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Experiences of Local Participation in NPP
Construction in Pakistan
Muhammad Tahir Khaleeq
Pakistan Atomic Energy Commission
Highlights
Introduction
Current Status of Nuclear Power
Process of Localization for Nuclear Power
Plant Construction
Capabilities and Experiences of PAEC
Capabilities and Experiences of Local
Industries
Human Resource Development for Nuclear
Power Plants
Introduction
• All seven projects of Nuclear Power Plants Construction so
far have been turnkey projects but some local participation in
these projects resulted in enhancement of capabilities and
experiences of PAEC and local industries.
• For the sustainable nuclear power program, Pakistan
increases the indigenization level in NPP construction by
utilizing the experience already gained for greater self-
reliance and participation of local industries.
• The local effort to address the aging, obsolescence of
equipment and the life extension of the Karachi Nuclear
Power Plant (KANUPP) beyond its designed life resulted in
a good experience in local involvement for NPP construction
Introduction
• Our aim of indigenization and self-reliance not only for more
participation in construction of future nuclear power plants but
also for providing support to the operating plants by
manufacturing spare parts and replacement components as
well as by rendering technical service in fuel management,
in-service inspection, etc.
• In the long term, the indigenization program will raise the
technical know-how level of domestic industry.
• The presentation highlights the local involvement in NPP
construction and capabilities and experiences gained for
sustainable local involvement for future NPP Projects.
Nuclear Power
Plants
Type
Capacity
(MWe)
Year of
Commissioning
In Operation
KANUPP (K-1) PHWR 137 1972
CHASNUPP-1 (C-2) PWR 325 2000
CHASNUPP-2 (C-3) PWR 325 2011
Under-construction
CHASNUPP-3 (C-4) PWR 340 2016
CHASNUPP-4 (C-5) PWR 340 2017
KANUPP-2 (K-2) PWR 1100 2021
KANUPP-3 (K-3) PWR 1100 2021
Current Status of Nuclear Power
• A Contract is signed with the vendor of NPP. A clause of
local participation is included in the contract.
• The basis of localization is the capability in different areas
of nuclear power plants construction, including civil
construction, manufacturing of equipment (mechanical,
electrical, etc.), operation and maintenance etc. Presently,
the percentage of local participation for civil construction
and manufacturing of equipment is very low (<1%). The
local participation in operation and maintenance is 100%.
• Local manufacturers/suppliers are introduced to the vendor.
Vendor make sub-contract with the manufacturer directly or
through PAEC
Process of Localization for
Nuclear Power Plant Construction
• Overall survey is conducted to see capabilities of the local
manufacturers/suppliers and selected manufacturers/suppliers
are introduced to the vendor.
• PAEC arranges dialogue directly between vendor and potential
manufacturers/suppliers
• The local industries are selected on the basis of their previous
experience with PAEC for supply/manufacturing of equipment for
nuclear power plants or already participated in the construction of
nuclear power plants in Pakistan or have experience of
manufacturing/supply of equipment for thermal power plants.
Qualification of local manufacturers/suppliers is checked on the
basis of vender’s lay down standards.
Process of Localization for
Nuclear Power Plant Construction … (2/3)
• Procedure of limited tenders is used for national
involvement. Those industries/companies are involved in
tendering process that have been short listed on the basis
of our last experience or their capability and experience for
the particular task.
• The vendor arranges contacts and visits of our local
manufacturers/suppliers to his qualified manufacturers/
suppliers for transfer of technical knowhow and up-
gradation of their facilities
Process of Localization for
Nuclear Power Plant Construction … (3/3)
Scope of Engineering and Technical Support
• Equipment Design and Manufacturing
• Inspections (ISI, PSI, NDT)
• Testing and Qualification
• Installation
• Technical Studies
• Ageing management
Capabilities and Experiences of PAEC
Design and Development
• PAEC has developed the capabilities in the areas of
nuclear design, in-core fuel management, thermo hydraulic
design, shielding design, safety analysis radiological
analysis for the preparation of basic and detailed design.
• PAEC has the capability to structure design of NI buildings.
• PAEC has the capability in structure design of Conventional
Island (CI) and BOP buildings. Reasonable capability exists
in the design of Process, Electrical and I&C systems.
Capabilities and Experiences of PAEC (2/9)
Mechanical Equipment Manufacturing
• PAEC has main mechanical equipment manufacturing
facilities. These have an appreciable capacity and
capability to manufacture mechanical equipment /
components for NPP.
• In addition to specialized machining capability, state of
the art welding machines are available. Adequate testing
facility quality assurance & quality control setups are also
available.
Capabilities and Experiences of PAEC (3/9)
• HMC-3 currently has ASME U, U2, A, PP, S certificate
Authorization for stamps.
• HMC-3 is registered with the American National Board’s
Certificate for Repair (R) and has various API Certificates.
• HMC-3 is registered with the Pakistan Federal Boilers and
Pressure Vessel Safety Board and ISO 9001 Certified.
