August 2014 Lee, Myung Key - Atoms for Peace and Development · Technology Self- reliance Program Project Contract (YGN 3&4) ... - Computer Program - Training ... Korean Technology

August 2014

Lee, Myung Key

KEPCO International Nuclear Graduate School

Contents

1. Overview of Localization Program

2. Localization Experience

3. Development of Korean NPP

4. Recommended Program on Localization

Overview of Localization Program

4

History of Technology Development

Late 1990s

2000s 1980s

Introduction

of NPP(‘71~

Kori 1

Kori 2

Wolsong 1

Early 1990s

Establishment of

Localization (`~’85)

Kori 3&4

Ulchin 1&2

Yonggwang 1&2

1970s

Technology Self-reliance

Turn-Key Approach

Component Approach

OPR1000

Development (`95)

Yonggwang 3&4

OPR1000 Const.&Opr.

APR1400

Development (`02)

Ulchin 3,4,5&6

Wolsong 2,3&4

Yonggwang 5&6

Shin-Kori 1&2

Shin-Wolsong 1&2

2010s

APR1400 Construction

APR+

Development (`15)

Shin-Kori 3&4

(Under Const.)

Shin-Ulchin 1&2

(Under Const.)

Shin-Kori 5&6

(Planning)

Shin-Ulchin 3&4

(Planning)

4

5

1970's

Introduction of NPP

Turnkey approach

1980's

Accumulation of NPP

Technology

Component approach

1990's

Technology Self-Reliance

Development of OPR1000

Development of APR1400

Foreign - Local Joint Design, Joint Manufacturing

- Foreign : Prime Contractors

- Local : Sub-contractors

Step by Step Approach

Foreign Contractors

Led by Local Contractors

- Local : Prime Contractors

- Foreign : Sub-contractors

Basic Policy

6

Basic Policy

1970's

1st Generation

1980's

2nd Generation

1990's

3rd Generation

Turn-Key Non Turn-Key Non Turn-Key

KRN #1,2

WSN #1

KRN #3,4, YGN #1,2,

UCN #1,2 YGN #3,4, UCN #3,4

Foreign Contractor

Local Labor Supply

Foreign Prime Contractors

Local Sub-contractors Local Prime Contractors

Foreign Sub-contractors

Technology

Dependency

Technology

Accumulation Technology

Self-Reliance

Evolution of Project Structure

■ NPP Introduction Program

■ Technology Accumulation Program

■ Korean Technology Development Program

Localization Experiences

8

Preparation for 1st NPP

Tasks

NPP Steering Committee

NPP Feasibility Study Team

Candidate Sites Survey

Manpower Development

Nuclear Technology Survey

Site Selection

Reactor Type Selection

Contract

Construction Start

’62 ’63 ’64 ’65 ’66 ’67 ’68 ’69 ’70 ’71

10 years

NPP Introduction Program


1st NPP, Turnkey Approach

Bidding & contract scheme

Kori #1 : International open bidding, Turnkey

Kori #2, Wolsong #1 : Sole source bidding, Turnkey

Division of responsibility

Prime contractor

Project management, including quality control

Design and Engineering

Equipment & material supply

Construction & Start-up

Owner (KHNP)

Site preparation & miscellaneous building construction

Supply of sand, cement, etc.

Participation in Start-up


Localization with Turnkey Approach

No experience in NPP construction

Fully dependent on foreign technology due to limited infra-

structures to promote localization

No localization & technology transfer programs, except for

operation & maintenance

Localization achieved through implementation of projects

Kori #1 : 8.0 %

Kori #2 : 12.9 %

Wolsong #1 : 13.9 %

11

Project structure

♣ Project implemented by foreign prime contractor

Prime Contractor

W/H or AECL

NSSS T / G A / E Construction BOP Commission-

ing

Foreign Foreign Foreign/Local Foreign/Local Foreign Foreign

Owner

KHNP(KEPCO)


12

Technology Accumulation Program

Outline

Kori #3,4, Yonggwang #1,2, Ulchin #1,2

Component approach

International open bidding

Major Policies

Perform under the leadership of government & KHNP

Key role in project management by KHNP

Set-up localization execution committee & implement long-

term localization plan

Establish national localization policy for project management,

equipment supply, construction & start-up

Overview

13


♣ Overall Project Management performed by Owner

Owner (KHNP) Foreign Technical

Consultant

NSSS

Foreign Prime Contractor

T / G


S / U

KHNP

BOP

KHNP

A / E


Construction

Local Constructor

Local

Doosan

Local

KOPEC

Project Management

Local &

Foreign

Project Structure

14

Machinery Industry Promotion Act (1967~)

