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Challenges & Successes of Candu Energy (former AECL)
in Nuclear Construction: Case Study of China and
Romania
IAEA Workshop on Construction Technologies for Nuclear
Power Plants: A Comprehensive Approach
Paris, France
12 – 16 December, 2011
Azhar KhanManager, Design & Layout
Candu EnergyCanada
Official Use Only | À Usage Exclusif
Scope of Presentation
• Qinshan CANDU Nuclear Power Plant
– Salient contract details and construction responsibilities
– Site Quality Assurance (QA)
– Major construction contracts
– Challenges
– Important construction decisions
– Major issues during construction
– Localization
– Major achievements
– Reasons for success of project
– Future CANDU Projects in China
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Scope of Presentation (Cont’d)
• Cernavoda Nuclear Power Plant
– Unit 1 and 2
– Salient contract details and construction responsibilities
– Challenges
– Important construction decisions
– Localization
– Major achievements
– Reasons for success of project
– Future CANDU projects in Romania
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Qinshan Nuclear Power Plant
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Qinshan Nuclear Power Plant
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Qinshan Nuclear Power Plant
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Qinshan III CANDU NPP: 2 Unit 728 MWe by AECL and TQNPC
International Project with financing from China, Canada, Japan and USA
Qinshan, Zhejiang Province, PR of China
Contract effective: 1997 Feb 12
First Concrete: 1998 June 8
In Service:
Unit 1
Planned: 2003 Feb 12
Actual: 2002 Dec 31
Days Ahead of
Schedule: 43
Unit 2
Planned: 2003 Nov 12
Actual: 2003 Jul 24
Days Ahead of
Schedule: 112
Official Use Only | À Usage Exclusif
Qinshan Nuclear Power Plant
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Major Participants
Official Use Only | À Usage Exclusif
Salient Contract Details and Construction
Responsibilities
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In-Service Unit 1: 72 months from start of excavation (February 12, 1997-February 12, 2003): Unit 2: 9 months later
Contract was between Third Qinshan Nuclear Power Company(TQNPC)-AECL
TQNPC Responsibilities:
Site Preparation Prepare Permanent Site Facilities Manage Balance of Plant (BOP) construction
AECL as General Contractor and was completely responsible for:
Overall Project Management Manage Nuclear Steam Plant (NSP) Construction at Site Site Quality Assurance
Official Use Only | À Usage Exclusif
Salient Contract Details and Construction
Responsibilities
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Bechtel was responsible for BOP Engineering and provided technical assistance at site for BOP construction
Hitachi was responsible for T/G Contract and Accessories
Construction contractors were responsible for:
NSP construction BOP construction Responsible for preparing Level 3 Schedules Quality Control of all construction activities
Major Contractors:
CNI-23 Construction Company Huaxing (HXCC) Construction Company CNI-22 Construction Company Zhejiang Thermal Power Company (ZTPC)
TQNPC was responsible for all payments
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Site Quality Assurance (QA)
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AECL - Quality a priority
AECL set QA requirements for all construction
AECL initiated non-conformance reporting culture:
Non-Conformance Report (NCR) process to control work, including Stop Work Orders
for major NCRs
Field Change Request Process to control design changes at site
TQNPC had own Quality Surveillance Team
AECL had own Quality Surveillance Branch
Construction Contractors responsible for Quality Control
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Major Construction Contracts
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Site Excavation (HXCC)
NSP Civil Construction (HXCC)
NSP Mechanical/Electrical Installation (CNI-23)
BOP Civil Construction (CNI-22)
BOP Mechanical/Electrical Installation (ZTPC) (Zhejiang Thermal Power Co.)
Piping Fabrication (CNI-23)
Supply of Concrete (CNI-22)
Official Use Only | À Usage Exclusif
Challenges
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Site:
Very restricted site; small peninsula on which plant was placed
Required considerable reclamation from sea to locate full plant
Required considerable detailed planning in early stages of construction
Very high silt content in water, divers of no use
Cultural differences/sensitivities: AECL, Chinese, Bechtel, Hitachi
Experience:
Young Chinese commissioning staff with first time on CANDU station
Construction contractors had no previous CANDU construction experience, but had
significant experience of nuclear power plant construction
Work to Canadian quality standards not previously performed in China
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Challenges (Cont’d)
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Challenges (Cont’d)
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Complex execution model:
Owner manages BOP construction
AECL manages NSP contractors - Owner pays
First time use of open top construction and modularization on a CANDU 6
Maximization of localization
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Important Construction Decisions
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Dedicated Concrete Batch Plant and concrete testing laboratory at Site
Confirmation of major concrete design mixes completed months prior to First Concrete
Establishing Welding Procedures and Welder Training Program very early in Construction Phase
AECL Sole Source for Procurement of NSP Material
Localization of HVAC, Electrical Conduits, Cable Trays
Open Top Method of Construction
Upgrading of Very Heavy Lift (VHL) Crane for Open Top Method of Construction
Maximize parallel works between Civil / Mechanical / Electrical Construction
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Major Issues during Construction
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Coordination between Construction Contractors
Hot Weather Concreting
Structural Steel, Unavailability of Heavier Sections
Lack of Structural Steel Shop Drawing Detailers in China
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Localization
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• General– Upgrading of Very Heavy Lift Crane with crane with manufactories supervision
• Civil– Execution-100% localized– Structural steel with fabrication and erection with expatriate supervision– Concrete with expatriate supervision– Architectural works -100% localized
• Mechanical/Piping– Installation of piping with expatriate supervision– Welding– Installation of heavy equipment with expatriate supervision– Piping fabrication– Very heavy lifts with 100% local effort– All HVAC materials and fabrications– Fabrication of steel tanks/vessels in BOP
• Electrical– Cable tray fabrication– Conduit fabrication
• Fuel Fabrication– 100 % localized due to use of natural uranium fuel
Official Use Only | À Usage Exclusif
Major Achievements
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Shortest construction of any NPP in China from 1st concrete to In-Service (54 months)
Shortest duration to construct perimeter wall (14 days)
Best integrated leak rate of all CANDU 6 nuclear power plants
70 heavy lifts of equipment with the VHL crane
Steam generator installed in 8 hours
Fuel channels installed in 64 days
Excellent performance of Chinese contractors with experience (50% less NCRs for Unit 2 in
comparison with Unit 1)
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• Unit 1 Declared in service 43 days early.
