construction of belene npp in bulgaria

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Construction of Belene NPP in Bulgaria

Dear participants of BulAtom Forum,

I would like to greet you and to present a Report on Belene NPP Construction in Bulgaria.

This state-of-art Project of Belene NPP Construction is characterized by such features as:

• Involvement of leading companies to implement this Project; • High level of international integration;• Use of modern technology and innovation technical and arrangement solutions; • Implementation in compliance with international normative base;

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National Electrical Company EAD

Employer

Worley ParsonsArchitеct-Engineer

JSC AtomstroyexportContractor

JSC AtomenergoproektGeneral Designer

Areva NPMain Foreign Subcontractor

RRC KurchatovskiyInstituteScientific Supervisor

JSC EDB GedropressRF General Designer

JSC AtomtehenergoLeading Commissioning

Organization

Bulgarian Construction and Erection

Organizations

JSC TVELNuclear Fuel

SupplierManufactures

Siemens AG400/100kWt

Facility

Belene NPP Project Organization Structure

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GNS GmbhSupplier of dual-purpose transport and storage casks

NUKEM Tech. GmbhSupplier of solid and liquid radwastes reprocessing technology

The Agreement of the implementation of the first priority works for construction of Belene NPP is made on this 29th day of November 2006 by and between JSC “Atomstroyexport” and NEK, according to which is being implemented the preparation of Engineering, Procurement and Construction Contract (EPC) and realization of the scheduled preparatoty works for construction of Belene NPP.

29.11.2006Agreement for FPW for Belene NPP Construction

01.07.2008Addendum No.4

October 2006 Results of the bid

18.10.2008Contract Agreement

28.12.2007Add. №1

18.01.2008Add. №2

History of the Project

10.06.2008Add. №3

01.11.2008 Add. №5

31.03.2010 Add. № 7

08.12.2009 Add. №6

The Contract Agreement for construction of Belene NPP was signed on 18.01.2008 in the presence of the Presidents of the RF and Bulgaria

The Contract Agreement is, by the terms, in compliance with Bid offer of Atomstroyexport JSC and the scope of obligations under EPC Contract. The Price of EPC Contract is3.997 billion Euro.

According to the Agreement start of BNPP Unit 1 construction is March 2009, Unit acceptance is January 2014,Start of BNPP Unit 2 construction is March 2010, Unit acceptance – January 2015

29.11.2006Agreement for FPW for Belene NPP Construction

01.07.2008Addendum No.4

October 2006 Results of the bid

18.10.2008Contract Agreement

28.12.2007Add. №1

18.01.2008Add. №2

History of the Project

10.06.2008Add. №3

01.11.2008 Add. №5

31.03.2010 Add. № 7

08.12.2009 Add. №6

The Agreement of 29.11.2006 stipulates the development of:

Conceptual Design (CD)

Technical Design (TD)

Intermediate Safety Analysis Report (ISAR)

Safety Analysis Report (SAR)

Report on surveys and inspection of civil and erection base

Technical specifications for long-lead items (LLI: Reactor Pressure Vessel,Upper Unit, Pressurerizer, ECCS hydroaccumulators, Polar crane)

Project Management and Quality Assurance Documents

Major scope of geological engineering surveys at the Site

Activities Scope: Scope of Activities under the Agreement of 29.11.2006

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1. Adjustment of the Technical Design for NPP

5. Issue of final revision of the Technical Design, PSA and ISAR

9. Development of the first revision of List of key equipment and Subcontractors

2. Development and adjustment of Conceptual Design for NPP

6. Development of technical specifications for LLI

10. Development of first revision of List of Bulgarian Subcontractors

3. Issue of 0-revision of the Technical Design, PSA and ISAR

7. Survey of civil and erection base

11. Introduction of information portal of the Project

4. Issue of first revision of the Technical Design, PSA and ISAR

8. Development of Quality Assurance Program of the Contractor

12. Development of Package of Documents for Project Management,including: «Integrated Overall Time Schedule» , «Project Arrangement and Management », «Site Mobilization Plan» and etc.

