Modularization Challenges and Opportunities · PDF fileModularization : Challenges and...
Transcript of Modularization Challenges and Opportunities · PDF fileModularization : Challenges and...
Modularization : Challenges and gOpportunities
Modularization Construction Experiences ofModularization Construction Experiences of World First AP1000 Unit
2011‐6‐22fd l@[email protected]
ContentsContents
1 Retrospect on Sanmen AP1000 Modularization Construction2 Modularization Construction Experiences of World First AP1000 UnitWorld First AP1000 Unit 3 Challenges and Proposals
OverviewOverview
1) Sanmen1# is the world first AP1000 unit.2) Features:. Passive safety system;Mod lari ation constr ction. Modularization construction;3)parties. Owner: SMNPC, SDNPC. Owner: SMNPC, SDNPC. Designer: WEC consortium. project Management : JPMO(WEC,SHAW,SNPEC) . Constructor: CNF, CNI22, CNI24
Overall ScheduleOverall Schedule
2008 2009 2010 2011 2012 2013 2014
Sanmen
Unit1
ATP+0 ATP+71
Haiyang
ATP 0 ATP 71
Unit2
Unit1y g
5month4month
6month
Unit2
5month6month
Milestones Sched le of Sanmen 1#UnitMilestones Schedule of Sanmen 1#Unit
2、Retrospect on Sanmen AP1000 NPP 、 et ospect o Sa e 000Construction
1#NI Basemat Construction
1#NI excavation started on 2008‐02‐26
1#NI Basemat Construction
The dental concrete started on Aug,24,2008
1#NI Basemat Construction
On Sep. 18, 2008, lower mudmat concrete of 1#NI finished.
1#NI Basemat Construction
On Oct. 15, 2008, upper mudmat concrete of 1#NI finished.
1#NI Basemat Construction
O J 12 2009 b t f 1# NIOn Jan. 12, 2009, basement of 1# NI rebar finished.
1#NI Basemat Construction
On Jan 22 2009 first equipment module KB10 was setOn Jan. 22, 2009, first equipment module KB10 was set.
1#NI Basemat Construction
On Feb. 19,2009, stay‐in‐place form installation finished.
1#NI Basemat Construction
On Feb. 28, 2009, the embedded piping installation was finished and ready for FCD.
1#NI FCD
1#NI FCD on Mar. 29, 2009
1#NI FCD
Night Shift
1#NI FCD
On Mar. 31, 2009, monolithic concrete placement of more than 5000 m3 was achieved. It took 47 hours for 1#Unit.
AP1000 Modularization Construction Process
Modularization Construction FlowchartModule Assembly
AP1000 Modularization Construction Process
shop Fabrication
Module Assembly
Module Transportation
Module Lifting
engineering Set
shop Fabrication of Structural Module
Construction Progress Show – CA20 Assembly
In August of 2008, CA assembly area was available.
Construction Progress Show – CA20 Assembly
By the end of 2008, the first batch of sub‐modules of CA20 delivered on site.
Construction Progress Show – CA20 AssemblySub‐modules Fitting‐up
CA20 Floor
Construction Progress Show – CA20 Assembly
Sub‐moduules W
eldding
Construction Progress Show – CA20 Assembly
1 21 2
The assembled subassemblies overturn and erected, ready for integrated assembly
3 4
Construction Progress Show – CA20 Assembly
Integrated assembly of structural module
Construction Progress Show – CA20 Transportation and Lifting
The structural module transported from assembly area to NI through heavy haul road
Two 25 axes hydraulic trailers
Construction Progress Show – CA20 Transportation and Lifting
CA20 module, about 1000T, lifted and set in NI on Jun. 29, 2009
CVBH Assembly and Lifting
on Oct. 23, 2008, CV assembly area was available
CVBH Assembly and Lifting
CVBH Assembly
CVBH Assembly and Lifting
CVBH Welding
CVBH Assembly and Lifting
CVBH welding finished and ready for transportation
CVBH Assembly and Lifting
CVBH Lifting 1#CVBH was set at NI on Dec. 21, 2009
CV Shell Assembly & T tTransport
1#NI CV1# ring was Set on Mar 18 2010
CV Shell Lifting
1#NI CV2# i g t 2010 05 31Set on Mar,18,2010 1#NI CV2# ring was set on 2010-05-31
CV Shell Lifting
1#NI CV3# ring was set on 2010-09-12
1#NI CV4# ring was set on 2010‐12‐17
shop Fabrication of Equipment Module
Equipment Module Equipment Module KB11 LiftingKB11 Lifting
Construction Progress Show –Equipment Module Lifting
KB11 LiftingKB11 Lifting
KB12 LiftingKB12 Lifting
R151 LiftingR151 Lifting
Construction Progress Show –Equipment Module Lifting
R161 LiftingR161 Lifting
2 Modularization Construction Experiences of2 Modularization Construction Experiences of World First AP1000 Unit1) A detailed intergrated schedule shall be prepared prior to1) A detailed, intergrated schedule shall be prepared prior to project construction and implemented to ensure continuous , smooth construction on site.
