EPR Flamanville 3 project

Robert PAYSDeputy Director - EDF Nuclear Engineering Division

© 2011 Electricité de France (EDF). All rights reserved

EPR Flamanvilleproject organisation

Project Management (schedule, cost, quality, interfacemanagement, Risk analysis …)Licensing process Definition of general technical codes and specificationsContract allotment and contract managementTechnical specifications and surveillance of main contracts (NSSS, I&C, TG, BNI design, nuclear fuel)In factory manufacturing surveillanceConstruction on site and commissioning test managementPreparation of commissioning test and operation

documentation

EDF Architect Engineer for FA3 project

Architect EngineerLevel 1

Detailed DesignLevel 2

SuppliersLevel 3

SUPPLY CONTRACTS

AREVA NP

ANP

NSSS + I&C BNI

EDF

BOP/BCI

Engineering sub-contractors

-

CALLS FOR BID

SOFINEL

DESIGN CONTRACTS

TG and Auxiliaries

ALSTOM

EDF

55% EDF,45% ANP

EDF Architect Engineer for FA3 construction

Contract management

150 main contracts

The 20 biggest lots represent about 80% of the construction budget

Contracts for equipment supply and erection on site

Competition for all the lots except for NSSS

Quality and Safety management

EDF, as architect Engineer, is in charge to perform the surveillance of suppliers activities to check the quality

Each supplier provides its own quality programme approved by EDF

EDF surveillance is based on surveillance programmes with check and hold points for design, manufacturing and site activities

The Safety Authority (ASN) control is based on Nuclear French regulation for the activities linked to safety. ASN performs inspections in the design offices, factories and on site (2 inspections per month)

Flamanville 3Design and manufacturing activities

Licensing application

• The start-up authorization file has to be sent to the French Safety Authority (ASN) one year before fuel loading at the latest. This file includes the Final Safety Report (FSAR) and the general operation rules (GOR)

• Anticipated issuance of FSAR files to ASN :• to secure the acceptability by ASN

• to anticipate the ASN assessment

• to mitigate the risks of late modifications further to ASN assessment

• Documentation already issued• Accident studies

• Most of the FSAR chapters

Full scope simulatorMCR replica is erected in simulator building on site

Full scope simulator implemented in engineering teams offices and in Flamanville for the operation teams training

Nuclear Steam Supply System - AREVA

NSSS components manufacturing :

Reactor Vessel ready for hydro-test

Vessel head ; welding defects on adapters under reparation

Steam Generators, Main coolant lines, Main coolant pumps : normal progress. Available beginning 2012

CI : ALSTOM

All the main equipmentmanufactured and deliveredon site

HMP barrel

HMP cylinder

LP cylinder

Flamanville 3on site activities

General progress of FA3 (End of September)

Electro mechanical activities

~18% Progress

Civil work activities

~85% progress

Total manpower on site (end of Sept. 2011): 2995

~ 15 million worked hours since the opening of the site

Main steps of Flamanville 3 project

2007

Gridconnection

Electromechanical erection

2008 2009 2010 2011 2012 2013 2015

Decree for authorizationto proceed

Preparatoryworks

Commissioning tests

2014 2016

Civil work

Reactor & fuel BuildingsHR

- Inner containment : 10th level completed- 19.50m slab partially concreted - IRWST wall liner in progress

HK- Pools concreted up to 14,80m- Top edge transfer pool welding in progress- Beginning of piping erection- Southern area below 0.00m: Reactor Boron Tank liner in

progress,

HL1-4HL2-3

Safeguard BuildingsHL1 & HL4

- Level between +21.00 and +24.70 civil construction in progress- Emergency feedwater 1&4 tank liners in progress- Piping and cable trays erection in progress

HL2 & 3- Level between +21.00 and 26.80 civil construction in progress- HV/LV transformers implemented in HL3- Piping and cable trays erection in progress- Beginning of Control Room insulation- Emergency feedwater 2 tank liners in progress

HN

HD1-2

Auxiliary Buildings

Auxiliary nuclear building- Construction of slab +19.50 in progress- Rooms in levels >10,50m available for erection

Diesel building 1-2- Roof concreted – parapets in progress- Secondary structural steelwork in progress below 8.10m- Start of electrical works

Waste treatment building-Building waterproofed- Painting below level 0.00m completed

HQ

Turbine hall Building

- Turbine and generator shaft line : erection in progress- Start of erection of HMP casing, HMP rotor installed at level 16m- Alstom piping and cable trays in progress- Main feedwater pump motors installed

Power Transmission Platform

Step down-transformer zoneEnd of erection tests in progressCable pulling

Substation zoneErection progress: 95% (inside building + roof)LV cable routing in progress

Main transformer zoneTransformers equipped, cooling erection under finalization Bunkers are closedLV cable routing in progress

Erection of HV cap

End of Civil Works – Painting in progressCirculating water pit: end of painting, rail erection in progressUltimate Heat Sink pit: pipes support erection in progressStart of erection of emergency cool down pumps and filters

Pumping Station and discharge structure

• End of Civil Works• 5T crane in operation• Pipes support erection in progress

25t crane in HCB

Auxiliary supplyThe Auxiliary Transformer is now transfered for temporary operation

And after Flamanville 3 …

23 - Présentation_fa3_30091023 - Présentation_fa3_300910

Flamanville 3 : an EPR first of kind for EDF group

Flamanville 3 is a first of kind which has requested :

The development of a complete set of detailed design, manufacturing procedures and construction methods

A learning curve for the suppliers and EDF after a 20 years without nuclear construction

Lessons learnt from Flamanville 3

Some positive pointsThe complete use of 3D mock up in order to manage all the layout interfaces (civil, piping, cabling, ducts,...)The development of a simulator for validation of the process and the operation documentationThe in factory surveillance for the manufacturing activitiesThe involvement of the local companies and the recruitment of local workers

Some points to be improvedLack of experience and competences in the nuclear field (knowledge of codes and standards)Beyond the selection of the suppliers, a need to agree on the subcontracting chainCompletion of basic design and a significant part of detailed design before the beginning of constructionSome construction methods to be improved (liner erection, anchor plates, ...)

A dedicated EPR feedback experience project

EDF has created a dedicated feedback project from Flamanville 3 with the following objectives :

- Analysis of the difficulties encountered during the detailed design, the manufacturing and the construction

- Issue of feedback sheets providing information on situation for FA3 and proposed solutions for the future project

- Modifications assessed to simplify the EPR design and improve the construction methods

A specific EDF feedback organisation : the EPR family

EDF Group is involved, alone or with partners, in 8 EPR projects as a future licensee and as an architect engineer :

France: Flamanville 3 + Penly 3 China: Taishan 1&2 UK: Hinkley Point C 1&2, Sizewell B 1&2

EDF has set up a specific organisation “ EPR family” with all its owner partners in order to facilitate the exchanges between the projects and to set up an organisation enabling each one to benefit from the feedback experience of the other projects

Conclusion

The performance of EPR Flamanville 3 construction should be evaluated as is a First of kind. The updated schedule takes into account this point for the electromechanical erection and commissioning tests

The EDF feedback process from Flamanville 3 is now under operation and good results are already obtained from the feedback experience for the construction of Taishan (China)

All the future projects with Flamanville 3 reference will reduce their risks for delay, cost and quality thanks to this feedback experience

THANK YOU FOR YOUR ATTENTION