Qinshan CANDU Project Construction Experiences and Lessons

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2003 February development of actual construction sequences and an iterative approach to schedule verification and improvement. Modularization and prefabrication are major features of the ACR design to achieve the project schedule. For the reactor building, approximately 80% of the volume is installed as modules or prefabricated assemblies. This ensured that critical path durations are achieved. To achieve the shorter schedule, the construction method/strategy was defined very early in the concept phase of the design, as it has a major impact on the construction schedule. This strategy was then included in the design requirements and considered in the plant layout as the design of the new product progressed. The layout of the reactor building was developed taking the construction method into consideration to ensure full integration of the plant layout with the proposed method of construction. When the layout of a system is developed, a particular area/volume within the reactor building in which to fit the particular system is identified. Details on construction strategy are found in Section C.1.4 of Appendix C. 15.3 BOP Optimization The conventional BOP for the ACR-700 was developed jointly by AECL and Hitachi, Ltd., of Japan. The steam turbine for the ACR-700 is based on Hitachi’s TC4F-52 impulse type. The turbine consists of one single-flow high-pressure cylinder and two double-flow low-pressure cylinders in a single-shaft tandem-compound arrangement, with direct coupling to the generator. There are two external two-stage moisture separator reheaters working in parallel to remove moisture and to reheat the high pressure turbine exhaust steam. The turbine generator, condenser and feedwater heating plant are based on proven designs; a characteristic that has minimized associated R&D work. 15.4 The Right Economics The estimated capital cost for a replicated ACR-700 plant is US $1000/kWe. 15.5 Capital Cost The reference plant design was developed with close attention to equipment specification and cost. Because AECL has had a continuous record for active CANDU projects, it has an extensive and up-to-date database of equipment and material costs. In addition, by working closely with manufacturers to establish realistic estimates for innovative components, an accurate plant cost estimate has been established. Key factors leading to capital cost reduction are: • Reduced heavy water and heavy water systems • Reduced core size • Improved turbine cycle • System and component simplification 56
2003 February • Improvements in product delivery 15.6 CANDU 6 to ACR Cost Evolution Elimination of D2O and associated systems: 7.5% Reactor size reduction: 6% Improved turbine cycle: 7% System and component simplification: 10% Design for reduced construction cost: 4% Improvements in product delivery technology: 5.5% 15.7 Construction Schedule: ACR/CANDU 6 Schedule Comparison Recent CANDU construction projects have established a record of meeting challenging schedule targets. The Wolsong 2, 3 and 4 CANDU 6 units in Korea were completed on time in 1997, 1998 and 1999 respectively. Qinshan 1 was completed ahead of schedule and 2 is in commissioning and ahead of schedule. Because of the design and engineering innovations included and because of the use of state-of-the-art project delivery technology, significant further schedule improvements are achievable. The ACR eliminates the previous heavy water commissioning steps for the coolant system and associated auxiliaries and also emphasizes layout for streamlined construction, in particular a highly modularized design. By preparing the complete reactor building design from the beginning in the form of drop-in modules, the total project schedule can be substantially reduced. The critical paths through such a schedule run through a limited number of large components. For the ACR-700, a project schedule of 48 months has been developed for the Nth replicated unit, with a 36-month construction period duration from First Concrete to Fuel Load. Modularization and prefabrication are ideal techniques for doing work in parallel. Multiple modules are fabricated in a shop while the civil work is progressing, ready to receive the modules. Using these techniques will • significantly reduce direct construction labour costs • reduce conventional shoring and scaffolding • shorten durations of critical activities • improve access • allow work to be completed away from the final construction area • improve safety Appendix C provides more details on ACR design and construction. 57
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QINSHAN CANDU PROJECT CONSTRUCTION
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2003 February TABLE OF CONTENTS SEC
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2003 February TABLE OF CONTENTS SEC
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2003 February design, which will ha
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2003 February ECGD Export Credits G
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2003 February 1. CONTRACT ORGANIZAT
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Figure 1-1 AECL Overall Project Con
Page 15 and 16: AECL Project Quality Assurance Mana
Page 17 and 18: Figure 1-5 Qinshan CANDU Project -
Page 19 and 20: 2003 February 3. LICENSING AND REGU
Page 21 and 22: 2003 February 2) A technical suppor
Page 23 and 24: 2003 February 4. SCHEDULES The hear
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Page 27 and 28: 2003 February 6. DESIGN AND PROCURE
Page 29 and 30: 2003 February format of the SPMO Co
Page 31 and 32: 2003 February 7) Disposition of tec
Page 33 and 34: 2003 February Steam generators (220
Page 35 and 36: 2003 February - Accounting Manageme
Page 37 and 38: 2003 February 9. METHOD TO SUBCONTR
Page 39 and 40: 2003 February 10. RESOURCES AND QUA
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Page 45 and 46: 2003 February 11. MATERIAL MANAGEME
Page 47 and 48: 2003 February 12.4 Accommodations E
Page 49 and 50: 2003 February TQNPC was responsible
Page 51 and 52: 2003 February 6. Loss of Class IV T
Page 53 and 54: 2003 February Open item management
Page 55 and 56: General Manager (TQNPC) Project Dir
Page 57 and 58: 2003 February Commissioning Technic
Page 59 and 60: 45 40 35 30 25 AECL BECHTEL M-M HIT
Page 61 and 62: Figure 13-6 TQNPC Commissioning Tec
Page 63 and 64: 2003 February 14. AECL STUDY: LESSO
Page 65: 2003 February 15. AECL’S STUDY: F
Page 69 and 70: 2003 February Appendix A Design and
Page 71 and 72: 2003 February • RFC(S) BOP Tech S
Page 73 and 74: 2003 February Appendix B Quality As
Page 75 and 76: 2003 February To initiate this surv
Page 77 and 78: 2003 February better records are av
Page 79 and 80: 2003 February philosophy and includ
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