Olkiluoto 3 Project. AREVA Suppliers Day Warsaw October 4, 2011
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1 Olkiluoto 3 Project AREVA Suppliers Day Warsaw October 4, 2011 Virginie MOUCQUOT-LAIHO AREVA OL3 Project Management Office & Communications Manager AREVA Reactor & Services - New Builds
2 EPR Project Fleet experience building Main priorities: Security, Safety and Quality Ensuring a safe and steadily working plant for a period of 60 years Evolution on technology: 4 safeguards & cooling systems Core Catcher APC (Airplane Crash) shell Maintenance during operation OL3 Project presentation October 4, p.2
3 Olkiluoto General View and layout OL3 Project presentation October 4, p.3
4 Structure of the OL3 Consortium (CFS) TVO Plant Contract FramatomeANP AREVA Consortium Agreement Siemens AG SAS France GmbH Germany OL3 Project presentation October 4, p.4
5 OL3 Turnkey Scope Turnkey, firm-price contract for: Design, procurement, construction and commissioning Siemens / Turbine Island (TI) Civil Work Turbine + Generator Balance of TI AREVA NP / Nuclear Island (NI) Civil Work NSSS Balance of NI (BNI) Operational I&C Balance Of Plant Training of TVO Operators Overall project coordination TI CW TI NI CW NI Siemens PG AREVA NP OL3 Project presentation October 4, p.5
6 Buildings of Nuclear Island - NI NI/TI Buildings Buildings of Turbine Island - TI Waste Building Auxiliary Building Fuel Building Diesels 2+1 Building Access Building Electrical Building Safeguard Building 4 Reactor Building Safeguard Building 1 Turbine Building Diesels 2+1 Building Safeguard Buildings 2+3 Circulating Water Pump Building Ducts & channels OL3 Project presentation October 4, p.6 Essential Service Water Pump Building
7 25/04/11 25/06/11 25/08/11 25/06/07 25/08/07 25/10/07 25/12/07 25/02/08 25/04/08 25/06/08 25/08/08 25/10/08 25/12/08 25/02/09 25/04/09 25/06/09 25/08/09 25/10/09 25/12/09 25/02/10 25/04/10 25/06/10 25/08/10 25/10/10 25/12/10 25/02/ CFS Site Manpower CFS ~ 3, nationalities NI ~ 3,115 TI ~ 355 NI TI Total OL3 Project presentation October 4, p.7 25/04/07
8 CFS nationalities Country Finland Poland Germany Croatia France Estonia Bosnia and Herzegovina Others % of site population 29% 20% 17% 9% 6% 4% 2% 12% OL3 Project presentation October 4, p.8
9 NI Organisation System-based organization Evolution in project s organization along with the construction phases Transfer of Project team to Site in 2009 Switch to system-based organization in 2011 Basic Design Detail Design Manufacturing Design Project Management Engineering & Tools (3D model) Procurement Construction Commissioning Transfer of Project team to Site Project Management Procurement System-based organization: engineering, construction, commissioning Headquarters Site OL3 Project presentation October 4, p.9
10 Health & Safety first CFS Safety indicators Preparation and continuous actions for numerous challenges Current co-activity: finishing works, electro-mechanical activities and new subcontractors on site (Works at height, superposition, X-rays, Tests) Electrical activities complexity and risks associated (medium voltages, energization...) Commissioning activities and ramping-up including Permit-To-Work process To keep the Project safety Indicators at the right level: Continuous increase of H&S surveillance Restricted areas Housekeeping organization Despite complexity, results quite good and in continuous improvement Frequency since 01/02/2005 = 10.8 Gravity since 01/02/2005 = 0.11 OL3 Project presentation October 4, p.10
11 Health & Safety CFS Frequency Rate August 2011 FREQUENCY RATE OL3 (Lost Time Accidents per million worked hours) Frequency on 12 months Frequency since 01/02/2005 Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May Jun- 10 Jul- 10 Aug- 10 Sep- 10 Oct- 10 Nov- 10 Dec- 10 Jan- 11 Feb- 11 Mar- 11 Apr- 11 May- 11 Jun- 11 Jul- 11 Aug- 11 OL3 Project presentation October 4, p.11
