localisation readiness and fabrication code opportunities

Localisation Readiness

and Fabrication

Code Opportunities

John Fletcher - Presenter

Larry Kloppenborg

Mark Mitchell

17 March 2016

Presented at Nuclear Africa

2016

22 March, 2016 / 2 © 2016 – EON Consulting (Pty) Ltd

Readiness for the Nuclear New Build (NNB)

• Readiness for Nuclear New Build (NNB)

vs.

• Nuclear readiness for new build

What do we understand by readiness …

Readiness for the NNB does not mean nuclear ready



• Understand the bidding process and the timelines

• Have sight of the localisation requirements and their implication on your

business

• Identify / contact or partner with suitable vendors / contractors / EPC – strategic

alliances deemed to be of mutual benefit

• Understand the more stringent quality requirements that are generally

associated with nuclear construction.

What do we understand by readiness …

No money spent yet. We are in a position to take an informed

decision to commit once the NNB commences



• The localisation requirements in the bid, which may be prescriptive, or framed as

a percentage of the contract value of a specific Work Package

• The scope of work or Work Package identified by the EPC/main contractor as

being contractually required or suitable for sub-contracting to local companies

• The bid document may specify the percentage localisation per unit and the

components and services that must be procured locally

– The DOE has commissioned more than one study on localisation and possible

localisation models and scenarios. In all likelihood the percentage of local content will

rise with each new unit up to some estimated achievable value for the final unit.

What informs the nature and scope of the readiness …

Understand how localisation requirements will be specified and how

to participate


• NNB opportunities

– Understand the potential localisation requirements

– Understand contracting models ( partnering, sub-contracting, etc.)

– Understand the composition of a typical nuclear plant

– Understand the plant areas where localisation opportunities exist

• Match company’s current capabilities, competencies, capacity and appetite for

possible participation in the NNB localisation opportunities.

Identifying the opportunities

Match your capabilities to localisation needs



Nuclear power plant

Nuclear Island Conventional Island Balance of Plant

22 March 2016 / 7 © 2016 – EON Consulting (Pty) Ltd

Localisation strategies

20%

30%

40%

Nuclear Island

Conventional Island

Balance of Plant

Plant

Value QMS

ISO 9001:2008• Industrial standards

• Best practices

ISO 9001:2008 + Plus• Approved standard

• Safety management

• NNR requirements

Nuclear QMS• Code of construction

informs the nuclear QMS

• Safety classification

Safety Class 1

components

Safety Class 2&3

components

Non-nuclear

components

Non-nuclear

components

Graded approach

10%

Graded approach to quality and safety

Localisation %

South Africa should have the

technical capabilities to achieve a

local content in the range of 50%


Potential localization candidates

• Pressure Vessels

• Tanks

• Certain Valves

• Certain Pumps

• Certain Compressors

• Certain Fans

• Certain Heat Exchangers

• Certain Cranes

• Certain Transformers

• Certain Electromotors

• Electrical Cabinets, Cables

• I&C Cabinets, Cables

• Structural and reinforcing steel

• Hangers

• Civil Concrete

• Rebar

• HVAC Ductwork

• HVAC Chillers, Heating Coils etc.


Nuclear construction



• Civil construction:

–Nuclear island

Foundations, steelwork, buildings

–Non-nuclear island and balance of plant

Roads, drainage, foundations, steelwork, buildings

• Mechanical

–Nuclear island

Pressure vessels, piping, pumps, valves, storage tanks, cranes, fire detection &

suppression

Special processes, NDE/NDT, welding and weld heat treatment (pre and post)


Pressure vessels, piping, pumps, valves, storage tanks, cranes, compressors, fire

detection & suppression

Special processes, NDE/NDT, welding and weld heat treatment (pre and post).

Components and services


Nuclear island

Scale



•Electrical, I&C

–Nuclear island

Reticulation, lighting, UPS, diesel generators, instruments, cabling, motors,

control centres


Power evacuation, reticulation, lighting cabling, instruments, motors, control

centres

•Services

–During construction

Labour, NDT/NDE, inspection, catering, cleaning, scaffolding.

Components and services


Conventional island & balance of plant

Components and services … local and imported


Appropriate codes and standards

• Pressure equipment

– Compliance with pressure equipment regulations & NNR requirements

Nuclear island

– ASME Section III - Rules for Construction of Nuclear Facility Components (Divisions 1, 2 & 3)

– RCC-M Design and Construction Rules for Mechanical Components of PWR Nuclear Islands


– ASME Section VIII – Rules for Construction of Pressure Vessels (Divisions 1, 2 & 3)

– ASME B31.1 - Power Piping

– ASME B31.3 - Process Piping

– ASME B31.9 - Building Services Piping

– ASME B16.34 - Valves - Flanged, Threaded, and Welding End

– PD 5500 – Specification for Unfired Fusion Welded Pressure Vessels

– EN 13445 – Unfired Pressure Vessels

– EN 13480 – Piping

– CODAP – Code for Construction of Unfired Pressure Vessels

– AD 2000 – Technical Rules for Pressure Vessels



• Civil works and buildings

– SANS 10400: The Application of the National Building Regulations

– ACI 349-13: Code Requirements for Nuclear Safety-Related Concrete Structures

– ACI 318-11: Building Code Requirements for Structural Concrete

– ASME Section III, Division 2- Concrete Containment

– ASME Section III, Division 1, Subsection NE, Metallic Containments

• Control and instrumentation

– IEEE Std. 603

– IEEE Std. 279

• ASME offers 48 Performance Test Codes (PTCs):

– Power Production

– Combustion and Heat Transfer

– Fluid Handling, and

– Emissions.



