Future EQ Perspectives for Russian Global New-Build Projects
Natalia Amosova Principal Consultant Lean Six Sigma Black Belt [email protected] +41 79 458 77 13
Prepared for 2020 Curtiss-Wright EQ Technical Meeting November 2020
November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 1 The Water-Water Energy Reactor “VVER” Development and generations
+ Total number of 106 VVER‘s build since 1960
+ Three generations in operation: + VVER-440 + VVER-1000 + VVER-1200 (AES-2006)
+ Generation III+ under construction: + VVER-1300 (TOI)
+ New designs developed for future projects: + MIR-1200 + VVER-1500 + VVER-1700 + VVER-600
November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 2 Rosatom Group
+ Russian government owned corporation, responsible for all nuclear applications
+ Consists of over 350 specialized companies throughout the whole fuel cycle, of which relevant for us: + Rosatom Overseas (RAOS) - vendor for VVER outside of Russia + AtomEnergoProm (AEP) - designer of the plant + AtomStroyExport (ASE) – main contractor for the international NPP construction + Titan-2 - main contractor for the international NPP construction + AtomEnergoMash (AEM) – Main equipment manufacturer
+ World leader in todays‘ newbuild portfolio + 28 VVERs under construction (international and domestic) + Total new-build portfolio >130 B. USD
November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 3 The Overseas New-Build Projects Overview
Rosatom Overseas (RAOS) Plant name Country Unit number Construction start Completion date Akkuyu Turkey 1-4 2018 2023-2025 Ostravets Belarus 1-2 2013 2020 Busher Iran 2-3 2016 2025-2027 El Dabaa Egypt 1-4 2017 2026-2028 Hanhikivi Finland 1 2021 2028 Kudankulam India 3-4 2017 2021 5-6 2020 2025 Paks II Hungary 5 2021 2026 6 2022 2027 Rooppur Bangladesh 1 2017 2023 2 2018 2024 Tianwan China 7 2021 2026 8 2022 2027 Suidapu China 3-4 2019 2028
25 Under 22 Under 22 Potential Construction Negotiation Future Projects
November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] Source: Rosatom 4 Equipment Conformity Assessment in Russia Laws and regulations relevant for equipment testing
Technical Document Review Mandatory Product Certification (Экспертиза технической (Обязательная сертификация документации) продукции) Safety classes 1, 2 and 3 e.g. GOST R 50.03.01-2017 e.g. GOST 50.08.01-2017
Acceptance . GOST R 50.06.01-2017 (Приемка)
Control . e.g. GOST R 50.05.05-2018 (Контроль)
НП-071-81 Tests . e.g. GOST R 15.309-98 (Испытания)
Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 5 [email protected] Mandatory Product Certification For all classes of safety related equipment Mandatory Product Certification (Обязательная сертификация продукции) Conducted by certification body and consists of 5 steps: e.g. GOST 50.08.01-2017
1. Submission and review of request for certification*, selection of the certification scheme ** 2. Development of the certification plan 3. Identification of test samples/specimen 4. Certification tests and certification of manufacturer’s QMS 5. Analysis of test results, decision if passed and granting of the certificate
* Request for certification has to include (among other documents) main parts drawings, calculations, manufacturing procedures, testing procedures ** Certification scheme
Scheme Test specimen tested in accredited labs QMS Audit Inspections during 3c Testing of test specimen - Testing of test specimen 4c Testing of test specimen Analysis of workshop condition Testing of test specimen and Analysis of workshop condition 5c Testing of test specimen QMS certification Testing of test specimen and QMS certification 6c Testing of the whole LOT - - 7c Testing of each test specimen - -
Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 6 [email protected] Technical Documentation Review Mandatory before release for manufacturing or acceptance to procure foreign goods Technical Document Review (Экспертиза технической документации) Mandatory Review of the following documentation to ensure compliance to the specification e.g. GOST R 50.03.01-2017 and any other set requirements
+ Design + Manufacturing + Quality assurance and control (processes and procedures) + Testing + Certificates
Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 7 [email protected] Types of Tests for Safety-Related Products Tests performed at different project stages
Test Type Test Specimen Purpose Preliminary Prototype Preliminary evaluation if prototype is compliant to TZ or TU draft (Proof the readiness for acceptance) Acceptance Test specimen or lot representative specimen 1.Compliance of technical parameters to ND, TZ, TU and KD (domestic) 2. Applicability of the design solution 3. Production methods compliant to quality requirement 4. Service and Maintenance friendliness 5. Safe operation 6. Lifetime Acceptance Lot representative specimen (foreign) Compliance of the product to the approved technical requirements to the НП-071-18 (May be also performed in a Rostechnadzor certified lab) FAT Each product (if made at another company to be Compliance to TU reflected in ITP) Type Any from a lot or test specimen Improving or maintaining of product design in case of an impact to it due to changes in design or manufacturing process Qualification Test specimen or lot representative specimen (min. 2) Check the quality if findings during FAT or periodical testing Manufacturing is transferred to another OEM or designed by another organization New LOT is being manufactured after more than 3 years Lot representative specimen Check compliance if requirements to the product were updated Comparative Lot representative specimen (conducted by the Comparison of most relevant technical characteristics of products from different customer) suppliers under same test conditions Periodical Lot representative specimen Confirmation of stable quality of manufacturing Certification Test specimen according to the certification plan Compliance of product properties to national and international regulatory (performed by a Rosatom certified lab). May not be documentation requirements. combine with any acceptance tests Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 8 [email protected] Acceptance Tests for Main Valves
No. Acceptance Test Scope 1 Control of the results of the preliminary test 2 Visual control 3 Material density and hardness tests, test, weld seams shell test, stability and tightness test of the assembled product 4 Leak test of weld joints, interfaces and joints 5 Functional test 6 Lifetime test* 7 Seismic resistance test, incl. natural frequency up to 20hz 8 Vibration resistance test 9 Vacuum tightness test (for equipment working with under pressure) 10 Total mass check 11 SB LOCA, LB LOCA, BDBE, DBE, steam leakage outside containment 12 Shut off valves leak tightness 13 Stroke limits indication tests 14 Thermal stress resilience 15 Blackout “stay in place” test for shut-off / control valves 16 External leak tests when actuator shutoff fails 17 Multiple hydraulic tests resilience 18 Defectiveness (Disassembly and examination)
*There are two classes of cycling tests for major valves, tests may be performed on 50% smaller test specimen and may not exceed testing capabilities of domestic labs. Tests will be conducted only if required by customer.
Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 9 [email protected] Authorized Test Labs Mandatory for labs working under or with the Rosatom system
+ Rosatom established the procedures for and provides accreditation of any test lab, which perform conformity assessments of safety related equipment + Rosatom trains and certifies experts who are entitled to perform accreditations of test labs + Rosatom maintains a list of all accredited test labs + Rosatom announces first-time and recurring accreditation audits every year + All information (list of accredited labs and their accreditation scope, list of accreditation experts, list of first-time and recurring test lab accreditation audits) is posted on Rosatom.ru + Today there are 55 accredited test labs Source: Stroyventmash + Every lab has an accredited scope, which specifies which tests and according to what norms the lab is accredited for
Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 10 [email protected] Main Testing Labs JSC "NPO CKTI"
. Located in St- Petersburg, Russia . Founded in 1927 . Provides tests of valves, heat exchangers and other equipment for NPP . Performs experimental research of thermohydraulic processes and hydrodynamic stability at a large-scale model of natural circulation circuit for LNPP-2 (Leningrad Nuclear Power Plant 2) of afterheat removal passive system through the steam generator(ARPS PG).
Sources: specmont.ru, hiddenside.ru; iocenter.ru Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 [email protected] Main Testing Labs JSC “SNIIP" Testing Lab subdevision “CMI”
. Located in Moscow, Russia . Founded in 1952, now part of Atomenergomash . Performance of Tests (Acceptance, Certification, Periodic, Comparative) of special valves, elements of safety systems, equipment and components for NPP’s and other industries; . Performance of tests for electrical equipment for NPP‘s
Sources: atomic-energy.ru; vestnik-aem.ru, yablor.ru Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 [email protected] Main Testing Labs AO “NIZ NPP” . Located in Koshyra, Russia . Founded in 1987, now part of Rosatom . Performance of Tests (Acceptance, Certification, Periodic, Comparative) of special valves, elements of safety systems, equipment and components for NPP’s and other industries; . Provision of services and technical support for the operation of valves of NPP’s; . Creation and maintenance of a database of special valves for NPP’s . Design, assembly, commissioning and acceptance tests of valves for NPP’s
Source: presentation of NIZ NPP from the year 2008 : niaes.ru Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 [email protected] Major Changes and Chances The system is adapting to international practices… Irrelevant for Overseas Projects
Now a „type test“ from a western EQ Technical Document Review Mandatory Product Certification Lab may be accepted (after review)* (Экспертиза технической (Обязательная сертификация документации) продукции) e.g. GOST R 50.03.01-2017 e.g. GOST 50.08.01-2017
Inspection and Test Plan Acceptance . GOST R 50.06.01-2017 (Приемка)
May be performed in an ILAC and Rosatom accredited test lab according Control . e.g. GOST R 50.05.05-2018 to Russian test plan (Контроль)
Tests . e.g. GOST R 15.309-98 (Испытания)
* New since Feb 2020
November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 14 Reasons for the Changes… Explanation and background
+ Despite of a governmental directive for Russia-source based equipment strategy, Russia still imports western safety-related equipment -> Reduction of costs through acceptance of „western“ qualification tests instead of Russian „acceptance test“
+ The Hanhikivi project is in Finland and sets the requirements according to YVL guides which is closer to the „western“ EQ requirements -> Russian suppliers should benefit from the need to perform only one kind of EQ test and meet Russian and international requirements at the same time
+ Strategy of Rosatom to expand further into western Europe and global markets -> Before Hanhikivi project, the Russian regulatory system was more or less completely accepted by the overseas importer nation -> Big investments were made into VVER-TOI in order to fulfill international design requirements
November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 15 VVER-1000 Reactor Perspective and Outlook Business Opportunities
+ As of today essentially no Russian OEM has performed EQ according to IEEE, QME-1, RCC-M, RCC-E
+ Partial or full EQ programs will have to be performed on the Russian equipment, which is subject to export to „non-Russian“ regulatory system countries
+ Several VVER types are planned to be built, which will mean new equipment will have to be integrated and qualified as well
+ Western equipment OEM‘s can use their western EQ but may be required to do some additional tests
+ Unique chance to participate in a Russian VVER-1200 new-build project according to Finnish regulation with (likely) no need to comply to Russian rules and requirements – not only as an OEM but also as a test-lab
November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 16 Conclusion
+ Today we are facing the very beginning of the transition of the Russian EQ/Conformity Assessment landscape towards more globally recognized ways of working
+ The VVER is the leader among todays‘ nuclear new-build technology – in order to expand further, these reactors will require equipment, which is compliant with EQ programs understood to U.S. and European service suppliers
+ A new service and equipment supply chain is being built for Western VVER projects
November, 2020 Curtiss-Wright EQ Technical Meeting 2020 - [email protected] 17 Europe Feldeggstrasse 19 8008 Zurich Switzerland +41 78 964 64 60 [email protected] apolloplus.com
Curtiss-Wright EQ Technical Meeting 2020 - November, 2020 18 [email protected]