• Unit 1 Criticality Sept. 20th, 2002, ahead of schedule
• Open Top and on site modularization methods resulted in effective execution.
• Large Civil Modules Fabrication/Installation near work face
• Unit 2 Criticality April 29th, 2003, 52 days ahead of schedule
• Great success with 3D CADDS as a production tool and use of electronic data management system
• Training of Contractor to Western Construction Methods
• Buy in by contractors of Quality philosophy of doing it right the first time. (It made economic sense)
• Aggressive QA & QS programs praised by Chinese Regulator
Qinshan Success
Official Use Only | À Usage Exclusif
Reasons for Success of the Project
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Client/Owner was fully 100% behind completion of project and gave full support to AECL
and its sub-contractors
Excellent teamwork between all participants
AECL had available manpower resources with extensive experience of construction
management and engineering expertise on overseas projects
Use of Open Top Method of Construction
Use of Modularization
Official Use Only | À Usage Exclusif
Future CANDU Projects in China
• China in the last 10 years has matured as a developer of nuclear power plants and can easily achieve 90% localization on future CANDU nuclear power plants in both supply of equipment and construction.
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CANDU Construction in China
Ahead of Schedule – Under Budget
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CANDU Construction in China
Ahead of Schedule – Under Budget
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Conventional Construction of
CANDU 6 Stations
Conventional Construction Method
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Open Top Construction Method
Strategically-placed Openings with Sliding Cover on the Temporary Roof for Heavy Lifting
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Open Top Construction Method
Skew Truss
Official Use Only | À Usage Exclusif
Dousing Steel and Lower Dome Formwork Assembly Area at Site (Unit 2)
Official Use Only | À Usage Exclusif
Qinshan Dousing System Module
on Mobile Crane
Official Use Only | À Usage Exclusif
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Qinshan - Dousing System Modules
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Open Top Construction Method
Lower Dome Formwork Being Lifted from Assembly Yard
Official Use Only | À Usage Exclusif
Cernavoda Nuclear Power Plant
• Situated off the River Danube in south east Romania
• Units 1 and 2 completed
• Unit 1 in service 1976
• Unit 2 in service 2007
• Unit 3 and 4 partially completed and presently being reviewed for completion
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Cernavoda - Site
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Cernavoda - Site
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Unit 1 & Unit 2 Salient Contract Details and
Construction Responsibilities
• NSP Engineering & Procurement was AECL responsibility
• BOP engineering/procurement was ANSALDO responsibility
• Unit 1 owner was RENEL now called SNN
• Unit 1 Construction management was responsibility of AECL and ANSALDO
• Unit 2 Owner is SNN
• Unit 2 Construction Management was responsibility of SNN, AECL and ANSALDO
• All construction was performed by Romanian contractors
42 Official Use Only | À Usage Exclusif
Challenges
• Civil– Works had been suspended for some time and exposed to natural conditions– Very limited structural steel industry. Large sections produced in Romania with welded plates
• Mechanical– Equipment had been installed for long time
• Electrical– Unit 1-some electrical equipment installed for some time
• Human Resources– Extensive turn over of staff
43
Maximization of Localization
Official Use Only | À Usage Exclusif
Important Construction Decisions
• Civil
– Thorough inspections performed, all deficiencies identified, repair methods evaluated– Performed preliminary pressure test of reactor building to find leaks in the building
• Mechanical/piping
– Setting up of welding training program prior to start of mechanical construction process
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Localization
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• All construction performed by Romanian contractors with only some specialty foreign contractors
• Structural steel sections fabricated with plates welded to form required sections
• All civil materials with the exception of epoxy finishes fabricated by Romanian contractors
• Site engineering performed by Romanian with supervision by expatriate staff
• Large number of BOP equipment (tanks, pumps, motors, water treatment plant) provided by Romanian industry
• Fuel Fabrication; 100% localized due to use of natural uranium fuel
• Heavy Water Supply: 100% localized
Official Use Only | À Usage Exclusif
Major Achievements
• Unit 1 completed on Schedule
• Unit 2 completed on schedule
• Extensive construction experiences gained by Romanian contractors
• Extensive analysis and design experience gained by Romanian engineers
• Extensive management experience gained by Romanian service staff
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Reasons for Success of Project
• Both Owner and Project managers determined to bring project to successful closure
• Extensive Romanian experience that began project in the 1980s was available during project completion phase in 1990s and 2000s
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Future CANDU Projects in Romania
• In civil engineering, extensive localization is feasible both with respect to construction and domestic industry
• In Mechanical/Piping engineering, extensive localization is feasible for construction but a review is required to estimate extent of domestic industry participation
• In Electrical, Control and Instrumentation engineering, extensive localization is feasible with respect to construction but a review is required to determine the extent of domestic industry participation
• In engineering, procurement and construction, extensive localization can be maintained and further expanded
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• New e-mail address:
THANK YOU
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Thank You
Official Use Only | À Usage Exclusif