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ASME Boiler and Pressure Vessel Code vs. PED and EN-standardsand nuclear safety requirements

Mikael KuokkanenInspecta Nuclear

Conference in Vilnius 11th of October 2012 „Visaginas nuclear power plant: aspects of practical preparation“

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ASME Boiler and Pressure Vessel Code vs. PED and EN-standards and nuclear safety requirements

Contents

Part A – Introduction to and prerequisites for Nuclear Power projects1) Brief overview of a NPP and major New Build project phases2) Regulatory framework, Codes, Standards, and Specifications3) Division into Safety Classes and implications to Specifications

Part B – Opportunities and handling of some challenges in NPP projects1) Experiences on NPP projects2) What is the extent of work in a New Build NPP3) Implications on opportunities from the choice of Specifications4) Important steps to be successful - start prepare in time

Summary

Brief overview of a NPP

Major systems and components in a NPP

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Brief overview of a NPP

Major systems and components in a NPP

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Regulatory framework, Codes, Standards, and Specifications Global principles but local regulation and control is needed

• Basic principles for nuclear safety are similar throughout the world, as originated from U.S. regulation (by NRC) and standards (by ANSI for nuclear and ASME for mechanical); and as generalised in IAEA safety handbooks and guides.− Power utilities have special cooperation forms for exchange of experiences (owner’s groups) and preparation

of utility requirements e.g. in Europe (EUR). − Western European nuclear regulatory authorities (WENRA) are in the process of harmonising general safety

and regulatory oversight practices.

• However, local legislation and guidelines gives the country’s legal specification for the safety requirements and the way in which operations are controlled− Sweden: national regulation for general safety principles and mechanical equipment, as supervised by the

Swedish Radiation Safety Authority (SSM) and inspected by the nuclear inspection bodies.− Finland: national safety regulation and also NPP guidelines (YVL Guides), as prepared by the Radiation and

Nuclear Safety Authority (STUK), supported by the technical research organisations and inspection bodies.− France: national regulation and practices, with the regulatory body (ASN), technical support organisation

(IRSN) and inspection bodies.− Germany: national regulation and nuclear standards (KTA), with local authorities, support organisation (GRS),

and inspection bodies.

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Regulatory framework, Codes, Standards, and Specifications

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Nationallegislation

National Guides (YVL) IAEA Safety Guidelines

Nuclear Codes (ANSI, ASME, RCCM)Quality Management Stds (NQA-1, ISO)

Established Standards (EN, ISO)Specific Licensee RequirementsDetailed Project Specifications

Legal Framework

Mandatory Guides

Licensee Requirements

Activities contributing to nuclear safetyWhy is nuclear power plant safety so different?

• Safety design− Defense-in-depth. Multiple barriers against radioactive releases into environment.− Safety functions. Process/electrical/automation systems protecting the barriers.

• Safety assessment− Reactor dynamics – nuclear fission power generation after disturbances.− Thermal hydraulics – water and steam flow in reactor circuit and containment.− Structures and materials – structural capability, endurance and integrity.− Risk assessment – failure scenarios, accident probabilities and consequences.

• Safety management− Safety culture & practices.− Quality assurance & control.− Operation & maintenance.

• Regulatory oversight− Licensing & permits.− Reviews & inspections.

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• Safety design− Defense-in-depth. Multiple barriers against radioactive releases into environment.− Safety functions. Process/electrical/automation systems protecting the barriers.

Division into Safety ClassesWhy is nuclear power plant safety so different?

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Safety Class 1

Safety Class 2Safety Class 3

Safety Class 4

Safety Classes and their implications to Specifications

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Safety Class 1

Safety Class 2

Safety Class 3

Safety Class 4

Design and strength calculation

ASME III, NB ASME III, NC ASME III, ND EN 13445 EN 13480

Material All materials according to harmonized European standards are approved and accepted. Note that ASME materials are not accepted without additional requirements .

Welding Certificate according to EN 729, EN 3834. All welding shall be done according to qualified procedures and by qualified personnel.

Manufacturing andInstallation

KBMASME III, NB

KBMASME III, NC

KBMASME III, ND

KBM

Example from Sweden:

KBM = owners detailed quality specifications for mechanical equipment

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Nuclear Power Plant Construction Specifications

Contents

Part A – Introduction to and prerequisites for Nuclear Power projects1) Brief overview of a NPP and major New Build project phases2) Regulatory framework, Codes, Standards, and Specifications3) Division into Safety Classes and implications to Specifications

Part B – Opportunities and handling of some challenges in NPP projects1) Experiences on NPP projects2) What is the extent of work in a New Build NPP3) Implications on opportunities from the choice of Specifications4) Important steps to be successful - start prepare in time

Summary

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Recent projects in Sweden

• PULS (Power Uprate with Licensed Safety) Oskarshamn 3 (BWR).Structural verification of reactor systems, internal parts, turbine systems for increased power. Westinghouse, ALSTOM