12 GRAVITY RATE OL3 (days lost per thousand worked hours) Health & Safety CFS Gravity Rate August Aug- 09 Sep- 09 Oct- 09 Nov- 09 Dec- 09 Jan- 10 Feb- 10 Mar- 10 Apr- 10 May- 10 Jun- 10 Jul- 10 Aug- 10 Sep- 10 Oct- 10 Nov- 10 Dec- 10 Jan- 11 Feb- 11 Mar- 11 Apr- 11 May- 11 Jun- 11 Jul- 11 Aug- 11 Gravity on 12 months Gravity since 01/02/2005 OL3 Project presentation October 4, p.12
13 Nuclear Safety Culture and Quality Continuous development for the best quality result Continuous development in Nuclear Safety Culture deployment Language Mapping Trainings, individual awareness and campaign Specific trainings for all employees on site per discipline ( inductions since 2005 / ref. TVO) Supervision charter Continuous information to reinforce application to all site employees Tool box talks on spot Surveys conducted with Owner Quality assessment Qualification audits Surveillance programs Lessons learned OL3 Project presentation October 4, p.13
14 Project Progress Overall Project progress: 80% Nuclear Island construction: 2/3 of all the works completed Piping, electrical and ventilation: full speed progress Primary system: all main components installed and welded Nuclear Island commissioning (164 systems) Documentation in approval process First phase of commissioning launched prior to fuel loading Full scope simulator ready for training of operators Turbine Island ready for commissioning OL3 Project presentation October 4, p.14
15 Energomontaz Polnoc / Polimex Involvement of Poland Main Polish Suppliers Containment Steel Liner manufacturing Elektrobudowa SA Electrical and I&C equipment installation KMW Engineering / Brochier Ducts pre-fabrication and HVAC equipment installation Polbau Civil construction Works for both the Turbine & Nuclear Islands OL3 Project presentation October 4, p.15
16 Consortium Civil Works International organizations Nuclear Island Civil Works main contractors: Bougyes and Heitkamp Labor: mostly Polish Construction workers Main Heitkamp subcontractor for Turbine Island: Polbau Several hundreds of Polish Civil Worker have been involved in the OL3 Project OL3 Project presentation October 4, p.16
17 Reactor Building NI Civil Works completed Concreted Steel reinforcement ongoing OL3 Project presentation October 4, p.17
18 Reactor Building Containment Steel Liner Containment Steel Liner by Energomontaz Polnoc / Polimex: Full qualification by AREVA/TVO/STUK Safety Class 2 Component and welding, performance of all Non Destructive Testing, pre-assembly, transport Manufacturing of all liner segments in Poland Support during installation on OL3 OL3 Project presentation October 4, p.18
19 Reactor Building From Liner slab shipment to Containment Steel Liner: Engineered at Babcock Noell/Germany Prefabricated by Energomontaz Polnoc / Polimex in /Poland Shipped in Gdansk for delivery to OL3 Finally welded, lifted and installed inside the OL3 Reactor Building on Site OL3 Project presentation October 4, p.19
20 Reactor Building Liner slab From lifting Liner - May slab to 2006 May 2006 Lifting of the liner bottom part. Lifting of the Inner Dome September 6, 2009 Containment Steel Liner: Engineered at Babcock Noell/Germany Prefabricated at Energomontaz/Poland Installed on OL3 Construction Site OL3 Project presentation October 4, p.20
21 Containment Liner lifting June 2007 OL3 Project presentation October 4, p.21
22 Reactor Dome Arrival of the Inner Dome week 19, 2009 Shipment delivery of the Reactor Dome from Poland on and lifting and installation on Lifting of the Inner Dome September 6, 2009 OL3 Project presentation October 4, p.22
23 Reactor Building Pre-stressing completed in 2010 OL3 Project presentation October 4, p.23
24 to external dome completion OL3 Project presentation October 4, p.24
25 Primary components Installation completed OL3 Project presentation October 4, p.25
26 Heavy Components Introduction of the RPV June 18, 2010 OL3 Project presentation October 4, p.26
