform

Wasted space with component

Narrow O&M space

Layout Optimization (Example)

Long piping route

Many Supports fixed on ceiling


Minimized Pipe Support Materials

MinimizedPlatform Size

Optimized module Component layout

EnlargedO&M space

ShortenedPiping route

ImprovedAccessibilityBefore Layout Optimization

Layout Optimization (Example)


Top Slab Module:550tonUpper Drywell Module:650ton

Piping Module:120ton

Base Mat Module:460tonRCCV Lower Liner Module:630ton

RPV:900ton

RCCV Upper Liner Module:170ton

Large Module Applications in R/B

Room Module:250ton


Large Module Applications in T/B

Roof Truss Module

Upper Condenser ModuleCF/CD ModuleT-G Pedestal Installation

Lower Condenser Module MSH Drain Tank Area Module

MSV/CV ModuleOff Gas Module


Modular Construction Standardization Yields Predictable Schedule

With Modularization Method

Construction Period = 38M (actual First ABWR)

S/C: Start ConstructionS/C: Start ConstructionR/I: Rock InspectionR/I: Rock Inspection

M/C: Mat CompletionM/C: Mat CompletionO/C: Operating Floor CompletionO/C: Operating Floor CompletionP/S: Power SupplyP/S: Power Supply

F/L: Fuel LoadingF/L: Fuel LoadingC/O: Commercial OperationC/O: Commercial OperationEOTC: Electric Overhead Traveling CraneEOTC: Electric Overhead Traveling Crane

RPV P/T: RPV Hydro Test CompletionRPV P/T: RPV Hydro Test Completion

F/C: First ConcreteF/C: First Concrete

Mechanical & Electrical Work In R/B

Milestones

Excavation

MMR

Base Mat

R/B Building Work

S/C R/I M/C O/C P/S RPV H/T F/L C/O

RCCV Installation

RPV ON

RCCV Liner Blocks

LowerUpperLiner

TopSlab

Commissioning

Upper Drywell

Mat Module

RIN Installation

ECCS/CRD Pre-Operation

EOTC

Roof Frame Work

F/C

:Civil/Building Work:Mechanical Installation

:Critical Path

Mechanical module

HCU Module (250t, Composite)

Mechanical module

Off Gas (27tons)

Mechanical module

CUW HX (40tons)

Mechanical module

Critical Module

RCCV Lower Liner (630t, Composite

Critical Module

Base Mat (460tons)

Upper Drywell (650tons)


Construction Schedule Comparison

29M 8M

30M10D 6M20D*1

3M

4.5M

37M

FC FLOC

37M(38M10D)（ 8M10D*2)

ABWR#1CO: 11/1996

ABWR#2CO: 07/1997

ABWR#3CO: 01/2005

ABWR#4CO: 03/2006

33M 10M3M

33M2M 10M15D 43.5M

43M

RIBuilding

Commissioning

*1: substantial period*2: official period

Single box R/BShift work(Additional request)

Double box R/B

Single box R/B

Double box R/B

Lesson learned #1ABWR

Additional SCC countermeasureFirst plant for customer (contingency plan)

First plant for customer (ABWR)

RI : Rock Inspection FC : First ConcreteOC : Overhead Crane Operation FL : Fuel Loading


Impact of experience and shift to modular construction

BWR(1,100MW) BWR(1,100MW) ABWR(1,356MW) ABWR(1,358MW)

[%]

61

100

72

83

8693

0

20

40

60

80

100

1990 1994 1997 2006

IND

EX

Normalized Construction Duration

*1

C/O

*2Normalized non-civil Fieldwork

(Man-hours)

100

76

Advanced construction technologies have been contributing greatly to Advanced construction technologies have been contributing greatly to shortening schedule & reducing cost as well as enhancing qualityshortening schedule & reducing cost as well as enhancing qualityResults of intensive application over a 15 year period: - Construction schedules have been reduced by nearly 20% - Non-civil construction man-hours have been reduced by nearly 40%

Advanced construction technologies have been contributing greatly to Advanced construction technologies have been contributing greatly to shortening schedule & reducing cost as well as enhancing qualityshortening schedule & reducing cost as well as enhancing qualityResults of intensive application over a 15 year period: - Construction schedules have been reduced by nearly 20% - Non-civil construction man-hours have been reduced by nearly 40%


SummaryConstruction Strategies

Site ConstructionManagement

support system

Open-top &

parallel construction

WorkLeveling

Site supportWork efficiency

Early and Detailedengineering before

on-site work

Workefficiency

Modularizationwith large

crane

On-site work reduction

Site Man-hour ReductionPeak Loading Reduction

Construction Schedule Shortening

Documents

Challenges of Engineering and Constructing the Next Generation of Nuclear Plants