#1G NEA Nuclear Energy Agency CASE STUDIES ON "PROJECT AND LOGISTICS MANAGEMENT IN NUCLEAR NEW BUILT❞ The ABWR Project at Shimane-3, Japan Sang-Baik Kim, Jan-Horst Keppler OECD Nuclear Energy Agency, Nuclear Development Division OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 1 OECD#2NEA Nuclear Energy Agency Contents Shimane Nuclear Power Plants Status of BWR Nuclear Power Plants in Japan • ABWR Development and Licensing • Practice in Construction of NPPs in Japan • . Project Management of Shimane-3 ABWR • Advanced Technologies in ABWR Construction • Workforce in ABWR Construction Summary OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 OECD 2#3NEA Nuclear Energy Agency Shimane Nuclear Power Plants (I) OECD • In Japan, before the Fukushima accident, nuclear energy accounted for almost 30% of the total electricity from 47.5 GWe of capacity (30 BWRs and 24 PWRS). • The Shimane nuclear power station is located in Kashima-chou, Shimane Prefecture, and owned by the Chugoku Electric Power Company (The Chugoku EPCO) • The Chugoku EPCO has two Boiling Water Reactors. The ratio of nuclear power generation capacity is less than 10%. - Unit No. 1 of Shimane (460 MW): Operation in 1974 - Unit No. 2 of Shimane (820 MW): Operation in 1989 This unit No. 1 is the first "all-Japanese plant", whose design, manufacture and construction were conducted by The Chugoku EPCO and Hitachi LTD. OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 3#4G NEA Nuclear Energy Agency Shimane Nuclear Power Plants (II) OECD . • Unit No. 3 of Shimane (Shimane-3) is under construction. - One of the largest and the 5th ABWR (1373 MWe) in Japan - After issuance of construction license, the excavation of main building started in Oct. 2006. - - Originally planned to enter commercial operation in Dec. 2011 - After the Fukushima accident, the construction was suspended (construction progress 94 %) In Sep. 2012, METI approved the restart of construction in Shimane-3 and Ohma-1 plants. The final schedule is not known. • The Chugoku EPCO planned to build two Kaminoseki ABWR nuclear Power units on Nasgashima Island and confirmed its intention to proceed in 2012. OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 4#59 NEA Nuclear Energy Agency ABWR NPPs in Japan OECD Since 1970, 32 BWRs (including 4 ABWRs) have been brought into operation. The first ABWRs were TEPCO's Kashiwazaki-Kariwa 6&7, build by a consortium of General Electric (USA), Toshiba and Hitachi. (MWe) 20,000 POWER 15,000 10,000 Domestic Production Phase Improvement and Standardization phase Advanced BWR phase ABWRY Construction Start 40 years of continuous experience Continuous workforce development > Additional ABWR orders in the future * COOPERATION CONSTRUCTION 5,000 SHIMANE – 1 FUKUSHIMA I-1* TSURUGA-1* 0 1970 1975 SHIMANE – 3 Commercial Operation JOHMA * 1383 MWe 1373 SHIKA - 2 1358 HAMAOKA - 5* 1380 ONAGAWA - 3* 825 KASHIWAZAKI-KARIWA 7* KASHIWAZAKI-KARIWA 6* KASHIWAZAKI-KARIWA 4 1356 1356 1100 HAMAOKA - 4* 1137 540 KASHIWAZAKI-KARIWA-5 SHIMANE - 2 HAMAOKA - 3* 1100 820 1100 FUKUSHIMA II - 4 FUKUSHIMA II - 2 HAMAOKA - 2* TOKAI - 2* FUKUSHIMA I -4 HAMAOKA 1100 1100 840 1100 784 540 460 460 3:57 2005 2010 1985 SHIKA - 1 1995 (Source: Hitachi-GE Nuclear Energy, Ltd.) OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 5#6G NEA Nuclear Energy Agency All ABWR NPPs in Japan OECD Plant Construction Commercial Start* Operation 7 ABWRs ●Hokuriku Electric Power Company Shika 2 ⚫EPDC Ohma Kashiwazaki- Nov. 1992 Nov. 1996 Kariwa 6 Kashiwazaki- July 1993 July 1997 Kariwa 7 The Chugoku Electric Power Company Shimane 3 ◆Tokyo Electric Power Company Higashidori 1 Hamaoka 5 July 2000 Jan. 2005 Shika 2 Aug. 2001 Mar. 2006 Tokyo Electric Power Company Kashiwazaki-Kariwa 6,7 Shimane 3 Sep. 2007 defered, TBD Chubu Electric Power Company Hamaoka 5 Ohma 1 Hagashidori May 2010 TBD defered (*: Construction Start is based on the first concrete of the reactor building base mat) OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 6#7NEA Nuclear Energy Agency ABWR Development and Licensing OECD • The development of the ABWR started in 1978 as an international- cooperation between five BWR vendors. - - The ABWR was included in the third standardization programme of Japan from 1981, carried out by Toshiba, Hitachi and GE with six Japanese utility and Japanese government. - From 1987 GE, Hitachi and Toshiba started project engineering and preparation of licensing for Kashiwazaki-Kariwa 6&7. - In Sep. 1987, GE applied for certification of the US ABWR standard design. USNRC adopted