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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1
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
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2
Current Capability in US
• Engineering/Design
• Procurement
• Manufacturing
• Construction
(Maybe not where we would like it)
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3
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)
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4
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
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5
Hitachi BWR Construction Experience
Domestic Production Phase
Improvement and
Standardization
phase
Advanced BWR phase
(MWe)
20,000
OMA – 1* Commercial Operation
Construction Start
• 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*
POWER
15,000
825
KASHIWAZAKI-KARIWA 7*
1356
KASHIWAZAKI-KARIWA 6*
1356
KASHIWAZAKI-KARIWA 4
SHIKA - 1
10,000
1100
HAMAOKA - 4*
1137
540
KASHIWAZAKI-KARIWA - 5
SHIMANE - 2
HAMAOKA - 3*
5,000
* COOPERATION
CONSTRUCTIO
N
SHIMANE - 1
FUKUSHIMA I -1*
TSURUGA-1*
0
1970
1975
1100
820
1100
FUKUSHIMA II - 4
1100
FUKUSHIMA II - 2
HAMAOKA - 2*
TOKAI - 2*
FUKUSHIMA Ⅰ-4
HAMAOKA - 1*
1985
1995
1100
840
1100
784
540
460
460
357
2005
2010
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6
Japanese model – Vertical Integration
Basic Design
Detail Design
Manufacturing
Construction
Maintenance
•Hitachi Plant Integrated CAE System provides
optimized design, visualization, and information
management throughout the plant lifetime.
Engineering CAE/CAD System/Database
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7
Reactor Pressure Vessel and Internals
Reactor Pressure Vessel
Core Shroud
Steam Dryer
Steam Separator
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8
Advanced Construction Technologies
Tower Crane
Large C/C
・1st Generation
1975
1980
Introduction of
Open-top method
using Tower Crane
・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
Modularization
Advanced Construction
Technologies (RFID)
2000
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9
Milestones
Modular construction is becoming more
sophisticated and more extensively employed
1980
2000
1990
Start Modularization
Large Crawler Crane
Dedicated Module Factory
235
Number of Modules
250
196
200
150
83
100
50
27
32
0
1990
1994
1997
2006
Plant Commercial Operation
Current
Project
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10
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
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11
Layout Optimization (Example)
Large Platform
Narrow O&M space
Wasted space with component
Long piping route
Many Supports fixed on ceiling
Poor accessibility
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12
Layout Optimization (Example)
Enlarged
O&M space
Optimized module
Component layout
Minimized
Platform Size
Shortened
Piping route
Minimized Pipe
Support Materials
Before
Improved
Accessibility
Layout Optimization
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13
Large Module Applications in R/B
RPV:900ton
Upper Drywell Module:650ton
Top Slab Module:550ton
RCCV Upper Liner Module:170ton
RCCV Lower Liner Module:630ton
Piping Module:120ton
Base Mat Module:460ton
Room Module:250ton
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14
Large Module Applications in T/B
Lower Condenser Module
MSH Drain Tank Area Module
Off Gas Module
T-G Pedestal Installation
Roof Truss Module
MSV/CV Module
CF/CD Module
Upper Condenser Module
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15
Modular Construction Standardization
Yields Predictable Schedule
With Modularization Method
Milestones
S/C
R/I
F/C M/C
O/C P/S
RPV H/T
F/L
C/O
Construction Period = 38M (actual First ABWR)
Mechanical module
Critical Module
Excavation
R/B Building Work
Roof Frame Work
MMR
Base Mat (460tons)
Base Mat
Commissioning
RCCV Installation
Top
Mat Module
Upper
EOTC
Slab
Lower
Liner
Upper Drywell (650tons)
RCCV Liner Blocks
ECCS/CRD Pre-Operation
RPV ON
Upper Drywell
S/C: Start Construction
R/I: Rock Inspection
RIN Installation
Critical Module
Mechanical & Electrical Work In R/B
Mechanical module
Mechanical module
F/C: First Concrete
M/C: Mat Completion
O/C: Operating Floor Completion
P/S: Power Supply
RPV P/T: RPV Hydro Test Completion
F/L: Fuel Loading
C/O: Commercial Operation
EOTC: Electric Overhead Traveling Crane
Mechanical module
RCCV Lower Liner
(630t, Composite
:Civil/Building Work
:Mechanical Installation
:Critical Path
HCU Module
(250t, Composite)
CUW HX
(40tons)
Off Gas (27tons)
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16
Construction Schedule Comparison
RI FC
ABWR#1
3M
CO: 11/1996
CO: 07/1997
CO: 03/2006
30M10D
2M
33M
8M
Building
Commissioning
37M
First plant for customer (ABWR)
6M20D*1
37M(38M10D)
10M15D
43.5M
Additional SCC countermeasure
First plant for customer (contingency plan)
Double box R/B
3M
FL
（8M10D*2)
*1: substantial period
Lesson learned *2: official period
#1ABWR
Single box R/B
CO: 01/2005
ABWR#4
29M
Single box R/B
Shift work(Additional request)
ABWR#2 4.5M
ABWR#3
OC
33M
10M
43M
Double box R/B
RI : Rock Inspection FC : First Concrete
OC : Overhead Crane Operation FL : Fuel Loading
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17
Impact of experience and shift to modular construction
[%]
100
INDEX
80
60
40
20
100
93
86
Normalized Construction Duration
*1
100
83
76
Normalized
non-civil
Fieldwork
(Man-hours)
72
61*2
0
C/O 1990
BWR(1,100MW)
1994
BWR(1,100MW)
1997
2006
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%
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18
Summary
Construction Strategies
On-site
work reduction
Work
Leveling
Modularization
with large
crane
Open-top
&
parallel
construction
Work
efficiency
Site support
Work efficiency
Early and Detailed Site Construction
Management
engineering before
support system
on-site work
Site Man-hour Reduction
Peak Loading Reduction
Construction Schedule Shortening
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19