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Challenges of Engineering and Constructing the Next Generation of Nuclear Plants

Challenges of Engineering and Constructing the Next Generation of Nuclear Plants. Jack Tuohy Director, Strategic Planning Hitachi Power Systems America, Ltd. Hideo (Hede) Yonemura Vice President &General Manager (Construction Management) Hitachi-GE Nuclear Energy, Ltd. MIT February 2008.

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Challenges of Engineering and Constructing the Next Generation of Nuclear Plants

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  1. Challenges of Engineering and Constructing the Next Generation of Nuclear Plants Jack Tuohy Director, Strategic Planning Hitachi Power Systems America, Ltd. Hideo (Hede) Yonemura Vice President &General Manager (Construction Management) Hitachi-GE Nuclear Energy, Ltd. MIT February 2008

  2. 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

  3. Current Capability in US • Engineering/Design • Procurement • Manufacturing • Construction (Maybe not where we would like it)

  4. 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)

  5. 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

  6. Improvement and Standardization phase Domestic Production Phase Advanced BWR phase (MWe) OMA – 1* Construction Start Commercial Operation 20,000 • 30 years of continuous experience • Continuous workforce development • Additional ABWR orders in the pipeline MWe SHIMANE - 3 1373 1358 SHIKA - 2 1358 HAMAOKA - 5* 1380 ONAGAWA - 3* 825 15,000 KASHIWAZAKI-KARIWA 7* 1356 KASHIWAZAKI-KARIWA 6* 1356 KASHIWAZAKI-KARIWA 4 1100 POWER HAMAOKA - 4* SHIKA - 1 1137 10,000 540 KASHIWAZAKI-KARIWA - 5 1100 SHIMANE - 2 820 HAMAOKA - 3* 1100 FUKUSHIMA II - 4 * COOPERATION CONSTRUCTION 1100 FUKUSHIMA II - 2 5,000 1100 HAMAOKA - 2* 840 SHIMANE - 1 TOKAI - 2* 1100 FUKUSHIMA I -1* FUKUSHIMA Ⅰ-4 784 HAMAOKA - 1* 540 TSURUGA-1* 460 460 357 0 1970 1975 1985 2005 1995 2010 Hitachi BWR Construction Experience

  7. Japanese model – Vertical Integration Basic Design Detail Design Manufacturing Construction • Hitachi Plant Integrated CAE System provides optimized design, visualization, and information management throughout the plant lifetime. Maintenance Engineering CAE/CAD System/Database

  8. Reactor Pressure Vessel and Internals Steam Dryer Reactor Pressure Vessel Steam Separator Core Shroud

  9. Tower Crane Advanced Construction Technologies Large C/C ・1st Generation Introduction of Open-top method using Tower Crane 1975 1980 ・2nd Generation Introduction of Large Crawler Crane for Module Placement 1985 ・3rd Generation Expanded use of Open-top Method & introduction of Parallel Construction 1990 ・4th Generation Advanced Construction Technologies (RFID) 2000 Modularization

  10. Modular construction is becoming more sophisticated and more extensively employed 2000 1980 1990 Start Modularization Milestones Large Crawler Crane Dedicated Module Factory 235 250 196 200 150 Number of Modules 83 100 32 50 27 0 1994 1997 2006 Current 1990 Project Plant Commercial Operation

  11. Advantages of Modularization • Displace Critical Path Activities • Shorten Activity Durations • Reduce and Level-off Site labor • Reduce Construction Cost • Improve Safety and Quality • Shorten overall schedule

  12. Layout Optimization (Example) LargePlatform NarrowO&M space Wasted space with component Long piping route Many Supports fixed on ceiling Poor accessibility

  13. Layout Optimization (Example) Enlarged O&M space Optimized module Component layout Minimized Platform Size Shortened Piping route Minimized Pipe Support Materials Improved Accessibility Layout Optimization Before

  14. Large Module Applications in R/B RPV:900ton Upper Drywell Module:650ton Top Slab Module:550ton RCCV Upper Liner Module:170ton Piping Module:120ton Room Module:250ton RCCV Lower Liner Module:630ton Base Mat Module:460ton

  15. Large Module Applications in T/B Roof Truss Module Lower Condenser Module MSH Drain Tank Area Module Off Gas Module MSV/CV Module Upper Condenser Module T-G Pedestal Installation CF/CD Module

  16. :Critical Path :Civil/Building Work :Mechanical Installation Modular Construction Standardization Yields Predictable Schedule With Modularization Method S/C R/I F/C M/C O/C P/S RPV H/T F/L C/O Milestones Construction Period = 38M (actual First ABWR) Mechanical module Critical Module Excavation R/B Building Work Roof Frame Work MMR Base Mat Commissioning RCCV Installation Mat Module Top Slab Upper Liner EOTC Lower Upper Drywell (650tons) RCCV Liner Blocks RPV ON ECCS/CRD Pre-Operation Upper Drywell Base Mat (460tons) RIN Installation Critical Module Mechanical & Electrical Work In R/B Mechanical module Mechanical module Mechanical module RCCV Lower Liner (630t, Composite CUW HX (40tons) HCU Module (250t, Composite) Off Gas (27tons)

  17. Construction Schedule Comparison Building FC OC FL RI Commissioning ABWR#1 CO: 11/1996 3M 29M 8M 37M • Single box R/B • Shift work(Additional request) • First plant for customer (ABWR) 4.5M 30M10D 6M20D*1 37M(38M10D) ABWR#2 CO: 07/1997 （8M10D*2) *1: substantial period *2: official period • Single box R/B • Lesson learned #1ABWR ABWR#3 CO: 01/2005 2M 33M 10M15D 43.5M • Double box R/B • Additional SCC countermeasure • First plant for customer (contingency plan) ABWR#4 CO: 03/2006 3M 33M 10M 43M • Double box R/B RI : Rock Inspection FC : First Concrete OC : Overhead Crane Operation FL : Fuel Loading

  18. Impact of experience and shift to modular construction [%] 100 93 Normalized Construction Duration 100 86 *1 100 83 80 76 60 72 INDEX Normalized non-civil Fieldwork(Man-hours) *2 61 40 20 0 C/O 1990 1994 1997 2006 BWR(1,100MW) BWR(1,100MW) ABWR(1,356MW) ABWR(1,358MW) Advanced construction technologies have been contributing greatly to shortening schedule & reducing cost as well as enhancing quality Results 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%

  19. SummaryConstruction Strategies On-site work reduction Work Leveling Work efficiency Site support Work efficiency Open-top & parallel construction Site Construction Management support system Early and Detailed engineering before on-site work Modularizationwith large crane Site Man-hour Reduction Peak Loading Reduction Construction Schedule Shortening

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