AP1000 Modularization Experiences:

Challenges and Opportunities:

The AP1000 Case in China

IAEA Workshop on Construction

Technologies for Nuclear Plants
Duke Energy Paul Anderson Auditorium
Charlotte,, NC
August 19, 2010

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 AP1000 Modularization Experiences:

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 AP1000 Standardized Plants

Conventional nuclear p plants were designed

g based on
limited information available at the time of their
construction (just in time deliveries)

Modularization was limited

Stick Build was the term in plant construction

Standardization benefits were minimal

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 AP1000 Standardi
Standardized
ed Plants

AP1000 is Different

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 AP1000 Construction Approach
Simplification of systems
Major reduction in bulk materials and field labor
Maximize use of modularization
rail-shippable equipment and piping modules
large structural modules
Assembled on-site from rail-shippable structural modules
Factory-based manufacturing and assembly of modules
Predictable,
Predictable short manufacturing schedule
Improved quality control
Pre-testing and inspection prior to shipment
Streamlined field installation
Modules reduce field labor and overall schedule duration costs (CII
survey ranged from 12-15% for power projects reviewed)
Use of detailed work sequencing

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 Modularization Impact on Construction
Reduced schedule and manpower
Module fabrication performed parallel with
civil / structural work
Optimizes and levels man loading for
mechanical
and electrical work
Site congestion reduced
Inspections performed at fabrication shop
Reduced on-site work

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 Modularization
Impact on Construction (cont
(cont.))
Concrete placement setup time and placement
time is drastically reduced
Field damage is limited
Timely material deliveries are addressed
Repetitive tasks benefits over unique tasks

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 Modularization Impact
PLUS DELTA
Reduce Construction IIncreased
dEEngineering
i i ffor
Schedule Modules
Reduce Field Work and Increase Temporary
Manpower On-site
On site During S pport Structure
Support Str ct re / Lifting
Construction
and Rigging Requirements
Increased Productivity and
Quality Control at Module Early Material
F b i
Fabrication
i Facilities
F ili i Requirements
Standardization Reduces Additional Transportation
Costs for Multiple Plant Cost (Large trailer truck,
Orders Barge)

Reductions in Construction Schedule

Demonstrate Net Savings

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 Challenges of Modularization
Early design completion
Procurement of modules and associated equipment
As Procured equipment may be different from As
Designed
Parallel fabrication of modules early in the construction
phase
Many modules are near critical path sequence due to
parallel fabrication
Marshalling warehouses Ensure correct types and
numbers of components go to module fabricators
Larger lay down area on assembly site

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 Location in Plant

Shield Building

Steel
Containment Security RelatedInformation
Vessel Withholdunder10CFR2.390

Auxiliary Building

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 Mechanical Modules: Types
Q/R/W Type: Piping/Commodity Modules*
Piping, Valves, HVAC, and(or) Electrical
Raceway combined on a common structure
KQ/KB/KT Type: Equipment Modules
Modules*
Piping and Equipment outfitted on common
structure/skid
KU Type: Service Modules

* Letter designations indicate locations

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 Containment Piping Module Q223:
DVI A Valve Module

Si (N x E x Height):
Size H i ht)
28 x 37
37--3 x 10-
10-9
[8.5mx11.3mx3.3m]

Dry Weight:
33,000 lbs. [15 Mg]
Room (Area):
11207 (1124)
Plant Elevation:
96--0
96
Classification:
S f t
Safety

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 Containment Piping Module
Q601: RCS Stages 1, 2, 3 ADS Module
Si (N x E x Height):
Size H i ht)
12 x 12 x 15
15--9
[3.6mx3.6mx4.8m]

Dry Weight:
110,000 lbs. [50 Mg]
Room (Area):
11603 (1162)
Plant Elevation:
153--0
153
Classification:
S f t
Safety

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 Structural Modules: Types
CA/CB Type: Steel formwork modules
Concrete-filled
C t fill d or poured
d aroundd steel
t l fframe
CA modules take structural credit for steel
CG/CH Type:
T Set
S t in
i place
l as partt off building
b ildi
structure
CH modules outfit mechanical commodities (i (i.e.
e
grating)
CG modules have not outfitting
CS Type: Stairway modules

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 CA20 Structural Module

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 CA20 Structural Module

CA20 comprised of 72
Sub--Modules:
Sub
Size (N x E x Height):
44--0 x 68
44 68--9 x68
x68--0
[13mx21mx20.7m]

Dry Weight:
1,629,903 lbs. [739 Mg]
Room (Area):
N/A
Plant Elevation:
66--6
66
66 6
Classification:
Seismic Category I

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 CA20 Sub
Sub-Module
Module Configurations

L-Shapes
p Flat Panels T-Shapes
p Floor Plates
8 Sub-Modules 17 Sub-Modules 3 Sub-Modules 32 Sub-Modules

Miscellaneous
12 Sub-Modules

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 CA20 Major Sub Assemblies
Sub-Assembly 4

Sub-Assembly 3

Sub Assembly 2
Sub-Assembly

Sub-Assembly 1

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 CA20 - Outfitting

CA20 comprised of 72
Sub--Modules:
Sub
Outfitted CA20 Lift:
R219 R451 2 Piping Modules
7 Equipment Modules
2 Pipe Assemblies

R261
After CA20 is Installed:
5 Additional Piping
Modules attach per
construction sequence

R104 R161

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 Summary Standardized Design
Modularization Advantages
Cost
Major
M j reduction
d ti in i bbulk
lk materials
t i l on site
it
Reduce field work and on-site manpower
Streamlined Construction
Constr ction Sched
Schedulele
Predictable and shorter manufacturing
Pre-assembly
Pre assembly and testing of major components
Parallel construction activities
Quality
Work performed in optimal conditions

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