as final design certification rule for the US ABWR design in May 1997. Both Toshiba and GE-Hitachi have applied separately to NRC for design certification renewal. In 2011, the NRC certified for GE- Hitachi an evolved version. Hitachi was also developing 600, 900 and 1700 MWe versions of the ABWR. OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 7#8NEA Nuclear Energy Agency ABWR Development and Licensing FY Reactor Type Recirculation (Output) Method Safety System '80 '90 '00 '10 '20 '30 '40 Development Construction Active ABWR Forced circulation safety (1,350 MW) system Passive ESBWR Natural (1,550 MW) circulation safety system Next- Hybrid generation Forced safety BWR (1,700-1,800 MW) circulation system [Raise output】 Development Construction (1,500 MW) Development Construction OECD (Source: Hitachi- GE Nuclear Development Construction Energy, Ltd.) GE Hitachi's ESBWR is in advanced stages of licensing review with the US NRC. Japan launched the Next-Generation LWR development program in 2008, for one PWR & one BWR design. OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 8#9NEA Japanese Practice in Construction of NPPS Nuclear Energy Agency OECD (Source: IAEA N. E. series No. NP-T-2.7).) • Japanese legislation define that the sole licensee must be the electric power company, which is responsible for the safety of the plant and must submit for the approval of the safety analysis report and the construction permit. • . All Japanese electric companies are large and have the tradition to do the engineering of their power plant themselves. The owner/utilities in Japan carry the burden of major portions of the engineering, procurement and construction (EPC) of their NPPs. Consequently, the Japanese electric companies have built NPPs by awarding split-package contracts (the so-called island approach) as well as smaller component contracts. Given the large number of utilities in Japan, each company built relatively few NPPs and this has made it difficult to maintain a highly qualified workforce. All utilities in Japan have developed and maintained good relationship with each other and willingly share their human resources. Salaries and expenditures continued to be paid by the original employers. OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 9#10• • - NEA Project Management of Shimane-3 (1) Nuclear Energy Agency OECD For Shimane-3, the Chugoku EPCO coordinates all contractors in civil, building and mechanical fields, and control work progress among each contractor. Civil work (land forming, intake and discharge structure): Civil Joint Venture - Building work (main building): Building Joint Venture - Mechanical work (piping/equipment/commissioning): Hitachi-GE The project management is responsible for the cost, schedule and technical performance of the project and is in control of design, engineering, procurement, manufacture, construction and commissioning. There are many activities in project management, for project planning and scheduling, design schedule, construction schedule, control of project progress, management of information and method to subcontract materials and construction works. The quality assurance (QA) programme is an interdisciplinary management tool that provide a mean that all work is adequately planned, correctly performed and assessed. OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 10#11NEA Project Management of Shimane-3 (II) Nuclear Energy Agency OECD • The most significant point in ABWR is standardization, which consists of design standardization, document standardization and quality management standardization. Site K-6/7 Steering Committee K-6/7 Project Meeting Head Office Architectural Schedule Mechanical Electrical / Civil Coordination Meeting Regular Meeting Regular Meeting Regular Meeting Pre-ope. Start-up Meeting Quality Assurance Subcommittee Construction Technical Schedule Permit Subcommitted Subcommittee Subcommittee Yard Regular Meeting Fig. Project Organization for TEPCO's Kashiwazaki-Kariwa 6&7 Project OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 11#12. NEA Advanced Tech. in ABWR Construction (I) Nuclear Energy Agency Comparison of construction periods of Kashiwazaki-Kariwa Power Station OECD . Livt SC DI SPV FUT ランピーヒン 1-85 78.12.1 S/C 17.5M 7M 30M SM BM 10M K-1 81.5M 64M 85.9.18 C/O K-2 S/C 83.10.26 90.9.28 23M 7.5M 26.5M OM 7M 10M 83M 60M C/O K-5 S/C C/O 83.10.26 '90.4.10 17.5M 6M 28M 9M BM 9.5M 77.5M 60M 87.7.1 K-3 S/C 15 M BM 25.5M 7M TM 10M 72.5M 57.5M 93.8.11 C/O K-4 S/C 4.8.11 88.2.5 21M 8.5M 25M 7M 7M 10M 78.5M 57.5M