Supply Chain Services for Nuclear Power Plants: How to build and control the supply chain
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1 Supply Chain Services for Nuclear Power Plants: How to build and control the supply chain Dr. Boris Gehring Centurion, South Africa, March /03/2016 Nuclear Services
2 Our heritage: 150 years of business success Establishment of a Mannheim-based steam boiler inspection association by 21 operators and owners of steam boilers, with the objective of protecting man, the environment and property against technology-related risks First vehicle periodic technical inspection (PTI) 1926 Introduction of the TÜV mark / stamp in Germany 1958 Development of a Bavaria-wide network of vehicle inspection centres in the late 1950s 1960s 1964 First activities in South - Africa 2006 Expansion of services in ASEAN by acquiring Singapore-based PSB Group 2009 Launch of Turkey-wide vehicle inspection by TÜVTURK Today Start Nuclear Inspection / Consultancy business TÜV SÜD continues to pursue a strategy of internationalization and growth TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 2
3 Global expertise. Local experience. Global Headquarters Munich, Germany Legend: Countries with TÜV SÜD offices Regional headquarters Note: Figures have been rounded off. GERMANY Euro 1,240 mio 11,400 staff INTERNATIONAL Euro 820 mio 10,600 staff TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 3
4 Problems with nuclear new build projects Source: Internet, May 2015 TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 4
5 Nuclear new build projects today Expensive and long lasting complex, multi-national projects HCP 3 French /Chinese consortium building a NPP in UK SINOP Japanese / American consortium building a NPP in Turkey based on French (RCC) /American (ASME) design codes OR Challenge: Permanently changing requirements from different cultures and sources Requirements management TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 5
6 Why delays? Why cost overruns? -Complex projects -Supply-Chain is complex -OEM, manufacturers, owners, operators on different locations -High safety standards -Changing requirements (Regulator...) -Different understanding of codes / specifications / regulations TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 6
7 How to avoid cost overruns and delays? -Solid project management -Managing and controlling the Supply-Chain -Quality control / Quality assurance (components and plant) - Translator for all involved parties in codes / standards / regulations needed -Support in Know-how and staffing to manage the resources on the side of the regulator, manufacturers, OEM TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 7
8 Positive Example: UAE Barakah Quality assurance for nuclear power plant About 270 km Abu Dhabi Barakah Nuclear Power Plant (BNPP) Source : 2012 KEPCO E&C Sustainability Report, Google Map Utility owner: ENEC (Emirates Nuclear Energy Corporation) Type: APR 1400; Capacity: 5,600 MWe EPC company: KEPCO (subcontractor: KHNP, KEPCO E&C, Hyundai E&C, Doosan Heavy Industry, Samsung C&T) Completion plan: Unit 1 (May, 2017), Unit 2 (May, 2018), Unit 3 (May, 2019), Unit 4 (May, 2020) QA/QC external Code consultancy / Training Translator for local requirements and specification of the OEM External Managing / consulting the supply - chain TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 8
9 1 st party to 3 rd party conformity assessment Inspection by Contractor Inspection by Contractor Independency and Transparency Independent Inspection Entity Independent Inspection Entity Nuclear Safety Authority Statutory Inspection Voluntary Inspection 3 rd Party Inspection by Contractor Licensee / Owner charges Inspection Entity 2 nd Party Inspection by Supplier 1 st Party TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Folie 9
10 New build: Licensing for nuclear power plants: Requirements Assessment & consulting services for authorities Supervisory structures has to be created / optimized / adapted to new build NPP Developing a licensing procedure Conducting feasibility studies Quality management system Certification System for components licensing documents with respect to regulation compliance for: Siting Environmental impact analysis Safety assessments Hazard analyses Quality assurance Training Customised training programmes Specialised expert workshops TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 10
11 Nuclear new build projects today / UK Horizon BWR Requirements management TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 11
12 Nuclear new build projects today / UK Horizon BWR Requirements management TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 12
13 Actual situation: Generic design assessment process (GDA) UK Regulator / ONR scope of requirements Technical Consultant Independent Nuclear consultant Design review / approval Safety Case / reliability Study Certification system Hazard identification Siting support Design review Quality assurance Environmental Impact Study Hazard Analyses Compliance of specification Plant Security & Fire Protection Radiation Protection Decommissioning & Radioactive Waste Management TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Folie 13
14 New Build: Design and construction of nuclear power plants What does it mean? Assessment & consulting services for authorities and manufacturers Evaluation of plant and reactor core designs Deterministic and probabilistic safety analysis Review of structural design against human-induced and natural events Evaluation of the supply-chain Prequalification of components Evaluation of quality assurance concepts Evaluation of radiation protection concept Evaluation of operating manuals and procedures Training Customised training programmes Specialised expert workshops TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 14
15 New build: Commissioning for nuclear power plants OEM, Manufacturers and operators: handling the Supply-Chain Quality Assurance / Quality control on components manufactured Understanding of the regulation Preparation of licensing documentation Establishment of a quality management system Risk analyses e.g. FMEA, HAZOP or RAM-studies TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 15
