1. Nuclear Power Plant Construction Specifications
VAE conference, 15 June 2012, Vilnius
”How to properly prepare for the Visaginas NPP”
Jens Gunnars, Inspecta Technology
Mikael Kuokkanen, Inspecta Nuclear
1 2012-06-20

2. Nuclear Power Plant Construction Specifications
Contents
Part I – Introduction to and prerequisites for Nuclear Power projects
1) Brief overview of a NPP and major New Build project phases
2) Regulatory framework, Codes, Standards, and Specifications
3) Division into Safety Classes and implications to Specifications
4) Experiences on NPP projects
Part II – Opportunities and handling of some challenges in NPP projects
5) What is the extent of work in a New Build NPP
6) Implications on opportunities from the choice of Specifications
7) Important steps to be successful - start prepare in time
Summary
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3. Brief overview of a NPP
Major systems and components in a NPP
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4. Major project phases in NPP New Build projects
Why should Licensee be involved during Engineering & Manufacturing in a Turn Key Project
0 >60 Years
Planning Engineering Manufacturing
& Design & Installation Operation
100% initiative by Successive more involvement by Supplier. Licensee has 100%
Licensee However, at all times the Licensee still responsibility and interest for
needs to maintain project leadership long term operation
(also in Turn Key projects)
Maintained project leadership by the licensee is essential in all phases since
(i) the Licensee has full responsibility and interest for long term operation
(ii) this can increase the opportunities for the local industry
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5. Regulatory framework, Codes, Standards, and Specifications
Global principles but local regulation and control is needed
• Basic principles for nuclear safety are similar throughout the world, as originated
from U.S. regulation (by NRC) and standards (by ANSI for nuclear and ASME for
mechanical); and as generalised in IAEA safety handbooks and guides.
− Power utilities have special cooperation forms for exchange of experiences (owner’s groups) and preparation
of utility requirements e.g. in Europe (EUR).
− Western European nuclear regulatory authorities (WENRA) are in the process of harmonising general safety
and regulatory oversight practices.
• However, local legislation and often guidelines gives the country’s legal specification
for the safety requirements and the way in which operations are controlled
− Sweden: national regulation for general safety principles and mechanical equipment, as supervised by the
Swedish Radiation Safety Authority (SSM) and inspected by the nuclear inspection bodies.
− Finland: national safety regulation and also NPP guidelines (YVL Guides), as prepared by the Radiation and
Nuclear Safety Authority (STUK), supported by the technical research organisations and inspection bodies.
− France: national regulation and practices, with the regulatory body (ASN), technical support organisation
(IRSN) and inspection bodies.
− Germany: national regulation and nuclear standards (KTA), with local authorities, support organisation (GRS),
and inspection bodies.
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6. Regulatory framework, Codes, Standards, and Specifications
Legal
National Framework
legislation
National Guides (YVL)
IAEA Safety Guidelines Mandatory
Nuclear Codes (ANSI, ASME, RCCM) Guides
Quality Management Stds (NQA-1, ISO)
Established Standards (EN, ISO) Licensee
Specific Licensee Requirements Requirements
Detailed Project Specifications
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7. Activities contributing to nuclear safety
Why is nuclear power plant safety so different?
• Safety design
− Defense-in-depth. Multiple barriers against radioactive releases into environment.
− Safety functions. Process/electrical/automation systems protecting the barriers.
• Safety assessment
− Reactor dynamics – nuclear fission power generation after disturbances.
− Thermal hydraulics – water and steam flow in reactor circuit and containment.
− Structures and materials – structural capability, endurance and integrity.
− Risk assessment – failure scenarios, accident probabilities and consequences.
• Safety management
− Safety culture & practices.
− Quality assurance & control.
− Operation & maintenance.
• Regulatory oversight
− Licensing & permits.
− Reviews & inspections.
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8. Division into Safety Classes
Why is nuclear power plant safety so different?
• Safety design
− Defense-in-depth. Multiple barriers against radioactive releases into environment.
− Safety functions. Process/electrical/automation systems protecting the barriers.
Safety Class 3
Safety Class 2
Safety Class 1
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9. Safety Classes and their implications to Specifications
Example from Sweden:
Safety Class Safety Class Safety Class Safety Class
1 2 3 4
Design and ASME III, NB ASME III, NC ASME III, ND EN 13445
strength EN 13480
calculation
Material All materials according to harmonized European standards are
approved and accepted. Note that ASME materials are not accepted
without additional requirements .
Welding Certificate according to EN 729, EN 3834. All welding shall be done
according to qualified procedures and by qualified personnel.
Manufacturing KBM KBM KBM KBM
and ASME III, NB ASME III, NC ASME III, ND
Installation
KBM = owners detailed quality specifications for mechanical equipment
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10. Experiences on NPP projects
Recent projects in Sweden
• PULS (Power Uprate with Licensed Safety) Oskarshamn 3 (BWR).