C/O 91.9.17 10.5M GM 21.5M M 7M 9.5M S/C K-6 62.5M 52M 56.12.1 C/D (予定) 92.2.3 13.5M 6.5M 23.5M 7M 7M BM K-7 S/C 65.5M 52M 97.7.15 C/O Legend: S/C- Start of construction I/F - Inspection of foundation C/F- Completion of foundation mat C/R- Completion of refuelling floor RPV H/T- RPV First hydrostatic test F/L- Fuel loading C/O- Start of commercial operation (Source IAEA-SM-353/36) The normal definition of the construction period refers to "from pouring of first structural concrete to start commercial operation". In case of K-6, the time from I/F (July 1992) to C/O was 51.5 months. From the first concrete (Nov. 1992) to the first criticality (Dec. 1995), it took 37 months. The 40-month schedule is a aggressive target in comparison with the past U.S. construction experience(Before the TMI it was 60-70 months; after that, extended significantly) OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 12#13NEA Advanced Tech. in ABWR Construction (II) Nuclear Energy Agency OECD Advantages of ABWR in construction of Kashiwazaki-Kariwa 6&7 as FOAK (first of a kind Engineering) - Design features of ABWR for better plat constructability - Prudent design change control with a principle of "test before use" - Advanced construction technology - Detailed engineering at early stage of the project Good construction management Main features in reduction of construction time in Kashiwazaki-Kariwa 6&7 - Increased composite modularization - Increased pre-fabrication - Application of steel-concrete structure - Inspections rationalization - - Better communication through IT OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 13#14• • NEA Advanced Tech. in ABWR Construction (II) Nuclear Energy Agency Applied Construction Technologies in Shika-2 - OECD Broader application of large module/block construction methods - Open-top and parallel construction method - Application of floor packing construction methods - Full application of information technology to qualify plant engineering and construction achievements. Further Improvement of Construction Technology in Shimane-3 - Parallel construction - Floor packaging construction - Modularization about 190 modules including the HCU (hydraulic : control unit) room module - Development of integrated on-site construction system - Advanced construction management using RFID (radio-frequency identification) OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 14#15NEA Advanced Tech. in ABWR Construction (IV Nuclear Energy Agency GECD • Modularization Method Upper Drywell Module (650 ton) RCCV Lower Liner Module RPV RCCV Top Slab Stator (900 ton) (550 ton) (420 ton) Upper Condenser Module (630 ton) (270 ton) RPV Pedestal Module Base Mat Module HPU Module Lower Condensor Unit (410 ton) (460 ton) (270 ton) (260 ton) TACH (Source: Hitachi-GE Nuclear Energy, Ltd.) OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 15#16NEA Nuclear Energy Agency Workforce in ABWR Construction · Owner's Project Management Team in case of Kashiwazaki-Kariwa 6&7 civil engineering architectural engineering Omechanical & electric engineering Pre-operation (man year) 250 Start of project Construction permit issued 200 150 100 50 Total:about 1300men from the start of project 1 2 3 Unit 1 Turn over Unit 2 Turn over 5 6 7 8 year OECD Note: For twin ABWR plant: about 1,300 men-year, out of which: mechanical & electrical (average57, max 72); architect (19, 22); civil (20, 24); administration (61, 82) Other resources utilized in Kashiwazaki-Kariwa 6&7 - - (Source IAEA-TECDOC-1390.) Manpower-construction [ man-hours]: U6 14,400,000; U7: 10,800,000 Materials Piping [tons]: U6: 11,000.; U7: 6,000. Concrete [m3]: U6: 200,000.; U7: 167,000. OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 16#17NEA Nuclear Energy Agency Summary OECD • The ABWR is the evolutionary design of the conventional BWR and . . the first design, among Generation III LWR designs, with construction and operating experiences. The first ABWR, Kashiwazaki-Kariwa 6, was constructed on a 37 months schedule from the first reactor building structure concrete pour to fuel load. The advanced management and construction technologies have been developed and demonstrated through continuous experiences of ABWR construction in Japan. • The Shimane-3 was constructed for "On-budget and On-schedule" with application of more advanced design and construction methodology, just before the Fukushima accident. It was 94% complete and construction was suspended in March 2011. OECD NEA Workshop on Project and Logistics Management, Paris, 11th March 2014 17