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equipment overseeing section mainly coordinates with the manufacturing plant, and feeds back
to the plan management section.
The responsibilities of the plan management section are as follows:
a) Responsible for coordinating ASE to submit the plan of the manufacturer determination
and the contract signing, according to the project schedule and the supply plan of the
Russian-supplied items, tracking and supervising the preparation of the items for
manufacture;
b) Responsible for tracking and supervising the implementation progress of the item
manufacturing plan according to the project schedule and the Russian-supplied item supply
plan;
c) Responsible for the coordination and early warning of item manufacturing and delivery
schedule, and expediting the delivery of the delayed equipment in key-path;
d) Tracing the delivery date of Russian-supplied items, and collect the quantity, departure
date, transportation method, planned arrival of the items to be shipped;
e) Responsible for the coordination interface between the schedule plan of Russian-supplied
items and JNPC engineering management department.
The responsibilities of main/auxiliary equipment overseeing section as follows:
a) Responsible for coordinating and supervising the manufacturing plant to complete the
production readiness in accordance with effective manufacturing plan;
b) Responsible for supervising the manufacturing progress of the manufacturer according to
the effective manufacturing plan;
c) Responsible for controlling the manufacturing and delivery schedule of equipment,
analyzing schedule deviation, and feed back to the Plan management Section;
d) Responsible for submitting weekly progress reports;
e) Responsible for collecting and feeding back to the plan management section the
information on the preparation of the equipment for shipment, quantity, date of departure,
mode of transportation, and delivery documents of the shipped equipment;
2. Basis for schedule management
Our supply plans for the manufacturing schedule management are as follows.
Level 3 Project Schedule of construction Tianwan Units 7&8 and Xudapu units 3&4;
Level 3 Project Schedule of Equipment Supply Units 7,8 and Xudapu units 3&4;
The annual amendment to the general contract of equipment supply;
Delivery plan of over-size and heavy-weight equipment by sea;
Schedule of LLME milestones.
Based on these plans, the Plan Management Section formulates a plan control tracking table,
and the manufacturer prepares a detailed equipment manufacturing plan.
“制造和建设监督”国家研讨会交流资料
defects in the surfacing welding of the core shell section, the coordination period was as long as
5 months, and finally the core shell was rejected, and the core shell forgings of Unit 4 was
transferred for Unit 3 re-surfacing welding.
This is the picture of defects found in the surfacing welding of core shell. The first picture is the
defect revealed by local grinding in early stage,we can see a little long defect. The second
picture is the defects revealed by machine, We can see two adjacent circumferential long
defects.
The ultrasonic inspection of the anti-corrosion surfacing layer on the inner surface of the 3#
core shell section found that there are many indications in the fusion zone. The reason is
assumed improper adjustment of the welding equipment during the surfacing welding, resulted
in slag inclusions at the overlap of adjacent weld passes. According to ПНАЭГ-7-010-89
standard evaluation, some indications belong to exceeding standard defects, and some were
not exceeding. Manufacturing Plant developed the non-conformity report.
The corrective measure was to partially remove the surfacing layer where the exceeding
standard defects, and repair it locally. When we reviewed the non-conformity, we considered
that the defects was due to the lack of fusion at the overlap of adjacent weld passes. However,
due to the limitation of the ultrasonic detection method, some linear unfused defects in the
circumferential direction were not detected.
The core shell of reactor vessel was in the most severely irradiated area of the reactor core.
After irradiation embrittlement, the unfused defect was easy to expand, and there was a risk of
cracking. The inner surface surfacing layer of core shell section should be entirely machined
removed and re-surfaced. Manufacturing plant disagreed with my opinion.
Under my insistence, after nearly 5 months of communication, in order to verify the correctness
of my opinion, the plant adopted the method of machining to remove the surfacing layer with a
width of about 3 bead lengths. The revealed defects tend to surround an entire circle.
Ultimately, the plant accepted my perspective and removed entire surfacing layer. However,
due to the large depth of the fusion zone of the surfacing layer, the thickness of the base metal
decreased when defects were removed, which eventually led to the rejected of the core shell.
A similar non-conformity also appeared on the support cylinder section of reactor vessel of
Tianwan Unit 7 manufactured by ATOMMASH. The non-conformity report was also reviewed
“制造和建设监督”国家研讨会交流资料
Figure 3: Grinding the bolt hole thread on Figure 4: The second installation of the main
September 9 bolts on September 10
Corrective measure: Threads of the No. 21 and No. 42 damaged bolt holes were newly made
with holes enlarged. The thread size was changed from M170×6-6G to M180×6-6G. The main
bolts corresponding to the No. 21 and No. 42 main bolt holes were no longer available, and 4
pieces of M180 main bolts were remanufactured (2 of which were used as spare parts). The No.
51 main bolt hole was accepted as it was.
The direct reason: when the main bolt was installed for the second time, it was installed while
grinding. After grinding, the main bolt was not thoroughly cleaned, resulting in foreign material
in the main bolt hole, causing the main bolt hole to be damaged.
The factory made a simulated bolt hole for a simulated test, and reviewed the work records.
We found the the root reason: After its first removal, the main bolt hole was not completely
polished with burrs and iron nodules, and there were foreign materials in the main bolt hole.
When the main bolts were installed for the second time, 7 bolts should be installed in the
evening shift according to the program requirements. However, workers rushed to install nearly
20 bolts on the evening shift, and they screwed in the main bolts fast, not at an even speed,
resulting in this event when screwing in.
“制造和建设监督”国家研讨会交流资料
Contributing factors: As the manufacturing schedule of Unit 4 reactor vessel was not under
control at the beginning of the manufacturing, the supply schedule was delayed. There was a
rush to prepare for the hydraulic test. After the trial assembly, the support ring should have
been dismantled according to the negotiation results of both parties and shipped separately.
However, the negotiation result was not taken seriously and the support ring was not
dismantled in time. Preparation for the hydraulic test was directly done, resulting in repeated
disassembly and assembly of the main bolts.
This event made me see the point that "without schedule, there would be no quality". If the
schedule is delayed, the plant inevitably wants to find a way to speed up the subsequent
production, which inevitably undermines the product quality. Therefore, it is required to
integrate schedule management into daily work, track and coordinate the manufacturing plant
to carry out manufacturing activities in compliance with the manufacturing plan. On the other
hand, manufacturing overseeing members must have strong professional knowledge, judge the
impact of the problem, and not disrupt the normal production process and rhythm as far as
possible.