• PNRA has issued necessary certification / license to HMC-3
to manufacture equipment of safety class 2 and 3 in relation
to those components that were manufactured for C-2 and
these are currently being manufactured for C-3 and C-4.
Capabilities and Experiences of PAEC (4/9)
• License for Nuclear Safety Class-I equipment and ASME
STAMPING for the manufacturing of Nuclear Equipment (N-
Stamp) have been acquired and currently these equipment
for C-3 and C-4 are being manufactured.
• Some 61 mechanical components for C-1 and some 97
types of equipment for C-2 have been manufactured. It has
also installed a number of vessels at site and has done
piping fabrication and installation at various sites. In order
to ensure that equipment manufactured is quality assured,
a quality assurance set-up is available.
Capabilities and Experiences of PAEC (5/9)
Instrumentation and Control (I&C) Equipment
• PAEC has existing facilities consist of fabrication and
testing of some reactor instruments and systems on small
scale.
• Some new systems including Internals Vibration Monitoring
Systems and Loose Part Monitoring System have been
locally developed and installed in C-1. Thermal Fatigue
Monitoring System has been installed in C-2.
• Few other systems like nuclear power monitoring systems
and some other systems for C-1 and KANUPP has been
designed and developed.
• Full scope training simulators have also been developed
for C-1 and C-2 another is being developed for C-3/C-4.
Capabilities and Experiences of PAEC (7/9)
Commissioning
• In case of C-1, Participation of PAEC engineers was limited
to witness or observation only. PAEC engineers were not
allowed to do any hands on work:
• In case of C-2, about 120 qualified personnel took part in
the commissioning including preparation of commissioning
procedures, thus provided ample opportunities for learning.
The responsibility of commissioning of C-2 was on CZEC.
Capabilities and Experiences of PAEC (8/9)
NDT Services for NPPs
• Control-point participation as NDT experts during fabrication
of vital components of C-1/ C-2/ C-3 / C-4
• Participation in RFOs of C-1
• Participation as observer in PSI of C-1/C-2
• Participation in RFO of C-2
• Inspection services provided to NPPs other than scheduled
shut-downs
• Training and qualification of NDT manpower
• Flow Accelerated Corrosion (FAC) studies carried out
for C-1 / C-2
Capabilities and Experiences of PAEC (9/9)
Capabilities and Experiences
of Local Industries
Mechanical Equipment Manufacturing
Local manufacturing capability of following mechanical components
are available.
• Nuclear Safety class 2 and 3 vessels and fittings
• Non Nuclear class vessels and heat exchangers
• Hoisting facilities
• Steel structures
• Special tools
• Non nuclear class pumps
• Non nuclear class air conditioners
• Non-1E class low voltage motor
• Non-1E class cables/medium voltage electrical cubicles
• Non-1E class immersed type step down transformers
Capabilities and Experiences of Local
Industries ….. (2/5)
• Some reputed industries may be entrusted for the
manufacturing of NPP equipment.
• To achieve the objective some organizations can be
encouraged to enter into technology transfer arrangements
with the counterpart foreign organizations to undertake
local design and manufacture.
Electrical Equipment Manufacturing
• Local industry is already manufacturing electrical equipment
in different categories for conventional power plants.
• Capabilities of local industry can therefore be utilized for
manufacturing of most types of non safety related electrical
equipments for NPP.
• Local manufacturers are not in a position to manufacture
safety related electrical equipment due to lack of fabrication
facilities and equipment qualification programs.
Capabilities and Experiences of Local
Industries ….. (3/5)
Civil Construction
• Most of the civil works of a nuclear power plant can be
carried out by high profile local construction companies.
The construction materials are available in the country. The
structural design of buildings is carried out by many
departments, depending upon the type of structure.
• The construction of Conventional Island (CI) can be
undertaken by many construction companies, including
M/s. Habib Rafiq, M/s. Descon Ltd, M/s. Interhom and
M/s. Paragon.
Capabilities and Experiences of Local
Industries ….. (4/5)
• These companies toke part in C-2 and currently
participating in construction of C-3 and C-2.
• The local construction companies is also being involved
in construction of K-2 and K-3 Nuclear Power Plants.
• The construction is supervised by PAEC civil engineers
and overall QA work is also the responsibility of PAEC.
Capabilities and Experiences of Local
Industries ….. (5/5)
• Pakistan Institute of Engineering and Applied Sciences (PIEAS)
–Masters and Ph.D Programs in Engineering and Sciences
• Karachi Institute of Nuclear Power Engineering (KINPOE)
–Masters, Post-Graduate and Post-Diploma Programs in
Nuclear Power Technology
• CHASNUPP Centre of Nuclear Training (CHASCENT)
–Post-Graduate and Post-Diploma Programs
–Training for Licensing of PWR Operations Shift Supervisors
using a Full Scope Training Simulator
• National Centre for Non-Destructive Testing (NCNDT)
• Pakistan Welding Institute (PWI)
Human Resource Development
for Nuclear Power Plants
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