Long-term Power Development Plan

MOCIE / KHNP

Program for machinery Industry Promotion

MOCIE

Submittal of Equipment Procurement Sources

KHNP

Decision of Procurement Sources

Localization Execution Committee Items not to be localized Items to be localized

Localization

Local Suppliers

Import

Foreign Suppliers


Imported Item Report and Approval System

15


■ Major components supplied solely by Doosan

■ BOP supplied by open bidding under responsibility of KHNP

■ Enhancing manufacturing capability by categorizing

equipment procurement source

CASE I : Local Supply

CASE II : Local/Foreign Joint Supply

CASE III : Foreign Supply

■ Construction by local companies as prime contractor

■ No technology transfer program for A/E and NSSS / TG

design, except for partial participation in the projects in the

form of OJT

Localization Program

16


44

35

-

13

-

14

Design (%)

Equipment (%)

-

8

46

10

20

30

40

50

KRN #1 KRN #2 WSN #1 KRN

#3,4

YGN

#1,2

UCN

#1,2

Design (%) Equipment (%)

(%)

40

37

29

Results of Technology Accumulation Efforts

17

Goal : 95% by 1995

MOCIE KHNP

Establish Nuclear Technology

Self-reliance Program (1984)

Overall PM

KHNP

Maintenance

KPS

Construction

Local Constructor

Start-Up

KHNP

NSSS, T/G

Doosan

Design & Engineering

KOPEC

BOP

Local/Foreign Suppliers

Fuel

KNFC

Korean Technology Development Program

Basic Strategy

18


Experience feedback from Previous NPPs

Implementation of Yonggwang #3 & 4 Project

Technology Transfer Contract

Technology Development

- Design Evaluation & Qualification

- Equipment Manufacture and Test

- Step by Step, Project by Project

Technology Accumulation

T/T Documentation

Acquisition of

Tech. Document Manpower Qualification

Manufacturing Design & Engineering

Project Management

Training Technical Consultant

Nuclear

Technology

Self-

reliance

Implementation Plan

19

Technology Self- reliance Program

Project Contract (YGN 3&4) - Phase I : S&L/WEC lead - Phase II : KOPEC lead

Technology Transfer Contract (YGN 3&4)

- Reference Document and Drawing - Computer Program - Training

Technology Localization - Utilizing reference document transferred from S&L/WEC

- Developing KOPEC reference document

Achieved Technology Self- reliance


Engineering Technology Development

20

Year '80 '85 '90 '95

Self-Reliant A/E

Basic Design: Local Detail Design: Local

UCN #3,4 Self-Reliance Implementation

Basic Design: Local + Foreign Detail Design: Local

YGN #3,4 Self-Reliance Preparation

Basic Design: Foreign

Detail Design: Foreign + Local

KRN #3,4, UCN #1,2, YGN #1,2 Foreign A/E

KRN #1,2


Self-Reliance

Progress

Partial

Foreign Manpower

Participation

Self Commitment

of Basic/Detail

Design Supported

by Foreign

Manpower Aux System Design : Intake/Discharge,

Water Treatment, Aux Boiler sys., SWRD etc

Main System Detail Design :

Small Pipe Design, Stress Analysis etc Self Commitment of Minor Facilities

Evolution of Engineering Technology

21

Scope of Technology * Component Design * Manufacturing * Project Management

Licensed

Products

* Reactor Vessel * Reactor Vessel Internal

* Steam Generator * Control Element Drive Mechanism

* Pressurizer * Reactor Coolant System Support

* Primary Piping * Refueling Equipment

Objective

To obtain the capability of component design, manufacturing and project

management for NSSS and T/G

Technology Transfer Agreement was made between Doosan and WEC(NSSS)/GE(T/G)

To provide ; 1) Technical Documents & Computer Codes

2) On the Job Training

3) Technical Support & Consultation

Equipment Manufacturing Technology Development


22


Contract: Local

UCN #3,4 Main Contract: Local

Sub Contract: Foreign

YGN #3,4

Cement, Aggregate

BOP (PP, HVAC, SW/YD...)

Main Equip. ( Partial Ass'y of S/G, T/G...)

NSSS, T/G, BOP

(T/T contract with

Foreign Contractors)

NSSS, T/G, BOP

Year '80 '85 '90 '95

Main Contract: Foreign

Sub Contract: Local

KRN #3,4, UCN #1,2, YGN #1,2 Foreign Supply

KRN #1,2

Localization

Progress

NSSS : Nuclear Steam Supply System, T/G : Turbine/Generator,

BOP : Balance of Plant, A/E: Architect Engineering

Evolution of Equipment Manufacturing

23

Korea Nuclear Fuel

Co.,Ltd ( KNFC ) KAERI

TIC with SIEMENS

License agreement

for manufacturing of

Fuel Assembly and

core components

Training

Supervisory services

during installation

ESC with SIEMENS

Basic design of the

plant

Foreign equipments

Upon request : Delivery

of FA structural

components and

conversion services

TIC with SIEMENS

License agreement for

FA design, engineering

& core management.