• FREJ – LOT 3 - Replacement of steam generators in Ringhals 4 – Verification of the structural integrity of reactor systems. AREVA

• PLEX Oskarshamn 2, Structural verification of reactor systems, internal parts, turbine systems. AREVA, SIEMENS

• GREAT/TURBO - Requalification of Ringhals 3/4 – turbine systems (PWR). ALSTOM

• Replacement of RPV-heads I Ringhals 3 and 4 (PWR). MHI• Replacement of Internal parts in Ringhals 1 (BWR). AREVA• Forsmark TU12/MSR. Power uprate. SIEMENS, Balcke Duerr• Forsmark 3, KYR. Preparation of power uprate. Westinghouse• Forsmark 3, Generator replacement. ALSTOM

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Experiences on NPP projects

Common experiences from NPP projects

Some challenges experienced during the projects

• Shortages of experienced designers and welders due to e.g. generation shift

• Start of manufacturing before full completion of design and engineering

• Worldwide shortage of qualified nuclear equipment manufacturers

• Many suppliers not used to the need of extensive documentation in nuclear industry

• Requirements not properly communicated through the supplier chain

• Personnel and method qualification issues when using a mix of standards and suppliers own practices

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What is the extent of work in a New Build NPP

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Successive more involvement by Supplier. However, at all times the Licensee still needs to maintain project leadership (also in Turn Key projects)

Major project phases in NPP New Build projects

Planning Engineering & Design

Manufacturing & Installation Operation

>60 Years0

100% initiative by Licensee

Licensee has 100% responsibility and interest for long term operation

Why should Licensee be involved during Engineering & Manufacturing in a Turn Key Project

Maintained project leadership by the licensee is essential in all phases since (i) the Licensee has full responsibility and interest for long term operation(ii) this can increase the opportunities for the local industry

Implications on opportunities

• Safety Class 1 and 2: − Only few global suppliers for major components, usually ASME-oriented

• Safety Class 3 and 4 and Non-nuclear:− Majority of components and systems belong here-− Good opportunities for smaller suppliers. − The choice of code largely affects opportunities, especially for 4 & non-nuclear

• One major effect for any mechanical equipment supplier on the abilities to go nuclear is the choice of Code, ASME or ”EN”, ie European standards.

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Implications on opportunities from choice of Specifications

Choices for manufacturing of safety critical mechanical equipment:

• The ”full ASME-track” − Provides opportunity to export outside Europe (especially US, CAN)− Entire manufacturing adapted to a specific code− Certification by ASME, AIA. All continuous surveillance by manufacturer

• The ”European Track”− Choice of European EN-standards gives access to EU-market− Complies with EU-directives− Large involvement of various third parties during manufacturing

• The ”mixed Track”− ASME/EN is partly used− Mix between fundamentally different codes for one system gives difficulties

• In all cases:− Adjustments must in any case be made to national nuclear legislation

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Important steps to be successful - start prepare in time

• Choice of specifications is a basis (national guides and standards)

• Start prepare in time:

− Detailed requirements breakdown

− Training and education of suppliers and sub-suppliers

− Qualify personnel and quality systems

− Start a forum for cooperation between authorities, licensee and industry

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Expertise area examples for NPP New Build and Operation

PlanningEngineering & Design

Manufacturing & Installation Operation

60 Years

Revisions

Modifications

In Service Inspections

Mgmt of Defects

Manufacturing Inspections

NDT & DT

QC

Site installation inspections

Structural Integrity VerificationMaterials Technology

Evaluation of Suppliers

Basic Design Review

Project Risk Mgmt

Preplanning for 60 years operation

Sub Supplier Req

Regulatory

License Application

Constr License Appl

Oper License Appl

0

Welding TechnologyLoad Analysis

Codes & Stds

Life Time Mgmt

Training and qualification of personnel at authorities, licensee, suppliers in these areas important

SUMMARY

Examples of initiatives to create opportunities for national industry

• Maintained project leadership by the licensee is essential in all project phases

• Choice of codes and standards that comply with national and European legislation and also that will promote national manufacturers

• Detailed requirements breakdown and then creation of clear specifications for the complete chain of suppliers and sub-suppliers

• Specification of both quality and documentation requirements.- high documentation requirements in the nuclear industry

• Training and education of suppliers and sub-suppliers – early on in the NPP project initiatives for training jointly by authorities, licensee and industry

• Create an open process between Authorities, Licensee, Contractor, Suppliers for cooperative handling of requirements

• Continue to build on the national expertise needed to support the nuclear industry

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FINAL WORDS…

• Inspecta Annual Nuclear Symposium is arranged 4-5 december 2012. Welcome!

• Thanks for listening! …And now on to Part II…!

For further inquiries, please contactInspecta Lithuania, Mr. Mantas Andriuskevicius, Mantas.Andriuskevicius@inspecta.com+370 61517558

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