27 Primary components Installation of Steam Generators OL3 Project presentation October 4, p.27
28 From 3D model to an isometric drawing OL3 Project presentation October 4, p.28
29 HVAC works Ducts and HVAC equipment HVAC works by KMW Engineering / Brochier Erection & Pre-commissioning of all Heating, Ventilation and Air Conditioning Systems (including pre-fabrication of HVAC Ducts in Poland) Contract of HVAC duct manufacturing and installation to consortium Brochier/KMW Installation of all HVAC ducts as well as other HVAC equipment such as dampers, fans, filters, air handling units, etc. Majority of staff from Poland OL3 Project presentation October 4, p.29
30 Electrical and I&C Battery Room Electrical and I&C works by ELEKTROBUDOWA SA Erection & Pre-commissioning of all Electrical and I&C Components and Systems (EM8 & 9) for OL3 Project Additional Nuclear Installation contracts from AREVA for other Projects OL3 Project presentation October 4, p.30
31 Electro-mechanical installation TI I&C Cabinets OL3 Project presentation October 4, p.31
32 Electro-mechanical installation Fuel pools leak tight test OL3 Project presentation October 4, p.32
33 Main Control Room (MCR) OL3 Project presentation October 4, p.33
34 Full Scope Simulator (FSS) Factory Acceptance Tested and TVO Operators training exercises OL3 Project presentation October 4, p.34
35 Primary circuit completion Paths Forward NI Construction & Commissioning Electromechanical installation completion for all systems I&C equipment installation Commissioning First phase finalization Completion of the operators training with the Full Scope Simulator Integration of TVO staff in Operation Integrated Organization Preparation for fuel delivery, fuel loading Preparation of nuclear commissioning phase OL3 Project presentation October 4, p.35
36 EPR Experience Feedback Status OLKILUOTO 3 FLAMANVILLE 3 TAISHAN 1&2 FUTURE EPRs EPR projects currently in Finland, France, China Licensing efforts proceeding in the USA and UK Full experience gained and shared within projects, to ensure: Good practices, ideas, challenges, improvements transfer to other projects Configuration management of the Standard EPR design Base for the future bids Including appropriate adaptations AREVA experience feedback: a continuous and ongoing process Our Target: EPR construction reliability and certainty, low risks and profitability of investment. OL3 Project presentation October 4, p.36
37 EPR Experience Feedback Being prepared to ensure project execution DOCUMENTATION: timing is all Adequate preparation time before construction Design completion before implementation: Design Configuration and change management, Detailed design with design specifications of all components, 3D-model (from drawings up to isometrics) for early start of detailed design (civil, piping, etc.) Suppliers documentation ready including Construction Plans and Inspections HUMAN RESOURCES: qualified personnel Skills qualification and local applicable requirements Suppliers chain to comply with all local applicable laws and regulations SUBCONTRACTING CHAIN: short and qualified Not only tier 1 Suppliers high qualification: by anticipation (including construction and/or manufacturing methods) and mastered Short suppliers network: maximum tier 3 OL3 Project presentation October 4, p.37
38 OL3 Experience Feedback In a nutshell Executed Detailed Design and computerized 3D model Standardized Primary Components (internal manufacturing facilities, on-the-shelf components) Globalized supply chain and clear production ratios Feedback experience process completely implemented (> 1200 items) TVO & CFS strengthening their partnership, heading to Fuel Loading and nuclear commissioning OL3 Project presentation October 4, p.38
39 Thank you! OL3 Project presentation October 4, p.39
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