Joint design in 1989/90

Technical information

Training

Licensing and Localized Equipment

Construction and Installation


TIC : Technology Introduction Contract

ESC : Engineering Support Contract

FA : Fuel Assembly

Fuel Manufacturing Technology

Development of Korean NPP

■ Development Program

■ OPR1000 Development

■ APR1400 Development

25

2010 2005 2000 1995 1990 2019 1980

APR 1400 (construction

/planning) Shin-Ulchin 1&2

APR 1400 Nth

Shin-Kori 3& 4 APR 1400 Development

Shin-Kori 1& 2

Shin-Wolsong 1& 2

Improved

OPR 1000 (construction)

Ulchin 3&4

Yonggwang 3&4

Yonggwang 5&6

Ulchin 5&6

OPR1000 (Operation)

Development Program

26

Applied Project

Yonggwang #3,4 and the following projects

Contract scheme

Prime contractors : Local companies

Doosan, KOPEC, KNFC were selected as the prime contractors to

promote technology accumulation

Sub-contractors : International open bidding

Technology transfer to Korean companies was one of the major

bidding requirements

ABB-CE, GE and S/L were selected as the sub-contractors

because of their favorable technology transfer conditions

OPR1000 Development

Development Outline

27

OPR1000 Development

Owner (KHNP)

NSSS

DOOSAN / KOPEC

T / G

DOOSAN

BOP

KHNP

A / E

KOPEC

Construction

Local Constructor

ABB-CE

Project Management

GE S & L

Start-Up

KHNP

Local / Foreign

Implementation Structure

28

Experience of Previous Projects (KRN #1, KRN #2, KRN #3,4, YGN #1,2)

OPR1000

(UCN #3,4, YGN #5,6, UCN #5,6)

Accumulation of Technology Projects

(YGN #3,4)

• Implementation of Projects

- Joint Design/Manufacturing

- Independent Procurement,

Project Management

• TT for Design/Manufacturing

- Reference Document

- Computer Code

- Training & Consultant

• Self Technology Development

- Design Verification

- Repetitive Design

- R&D

Development Methods

OPR1000 Development

29

In Operation

1000MWe

COD: 1995

In Operation

1000MWe

COD: 1998

Technology Transfer

Reference

Project

YGN 3&4 (1000MW)

OPR

T/G Perry#2

(GE,1000MW)

PLANT DESIGN Yonggwang#1&2,

Byron & Braidwood

(KOPEC/S&L,1000MW)

NSSS Palo Verde

(CE,1300MW)

Replication

of

OPR UCN 3&4

(1000MW)

ERPI URD

ADF

Design

Improvements

NPPs

Experience

Feed-Back

Latest Codes & Std

Construction & Operation

- YGN # 5,6, UCN # 5,6

- Shin KRN #1,2

- Shin WSN #1,2

Development Process

OPR1000 Development

30

Design Features of OPR1000

2 Loop, 4 Pump RCS Design Power Level : 1,050MWe/2,825MWt Plant Design Life : 40 years Plant Availability : 80~87%

Advanced Design Features

Human Factors Engineering

Design against Severe Accidents

Leak Before Break (LBB) Concept

Increased Operability and Maintainability

Lower Occupational Radiation Exposure

31

APR1400 Development

■ Evolutionary ALWR based on OPR1000 and System 80+

■ Development Period : ’92 ~ ’02,

■ Standard Design Certificate : May 2002

■ First Concrete of First Commercial Plant (SKN #3,4) : Oct., 2008

Under Const. : 4 units

- SKN #1,2 (’12/’13)

- SWN #1,2 (’13/’14)

In Operation : 8 units

- YGN #3,4 / UCN #3,4

- YGN #5,6 / UCN #5,6

Under Const. : 4 units

- SKN #3,4 (’14/’15)

- SUN #1,2 (’16/’17)

Improved

OPR1000

OPR1000

1,000 MWe 1,000 MWe

APR1400

1,400 MWe

EPRI URD/EURD

KURD System. 80+ (CE, 1300MWe)