. Detailed design must be preliminarily completed to meet the requirements of material procurement and module fabricationrequirements of material procurement and module fabrication.
2 M d l i ti C t ti E i f W ld2 Modularization Construction Experiences of World First AP1000 Unit
2)Much longer duration is required to use heavy load equipments f lifti d t t tifor lifting and transportation
E i t AP1000 Oth PWREquipment AP1000 Other PWR
Heavy load Crane 2600T/3200T, for the whole construction
800T, interval utilization
period
Medium Crane Two 400T N/A
Hydraulic Transporter 1000T 400T 400THydraulic Transporter 1000T, 400T 400T
2 f ld2 Construction Experiences of World First AP1000 Unit
3) Module fabrication shall be started prior to FCD to meet i i h i ll i f b lk i l h ll bsite construction, The installation of bulk material shall be started right after FCD is finished. then:The procurement of bulk material and equipment shall. The procurement of bulk material and equipment shall
be started at an earlier time.. award of the construction contract shall satisfy the. award of the construction contract shall satisfy the construction requirements.
2 Construction Experiences of World First AP1000 pUnit
4) The parallel/intercrossed construction for civil and erection needs more close coordinate, and the civil and erection work shall be performed at the same time and together with outsideshall be performed at the same time and together with outside module fabrication.
. Logic relation.
. Lifting and transportation passage.
Typical Construction Logic Figure
CA01 set
CA05 setCA04 set
Concrete placement for layer 4
Concrete placement for layer 2 Concrete placement for layer1
Concrete placement for layer3
CV Internal Structure Construction
On Apr. 28, 2009, CR10 module was set.
CV Internal Structure Construction
On Aug 1, 2009, exterior foundation layer A was poured.
CV Internal Structure Construction
On Aug. 1,2009,CVBH was set.
CV Internal Structure Construction
On Jan 12, 2010 ,interior structure layer1 was poured.
CV Internal Structure Construction
On Jan 26, 2010, the lifting of CA04 module was successfully performed.
CV Internal Structure Construction
b lOn Feb. 10,2010, interior structure layer2 was poured.
CV Internal Structure Construction
On Feb. 28,2010,CA05 module was set.
On Mar. 11, 2011 interior structure2011,interior structure layer3 was poured.
CV Internal Structure Construction
CV Internal Structure Construction
CA01
CA011 Lifting1 Lifting
CV Internal Structure Construction
On Mar. 27, 2010, CA01 module was
f llsuccessfully set.
2 Construction Experiences of World First AP1000 Unit
5) The stick installation is changed into the modularization construction, which makes the work at shop(module fabrication) easier, while the site work (module transportation, assembly, lifting, erection)more difficult.Structure module assembly:Structure module assembly:. overhead position welding required;. Irregular shaped assembly structure, hard to locate the CG;. Irregular shaped assembly structure, hard to locate the CG; . Integral outline dimension is hard to control due to fabrication and assembly deviation accumulation.
2 Construction Experiences of AP1000 First Unit 6) Flexible site module adjustment
The actually delivered KB15 module is not completed, and the unfinished parts inside module, such as piping, will be installed on site.
Integrated KB15 module in 3D Model
2 Construction Experiences of World First AP1000 Unit2 Construction Experiences of World First AP1000 Unit 7) Weather Protective Measures . Temporary cover;. Hard and soft cover for individual;. Paint after permanent coverd.
The assembly for temporary topThe assembly for temporary top cover is ongoing.
Main trussAnnular truss
3 Challenges and Proposals
1) Increase of Construction Cost:The fees for lifting&transportation equipment are increased. The fees for lifting&transportation equipment are increased..More manpower resources: due to the parallel construction of civil and erection, the construction period for these two , pdisciplines has been extended, which caused that the manmonth input has been increased.