16 Qualification of nuclear components NPP Olkiluoto 3, Finland (EPR) Construction of EPR at Olkiluoto: design review of : Emergency diesel generators Safety related valves Heat exchangers and vessels Piping components and systems All safety related HVAC components Component support structures Scope of our work: Design review (e.g. seismic calculations, FEM analysis, GIPs and FIPs) Construction inspection at the manufacturer (e.g. functional test, compliance with construction plan) For SC3, SC4 and EYT components according to YVL 1.3 Commissioning inspection from 2015 TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 16
17 Finnland: Projekt Hanhikivi 1 Consultant for Fenovioma WWER-1200 Manufacturer: ROSATOM In operation: 2024 TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Folie 17
18 National Regulator: Regulatory background in Finland -Rule setting / Regulatory body -Supervision of the supply-chain itself (class 1 components) -Supervision of the supply-chain: approving 2nd parties to do the inspection / acceptance tests for class 1-3 components -Approval of the site and plant
19 Our Role in Finland STUK Decision 1/T412154/2012: TÜV SÜD Industrie Service GmbH is an Approved Inspection Organisation for conformity evaluation and approval of design & manufacture of mechanical devices and structures for the OL3 project according to YVL 1.3 (previous YVL guides) Validity: for NPPs under construction and in operation, but only until the current YVL guides have to be applied to all NPPs, which will be decided by STUK - expected in 2015 Status: approved on 29 th March, 2012 STUK Letter 8/0010/2014 STUK invites the authorised inspection organisations to apply for approval according to the new YVL E.1, which has replaced the YVL 1.3 Validity: for new build NPPs at the moment, for NPPs in operation and under construction after a forthcoming STUK decision Status: Approval expected in week 42/2015
20 Our Role in Finland STUK Decision 1/T /2015: TÜV SÜD Industrie Service GmbH is an Approved Testing Organisation for testing of mechanical equipment and structures in safety classes 1 to 3 and EYT according to YVL 1.3 Validity: for FORTUM s Loviisa 1 and 2 until 15 th July, 2020 Status: approved on 15 th July, 2015
21 Our Field of Activities in Finland YVL inspections according to YVL 1.3: Design review and construction inspection for SC3, 4 and EYT components (pumps, valves, pressure vessels, EDG and SBO diesel equipment, HVAC) Commissioning inspections are expected from III/2016 on Combined experience of 42 years (man years) in the Finnish inspection business since 2004 / total turnover about 7,8 million EURO
22 Our Field of Activities in Finland Expert s opinions, case studies, review and supervision for all Finnish utilities: TVO: evaluation of specifications and procedures (project specifications OL3 / configuration managment) FENNOVOIMA: review of PSAR Chapter 2 (geography, geology, meteorology and seismology) FORTUM: plant and system case studies (moisture separator reheater / HP turbine, APROS validation, supercritical pressure calculation) Combined experience of 6 years (man years) / total turnover about 0,5 million EURO
23 New Build: Support the OEM / manufacturers / owners / operators of nuclear power plants Owner s engineer Code consultancy for the OEM, manufacturers Alignment of specification and regulation Qualification of Manufacturers / Vendor qualification Support for the preparation of deterministic and probabilistic safety analysis Risk analysis e.g. FMEA, HAZOP or RAM-studies Prequalification of components Certification of components Support of setting up quality assurance concepts, protection concepts, operating manuals HSE Type, Acceptance and Commissioning testing Manufacturing supervision Concrete testing Training Customised training programmes Specialised expert workshops TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 23
24 Quality control ShinKori 1&2 -QA/ QC -Owners Engineer -Supply-Chain -code consultancy TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 24
25 Renewal of HP turbine and moisture separator reheater NPP Loviisa, Finland (VVER 440) Modernisation of Loviisa: Renewal of several components Review of transient behavior Analyses of operational transients and accidents (e.g. loss of coolant) Scope of our work: Performing thermohydraulic analyses with APROS for different plant configurations (two turbine shaft lines) Validation of model and results Interpretation of results, recommendations for future work APROS model and analysis instructions submitted by FORTUM TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 25
26 TÜV SÜD Accreditations Accreditations Our expertise standards DIN EN ISO/IEC 17020: 2012 (DAkkS) DIN EN ISO/IEC 17025: 2005 (DAkkS) ISO 9001: 2008 ISO 14001: 2004 KOLAS IAEA ASME NUREG KTA (Germany) SAPs (UK) KEPIC (Korea) PNAE (Russia) RCC (France) YVL (Finland) TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 26
27 What South Africa needs for NPP New Build Global support Ensure transparency Build up of a supply-chain Owners Engineering Code consultancy and Translation of Specification / Regulation. Safety analysis and transparent approval process with stringent quality control of manufacturing and construction. Code consultancy, quality manuals, quality control and certification services Enabling the local industry to manufacture for New Build (also international). Expediting / Commissioning: check the supply-chain independently, make sure that the components are in line with regulation / specification (of the OEM) TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 27
28 Contact us today! Dr. Boris Gehring Head of Power & Systems Business Unit Head of Nuclear Energy Business Unit TÜV SÜD AG Industry Service T: M: TÜV SÜD AG 30/03/2016 TÜV SÜD Corporate presentation Slide 28
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