Activities carrying out: Works fulfilled within the framework of the Agreement of 29.11.2006

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Adjustment of the Technical Design Development and adjustment of the Technical Design

Advance payment

Activities carrying out: Development and adjustment of the TD

Results of review of the TD by NRA

31.07.07

16.11.07

01.07.08 30.01. 10 July 201028.12.08

Advance payment

Adjustment of the ToR Development of

the TDAmendment 1Development of revision of TD, ISAR, PSAR not stipulated by the Agreement

Addendum 4Additional scopes

New Chapters of ISAR

Approval by the Employer

Other factors

01.01.07

31.12.07

(according to the Agreement)

(according to the Agreement)

More then 8000 issues came, 38 meetings were conducted in the course of review and adjustment of the TD, ISAR and PSA

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Activities carrying out: Quality of the Technical Design

A range of Bulgarian and international companies such as IAEA, Worley Parsons, Riskaudit, Enpro Consult, RWE, Risk Engineering were invited as experts to review Belene NPP TD.

Within the course of development and adjustment of Belene NPP TD ASE JSC received and prepared replies to more then 8000 issues of the Employer and his consultants;

38 meeting with the Employer and ASE JSC were conducted and minuted in the course of TD approval.

Laws and regulations of Bulgaria, Russia, codes and standards of EU, IAEA, Germany and USA were used while preparing TD of Belene NPP.

Today TD for Belene NPP, including ISAR and PSA is one of the most thoroughly developed and state-of-art in the field;

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Activities carrying out: use of new, state-of- arttechnical solutions in the course of development of the TD

Impact of large aircraft crash (Boing -747 (400 tons) on the containment is taken into account;

Use of state-of-art, referent technologies for reprocessing of solid and liquid radioactive wastes using plasma furnace for which NUKEM was specially involved into the Project;

Transfer from five to four circulation pumps to increase safety during operation and economic advisability. Revision of hydro-technical part of the project.

Modernization of corium localizing facility considering nuclear fuel of reactor plant of Belene NPP and seismic stability increase;

Use of referent, state-of-art, dual purpose transport and storage cask, developed by GNS, modified for fuel of the Reactor Plant of Belene NPP;

Development of spent fuel storage concept to 60 years, using dual purpose transport and storage cask mentioned above.

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Safety Assurance

Parameter/параметры AES-92 A-92Reactor Type/тип реактораModel/модификация

PWRWWER-1000/V392

PWRWWER-1000/V466

Reactor Pressure Vessel Service Life, yearsСрок жизни реактора

40 60

Unit Capacity Factor, %Коэффициент готовности блока, %

0.80 0.91

Net efficiency, %К.П.Д нетто, %

33.3 35.6

FA burnup, MWd/kgUГлубина выгорания

41 55

Steady state fresh FA loading, FA numberЗагрузка свежего топлива, количество ТВС

48 42

Project comparison AES-92 and А-92

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Safety Assurance

Parameter/параметры AES-92 A-92Containment/КонтайнментOuter wall thickness, mmТолщина внешней стены гермооболочки, мм

600 1500

Internal wall thickness, mmТолщина внутренней стены гермооболочки, мм

1200 1200

Site conditions/Условия площадкиExtreme Wind velocity, m/sМакс. скорость ветра, м/с

43 49

Extreme Snowfall, kN/m2Макс. снежная нагрузка, кН/м2

2 5.6

Maximum air temperature, °CМакс. температура воздуха, С

+38 +61

Minimum air temperature, °CМин. температура воздуха, С

-37 -57

SSE with PGA, g 0.12 (0.25) 0.24 (0.336)DBA with PGA, g 0.05 0.16

Project comparison AES-92 и А-92

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Project comparison AES-92 and А-92

Safety Assurance

Parameter/параметры AES-92 A-92Airplane Crash/Падение самолетаWeight, t/Вес, т 5.7 400Velocity, m/s/ Скорость, м/с 100 110-140-160Maximum force in the contact patch, MNМакс. усилие в месте контакта, мн

12 Up to 600

Spent Fuel Management/Управление отработавшимтопливом

SF Pool Capacity, cellsОбъем бассейна выдержки, ячеек

642 646

SF Cask Type/Тип чехла отработавшего топлива TK-13 CASTOR 1000SF Cask Capacity, FA Number/Объем чехлаотработавшего топлива, количество ТВС

12 19

SF Storage Capacity/Объем ХОЯТ, контейнеров 5 280

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On 03.07.2008 the Ministry of Regional Development and Public Works of Bulgaria issued Permit No.PC-30 to NEK for NPP construction.