3 Challenges and Proposals3 Challenges and Proposals
1)Increase of Construction Costs:1)Increase of Construction Costs:
. Lower labor efficiency :
The construction logic is strictly required, if any deviation of h d l li k h d i i t d t i l lschedule on any link, such as design, equipment and material supply,
the progress for major structure will be slowly, and even local suspension will be caused, so that the labor efficiency become lowersuspension will be caused, so that the labor efficiency become lower and lower.
. Heavy haul road, module assembly field and facilities shall be added.
3 Challenges and Proposals3 Challenges and Proposals1) Increase of Construction Costs‐large quantity for temporary steel structure
CVBH Temporary Steel Structure SupportStructural Module Temporary Steel Structure Support
3 Challenges and Proposalsg p1) Increase of Construction Costs‐large quantity for temporary steel structure
CVTH Temporary Steel StructureCVTH Temporary Steel Structure Supports
3 Challenges and Proposals 2) Increase of difficulty of Finished Products Protection2) Increase of difficulty of Finished Products Protection
Outdoor Installation ofInstallation of
Equipment Module
3 challenges and Proposals 3) Large Difficulty for Management of Intercrossed Construction
d f l d l d b dd d l•Intercrossed construction for structural module and embedded piping, civil
RV cavity structural module CA04
Embedded piping
CB65 structural module
Embedded cable conduit
3 challenges and Proposals 3) Large Difficulty for Management of Intercrossed Construction ) g y g
3)Bi Diffi l f M f I d3)Big Difficulty for Management of Intercrossed Construction Th l t f h b ildi f AP1000 i t th O T. The layout for each building of AP1000 is compact, the Open‐Top
method shall be adopted, so that the layout of site cranes, location of tower cranes and operation management are criticaltower cranes and operation management are critical.
3 Challenges and Proposals
4) Increase of Construction Difficulty :
The deformation control during structural module fabrication, assembly and installation is greatly difficult.
The connection after setting of equipment module, such as site piping, is very difficult to be performed.piping, is very difficult to be performed.
The location precision is high, and as the precision requirements for multi‐location and multi‐points need to be met, alignment is very difficult to be performed.
Pipe terminal of R155 module
Pi t i l f R151
Site connection issues after these two modules are set: as the accumulated deviations for module fabrication and installation, the pipe
position is difficult to be alignedPipe terminal of R151 module
position is difficult to be aligned.
3 Challenges and Proposals
5) Prior to design finalization, the detailed constructability &maintenance evaluation and optimization must be pperformed: . Module lifting and transportation passage. . The decoration after module set is very difficult to be performed, so that the final decoration must be finished before module settingbefore module setting.
Install equipment module by Open‐Top
Method
Lifting of equipment module
Equipment module setEquipment module set
3 Challenges and Proposals3 Challenges and Proposals
. Installation space, equipment module internal space is small, so that cable layout and maintenance is very difficult to be performedcable layout and maintenance is very difficult to be performed.
The distance between floor module and cable tray is very short, so that the cable layout and maintenance is
diffi l b f dvery difficult to be performed.
3 Challenges and Proposals 5) Prior to design finalization, the detailed constructability&mainenance evaluation and optimization must be performed:
.Operation space while installation (scaffolding, welding and NDE).
.Evaluation for module transportation and lifting passage..Evaluation for module transportation and lifting passage.
3 Challenges and Proposals
5) Prior to design finalization, the detailed constructability& i l i d i i i b f dmaintenance evaluation and optimization must be performed:
The evaluation of maintainability is also vey important:. The evaluation of maintainability is also vey important: equipment moved‐in through Open‐Top Method and the operation space and passage moveout of equipment components during maintenance must be considered.
3 Challenges and Proposals
6) Prior to design finalization, the detailed economy l ti d ti i ti t b f devaluation and optimization must be performed:
Whether module shall be adopted or not big or small size. Whether module shall be adopted or not, big or small size shall be used.
. Considering the costs for integrated link (design, fabrication and site construction).
Conclusion
The most valuable contribution for modularization is that the construction period (FCD~CO) reduced, so as to reduce the investment, however, partial works need to be performed in advance (change from after FCD to before FCD) and with good planning and organization & implementation, otherwise, the stick installation method is better.
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