• Safety

– IAEA Safety Series No. 110 “The Safety of Nuclear Installations”

– IAEA Safety Series No. 50-C/SG-Q

– INSAG-13: Management of Operational Safety in Nuclear Power Plants

– Safety Reports Series No. 11: Developing Safety Culture in Nuclear Activities (Practical

Suggestions to Assist Progress)

– IAEA NS-R 2: Safety of Nuclear Power Plants: Operation

– IAEA Safety Guide NS-G-2.4: The Operating Organisation for Nuclear Power Plants

– IAEA Safety Standards Series NS-R-1: Safety of Nuclear Power Plants: Design

– 10 CFR 830 : Nuclear Safety Management

– DOE 450.4 : Safety Management System Policy

– IAEA-TECDOC-1321: Self-Assessment of Safety Culture in Nuclear Installations

Highlights and Good Practices

– IAEA-TECDOC-1329: Safety Culture in Nuclear Installations. Guidance for Use in the

Enhancement of Safety Culture


ASME certification programme

• N-type certificates of authorization issued by ASME verify the adequacy of an

organization's quality assurance programme and allow the certificate holder to

design, fabricate, and install components and supports used in nuclear power

plants and other nuclear facilities. These components will be certified and

stamped with the Certification Mark in accordance with Section III of the ASME

BPVC. The Society issues six different N-type certificates that authorize the

following scope of activities:

N - Vessels, pumps, valves, piping systems, storage tanks, core support structures, concrete

containments, and transport packaging

NA - Nuclear shop assembly and installation

NPT - Parts, appurtenances, welded tubular products, and piping subassemblies

NS - Supports

NV - Pressure relief valves

N3 - Transportation containments and storage containments

Nuclear component certification


Procedure for obtaining an ASME “code stamp”

1. Determine which stamp(s)

2. Obtain and complete the application form

3. Contact and contract an authorised inspection

agency (AIA)

4. Prepare a quality control programme

• Prepare and qualify welding procedures and welders

• Prepare NDE procedures and qualify personnel in

accordance with ASNT document SNT-TC-1A or

make arrangements with an outside NDE laboratory

5. Have the authorized inspection agency review

and concur with QC programme

6. Prepare mock-up pipe/vessel or repair, as

appropriate for the stamp desired, following the

QC programme. Leave one major seam tacked

but not welded or as directed by the authorized

inspector.

7. The Quality Control Manual and its

implementation will be audited by a

representative of the National Board of Boiler

and Pressure Vessel Inspectors or Chief

Inspector of the local jurisdiction and your

authorized inspection agency supervisor and

your authorized inspector

• First day - Review of QC programme, Implementing QC

procedures, welding and NDE procedures

• Second day - Shop inspection to verify implementation

of programme. Revisions to QC programme

8. Audit team will advise in the exit interview

whether your programme passed or failed. You

may begin work with the concurrence of the

authorized inspector after a successful survey,

but you may not actually stamp anything until

you receive the stamp from ASME or National

Board, usually within a couple of weeks.There are cost and time considerations

with the obtaining of a stamp


EON Consulting – nuclear services

Nuclear design, review and oversight

• Independent nuclear engineering oversight

• Skilled and experienced engineering practitioners

• Verifying nuclear code compliance

• ASME code application knowledge

• ASME code consultation

• ASME code training

Project management

• Meeting nuclear regulatory requirements

Nuclear quality programme

Safety management and safety culture

Quality and safety culture training

New build localisation partner

• Readiness assessment

• Vendor qualification

Your Partner of Choice As a preeminent organization in today's challenging nuclear

industry, MPR actively pursues the highest standards of

engineering excellence, professionalism, and integrity. Our

growing firm is recognized as the leading specialty engineering

company in the power industry, having provided technology

solutions for every US nuclear power plant and more than 150

plants worldwide since our inception in 1964. MPR's Nuclear

Services Group offers clients a single, integrated resource that

supports all power plant areas:

Design and construction

Licensing procedures

Operations and maintenance

Decommissioning

In addition, MPR's technical evaluations have been used to make

long-term investment and run-or-retire plant decisions. These

evaluations have also led to comprehensive monitoring and

improvement programmes for critical equipment. At the same

time, MPR uses its advanced technologies to restore and protect

the environment for future generations.

EON’s Nuclear Partner:

EON Consulting - your nuclear engineering

localisation partner of choice

Follow me to assess your

readiness for the Nuclear New

Build Programme


In closing: safety of nuclear power

Many people in the world believe nuclear power is very dangerous and this is

aided by the enormous attention that any incident gets in the media, even if

someone falls off a ladder at a nuclear power station it gets in the press. The

worst accident ever, so far, as far as casualties are concerned is Chernobyl and

the aftereffects are still experienced. Thus I want to illustrate the need for quality

through the need for safety to satisfy public demands as shown below.

Questions and

discussion

@eon_consulting

[email protected]

www.eonconsulting.co.za

+27 (0)11 564 2300

localisation readiness and fabrication code opportunities

Engineering