Takeover Protocol of the approved design and permit for construction for the implementation of the specific construction dated 10th July, 2008, under which NEK officially submits to ASE Permit for Belene NPP construction in Bulgaria.

Protocol of construction Site opening , construction line and level of the buildings of the technical infrastructure indicating dated 30th July, 2008, which permitted to start the works under Addendum-3 to the Agreement dated 29.11.2006 between ASE and NEK for dismantling the existing structures not integrated in Project A-92.

On September 04, 2008, ASE was registered in the Central Register of Professional Constructors (Constructors Chamber of Bulgaria) and received the required documents for carrying out the civil works at the territory of the Republic of Bulgaria.

Works at the Site: Organization

Site Manager

Civil Activities Management Division

Industrial Preparation Department

Finance and Economy Division

Installation Activities Division

Production Technical Procurement Division Chief Engineer Division

Thermo-Mechanical Equipment

Department

Electro –technical Department

HVAC Department

Storage Facilities

Industrial Engineering Department

Reactor Hall Thermo-mechanical

Equipment Erection Department

Commissioning Technical Support

Service Administration

Division

Designer’s supervisors

(Supervisors)

Commissioning Directorate

Reactor Hall Construction Department

Turbine Hall Construction Department

Department of Common plant

structures installation

Other Functional Divisions (safety

personnel department, lawyer and etc.)

Department of preparation of commissioning

activities

Master Mechanic Service

Chief Power Engineering

Specialist Service Control Room

Department of Turbine Hall Thermo-Mechanical

Equipment Erection

Electro-technical Equipment Erection

Department

I&C Equipment Erection Department

Operation Engineering Support

Service

Operation Directorate

Personnel of ASE Sub‐contractors

…………………… …………………… ……………………

……………………

HVAC Equipment Installation

Department Non- conformities

Activities Department

Department of Inspections of

fire-protection, safety technique, radiation

safety, nuclear safety

Metal Inspection Department

Quality Department

Activities at the Site: Structure of ASE Branch in Belene

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Site Activities: Branch Mobilization Plan

ASE branch in Belene is staffed with qualified Russian and Bulgarian personnel.

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Total number of Contractor's Personnel at Belene NPP Site (pers.)

3476

6948

1062111491

10181

3625

Within the period of 2008-2010 all the buildings defined by ASE to be used for NPP construction are documented by taking over certificates. For this purpose ASE inspected these buildings and developed a detailed design of their reconstruction.

NPP construction is planned to be divided into 11 construction and 6 erection stages. Based on it the construction base and erection base are correspondingly divided into segments intended for allocation of supposed Executors of activities by the stages.

ASE performs restoration activities at engineering communication (water pipeline, sewage system, temporary power supply). For this person inspection, cleaning and flushing of drain engineering systems was carried out. Besides it is required to establish a fire water supply system again.

Site Activities: Civil and Erection Base Restoration

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In February 2009 a concrete mixing plant was put into operation, which is situated at Belene NPP Site and consists of 2 units, each with capacity of 100

concrete cubic meter per hour.


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Repair work of construction laboratory building was carried out. It was equipped with necessary equipment. The required documents were elaborated and submitted for accreditation.


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Canteen building restoration

Before reconstruction After reconstruction

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Purification plants of civil and erection base were erected

400 m. cub. 200 m. cub.

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Site Activities: Dismantling Activities

Due to the fact that earlier partially constructed objects В-320 could not be integrated in Project А-92 , activities on design of these buildings were fulfilled. In total, more than 130 thousand cubic meters of cast and precast reinforced concrete structures, more than 6 thousand tons of metal structures and equipment were required to be dismantled.

This work was not included into activities scope under the Agreement and into the price of ASE commercial offer.

In order to perform this work Addendum No.3 to the Agreement was signed with the Employer, and two Bulgarian companies were involved.

Design technology was based on the use of cutting diamond equipment for cutting cast reinforced concrete into units with weight of up to 60 t, use of mobile cranes with 300-500 t lifting capacity, crushing of units by hydro-hammers, removal or reinforcement and final crushing of concrete into broken rock in mobile crushing facilities.