Structural verification of reactor systems, internal parts, turbine systems for
increased power. Westinghouse, ALSTOM
• FREJ – LOT 3 - Replacement of steam generators in Ringhals 4 – Verification of
the structural integrity of reactor systems. AREVA
• PLEX Oskarshamn 2, Structural verification of reactor systems, internal parts,
turbine systems. AREVA, SIEMENS
• GREAT/TURBO - Requalification of Ringhals 3/4 – turbine systems (PWR).
ALSTOM
• Replacement of RPV-heads I Ringhals 3 and 4 (PWR). MHI
• Replacement of Internal parts in Ringhals 1 (BWR). AREVA
• Forsmark TU12/MSR. Power uprate. SIEMENS, Balcke Duerr
• Forsmark 3, KYR. Preparation of power uprate. Westinghouse
• Forsmark 3, Generator replacement. ALSTOM
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11. Common experiences from NPP projects
Some challenges experienced during the projects
• Shortages of experienced designers and welders due to e.g. generation shift
• Start of manufacturing before full completion of design and engineering
• Worldwide shortage of qualified nuclear equipment manufacturers
• Many suppliers not used to the need of extensive documentation in nuclear
industry
• Requirements not properly communicated through the supplier chain
• Personnel and method qualification issues when using a mixe of standards and
suppliers own practices
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12. Nuclear Power Plant Construction Specifications
Contents
Part I – Introduction to and prerequisites for Nuclear Power projects
1) Brief overview of a NPP and major New Build project phases
2) Regulatory framework, Codes, Standards, and Specifications
3) Division into Safety Classes and implications to Specifications
4) Experiences on NPP projects
Part II – Opportunities and handling of some challenges in NPP projects
5) What is the extent of work in a New Build NPP
6) Implications to opportunities from the choice of Specifications
7) Important steps to be successful - start prepare in time
Summary
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13. What is the extent of work in a New Build NPP
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14. Implications on opportunities
• Safety Class 1 and 2:
− Only few global suppliers for major components, usually ASME-oriented
• Safety Class 3 and 4 and Non-nuclear:
− Majority of components and systems belong here-
− Good opportunities for smaller suppliers.
− The choice of code largely affects opportunities, especially for 4 & non-nuclear
• One major effect for any mechanical equipment supplier on the abilities to go
nuclear is the choice of Code, ASME or ”EN”, ie European standards.
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15. Implications on opportunities from choice of Specifications
Choices for manufacturing of safety critical mechanical equipment:
• The ”full ASME-track”
− Provides opportunity to export outside Europe (especially US, CAN)
− Entire manufacturing adapted to a specific code
− Certification by ASME, AIA. All continuous surveillance by manufacturer
• The ”European Track”
− Choice of European EN-standards gives access to EU-market
− Complies with EU-directives
− Large involvement of various third parties during manufacturing
• The ”mixed Track”
− ASME/EN is partly used
− Mix between fundamentally different codes for one system gives difficulties
• In all cases:
− Adjustments must in any case be made to national nuclear legislation
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16. Important steps to be successful - start prepare in time
• Choice of specifications is a basis (national guides and standards)
• Start prepare in time:
− Detailed requirements breakdown
− Training and education of suppliers and sub-suppliers
− Qualify personnel and quality systems
− Start a forum for cooperation between authorities, licensee and industry
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17. Expertise area examples for NPP New Build and Operation
0 60 Years
Engineering Manufacturing
Planning Operation
& Design & Installation
Evaluation of Manufacturing
Codes & Stds Inspections In Service Inspections
Suppliers
Project Risk Mgmt Load Analysis Welding Technology Revisions
Basic Design Review Structural Integrity NDT & DT Modifications
Verification
Preplanning for Materials QC Mgmt of Defects
60 years operation Technology
Sub Supplier Req Constr License Appl Site installation Life Time Mgmt
inspections
Regulatory
Oper License Appl
License Application
Training and qualification of personnel at authorities, licensee, suppliers in these areas important
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18. SUMMARY
Examples of initiatives to create opportunities for national industry
• Maintained project leadership by the licensee is essential in all project phases
• Choice of codes and standards that comply with national and European legislation
and also that will promote national manufacturers
• Detailed requirements breakdown and then creation of clear specifications for the
complete chain of suppliers and sub-suppliers
• Specification of both quality and documentation requirements.- high
documentation requirements in the nuclear industry
• Training and education of suppliers and sub-suppliers – early on in the NPP
project initiatives for training jointly by authorities, licensee and industry
• Create an open process between Authorities, Licensee, Contractor, Suppliers for
cooperative handling of requirements
• Continue to build on the national expertise needed to support the nuclear industry
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19. FINAL WORDS…
• Inspecta Annual Nuclear Symposium is arranged 4-5 december 2012.
Welcome!
• Thanks for listening!
For further inquiries, please contact
Inspecta Lithuania, Mr. Mantas Andriuskevicius,
Mantas.Andriuskevicius@inspecta.com
+370 61517558
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