ADF/PDF

Latest Code & Std

Development Outline

32

Korea Brand Standard Nuclear Power Plants

APR1400 OPR1000

Pro

ven

Tec

hn

olo

gy

Power : 1,000 MWe

Life Time : 40 years

Const. : 51 months

Seismic : 0.2g (5.6)*

Evo

luti

on

ary

Gen

-III

Rea

cto

r

Power : 1,400 MWe

Life Time : 60 years

Const. : 54 months

Seismic : 0.3g (7.0)*

Advanced Power Reactor 1000 development currently under way

Recommended Program on Localization

■ Localization Program

■ Typical Program for Localization

34


Establishment of long-term Localization Program based

on the long-term energy plan led by Government &

project owner

Selection of one type of NPP Technology and repeated

order for standardization

Set-up of Localization Planning Committee

Set-up of policies for promoting national participation

Improvement of local industry’s capability

Basic Guideline

35


Connected with National Industry Development Plan

Covering all industrial sectors: heavy machinery, electrical,

chemistry, etc. as well as nuclear industry

Government’s strong support

Legislation and financial assistance to promote systematic

cooperation among local suppliers and plant owner

Assessment of local industries

For A/E, NSSS (Design & Manufacture), T/G, BOP, Construction,

Start-up and Overall Project Management

Long Term Plan

36

Government Long Term Energy Plan

Long Term Electric Power Development Plan

- Fossil (Coal, Oil, Gas, etc), Hydro, etc

- Nuclear Power Plant

Long Term NPP Development Plan

- 1st

NPP Introduction Plan

- NPP Technology Development Plan

NPP Technology Development Plan

- Infrastructure Development

- National Participation and Capacity Building

- Localization and Technology Self Reliance

Implementation Sequence


37

Organize project structures and responsibilities

Define scopes and responsibilities for government

authorities and related organizations

Decide leading entity for nuclear power plant construction

Close coordination and teamwork among Government,

project leading entity, local and foreign vendors

Active participation of local vendors


Implementation Program

38

Promote cooperative relationship with foreign partner that

possesses the following:

Proven technology with operational experience

Experience in technology transfer and equipment localization

through NPP projects

Ability to construct and operate NPPs most safely and

economically

Ability to arrange favorable financing



39

Establishment of long-term localization plan led by

Government & Owner

Establishment of NPP standardization program

Localization by step-by-step approach

Importance of owner's overall Project Management

capability

Close cooperation with experienced foreign companies



40

Typical Program for Localization

1st Step Technology Accumulation

- Implemented by foreign supplier with Local

participation

3rd Step

2nd Step Foreign - Local Joint Implementation

- Implemented by Owner with foreign assistance

Accomplishment of technology self-reliance

- Implemented by local prime contractor with

foreign assistance as sub-contractor

Program Outline

41

■ Turnkey contract for first two units

Local companies will participate for limited areas as sub-

contractor to foreign contractor

Starting with civil work and equipment installation

Field engineering as sub-contractor

Civil and Structural bulk material, non nuclear equipment

Construction as sub-contractor

Commissioning support

1st step : Technology Accumulation


42

Items of Localization Ratio

1. Equipment Supply 20%

- Low Pressure Heat Exchanger, Tanks, Piping in Turbine Building

- Low Voltage Cables, Lighting System

2. Design & Engineering

- Field Civil Engineering (limited portion)

3. Preliminary & Supplementary Works

- Site Preparation, Construction Offices

- Power Supply System, Tele-Communication Facilities

4. Construction Material & Installation

- Aggregate, Cement, Steel Material, Painting

- Equipment Installation, Cable Installation & Termination

5. Start-up Material Supply & Support


43

For 2nd and 3rd projects

Implemented by Owner with foreign assistance

Local industry will acquire further skill and expert knowledge

Joint design and extend to nuclear grade equipment

manufacturing

Joint design for power block

Joint manufacturing of nuclear grade equipment in NSSS

Construction by local contractor with foreign assistance

Start-up by Owner with foreign assistance

2nd step: Joint Implementation


44

1. Civil Work & Building 40%

- Design of Power Block & Auxiliary Building

- Construction Planning and Management

2. Equipment Supply

- Heat Exchanger, Tanks, Piping in NSSS

- Cranes & Hoist

- HVAC Duct & Stack

- Turbine Lubricating Oil System

- Fuel Storage Rack

- Cable, Lighting System, Grounding System


- Some Portion by Joint Participation

4. Construction & Startup

- With Foreign Assistance



45

For 4th and 5th projects

Establishment of technology self-reliance program

Development of standard NPP

Expected to participate in most areas of project:

Design by local prime contractor

Local supply of nuclear grade equipment

Construction by local prime contractor

Commissioning by Owner

3rd step: Technology Self-reliance


46

1. Equipment Supply 60%

- Safety & Non Safety Pump, Control Valve in NSSS

- Condenser

- Radwaste Processing System

- DC Power System, Auxiliary Motor

- Transformer, AC Power Distribution System

- Instrumentation & Control System


- Joint Implementation

3. Construction & Startup

- Technical Consultant



47

Case Study and Experiences on Local Industrial

Involvement in supply chains in Korea

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