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Site Activities: Dismantling

Panorama of РО�1 dismantling as of 01.10.2008 23

Site Activities: Dismantling

Dismantling activities are completed

Panorama of РО�1 dismantling as of 01.09.2009 24

Activities Performance: Ordering of Long Leаd Items (LLI)

According to the Agreement of 29.11.2006 ASE scope of responsibilities include elaboration of Engineering, Procurement and Construction Contract (EPC) and implementation of earlier scheduled preliminary activities for Belene NPP construction.

So that to make the timely order for LLI within the time limits ensuring fulfillment of contractual obligations for Belene NPP construction under the situation of delay in EPC coming into effect owing to lack of financing, on 05.11. 2008 ASE and the Employer signed Addendum No.5 to the Agreement of 29.11.2006 for LLI manufacture.

In order to perform the activities in accordance with Addendum No.5 on 18.08.2008ASE and Atomenergoprom JSC signed the frame agency contract No. 7732/08018/48-ДЭЗ for manufacture and supply of LLI for Belene NPP.

At present main LLI have been included into the contract, including: Reactor pressure vessel, Steam generators, Pressurizer, ECCS Hydro-accumulators, Upper Unit, Main equipment of turbine-generator set (Turbine, condenser, turbine generator and its auxiliary systems), Molten core catcher, Polar crane, etc.

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Performance of Activities: Project progress under the conditions of uncertainty

Despite the fact that EPC Contract negotiations and settlement of issues related to ensuring of financing for Belene NPP construction are going on from 2007, ASE does not cease the activities under the Project and proceeds to develop it beyond the framework of the valid Agreement:

The Contract with Atomenergoproekt JSC for development of Detailed Design was signed and came into effect (1360 documents are issued);

The Contract with OKB Gydropress for elaboration of documentation for complex design of Reactor Plant and technical specifications based on RP equipment was signed and came into effect (581documents was issued) .

SSDC with AREVA NP GmbH was signed and came into effect (34 documents were issued);

The contract with Nukem is signed for application of up-to-date reprocessing technologies of solid and liquid radwastes

Signing of contract with GNS for development and supply of dual-purpose transport and storage cask (for transportation and storage) and development of spent fuel storage concept for the period of 60 years is at the stage of finalization;

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Project Progress: Continuation of activities under the Project after 30.09.2010

The Bulgarian Party provides its own funds for the Project financing

The Bulgarian Party accepts the Russian proposal for participation in the Project

financing

Coming into effect of Addendum to the Agreement or EPC Contract

Detailed design (AEP)Order of First Priority Equipment

Performance of civil and erection activities

Deadline of EPC Contract coming into effect

LLI manufacture

Modification of transport and storage casks.

Reconstruction of civil and erection base

Detailed design (Areva NP)

«First concrete»

30.09.10

01.11.11Preliminary period. 13 months with consideration of current site availability and other Project participants.

Application of reprocessing technologies of solid and liquid radwaste

Elaboration of spent fuel storage concept

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Project Progress: Continuation of activities under the Project after 30.09.2010

«First concrete» Start of Unit 1 construction

10 20 30 40 50 60

DesignEquipment manufacture and supply

Construction of buildings and structuresErection activities

Preliminary Acceptance of Unit 1

0месяцы

Stage CStage B

Stage APreliminary stage

Pre‐commissioning activities

01.11.11

01.10.2017

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Start of Unit 2 construction

DesignEquipment manufacture and supply

Construction of buildings and structuresErection activities

Preliminary Acceptance of Unit 2

Stage CStage B

Stage APreliminary stage

Pre‐commissioning activities

01.11.12

01.10.201828

Concluding Remarks

In conclusion I would like to draw your attention to the following:

• ASE has performed its scope of responsibilities under the Agreement of29.11.2006 and has achieved great results regarding both the Technical part of the Project and its organization;

• Though there is a number of unsettled issues under the Project, in particular, the issue related to financing, ASE is willing to continue the Project and works on its development;

• The Russian Party believes that in case the activities under the Project are continued, Belene NPP will be constructed with high quality and within the time limits prescribed in the Agreement of 29.11.2006: 59 months before Unit 1 take-over into operation and 71 month before Unit 2 take-over into operation, starting from concreting of foundation slab of Unit 1 Reactor building.

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