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Owner Challenges & Expectations to Build the Next Generation of Power Plants Callum Ford 21-22 August 2008 Hilton Opera Hotel Hanoi, Vietnam
Owner Challenges & Expectations to Build the Next
Generation of Power Plants
Callum Ford
21-22 August 2008
Hilton Opera Hotel
Hanoi, Vietnam
Process, Power & MarineAgenda
About STP
Why are we doing this now? Current industry outlook
New Build Opportunities – Units 3&4
Another Opportunity – Units 1&2
Question & Answers
Process, Power & MarineCarl Sayko
Current Position: General Manager of Support Services for Units 3 &
4, STP Nuclear Operating Company
Responsibilities: Project information technology, scheduling,
estimating, cost, purchasing, contracts, records management,
document control, and human resources
Experience: 35 years in nuclear power management positions – 24
years with STP and 11 years with a major AE firm and as a consultant
Accomplishments: As project manager, set four world records in
Turbine Outage Schedule Performance. Project manager for STP
Units 1&2 Turbine Replacement Project which was awarded the 2007
Power Engineering Magazine Nuclear Project of the Year Award.
Education: Economics degree from the University of Pennsylvania
Personal: Married to Pamela and has 4 children
Process, Power & MarineAbout STP
The South Texas Project Electric Generating Station is located 90
miles southwest of Houston, near Bay City, TX.
South Texas Project Nuclear Operating Company (STPNOC) is jointly
owned by Austin Energy (16%), CPS Energy (40%) and NRG Energy
(44%) who share its output in proportion to ownership.
The current Units 1&2 produce 2.7GW annually.
On September 24th, 2007 STPNOC applied for a license to build and
operate two new units. This was the first application for a new nuclear
plant in almost 30 years.
Process, Power & MarineSTP Accomplishments
2008
May 7 -- STP receives another Best of the Best Award, the plant's third, andanother Top Industry Practice Award, the plant's seventh, for developing andapplying risk management for maintenance applications.
2007
The South Texas Project’s Unit 1 nuclear reactor safely led the nation – and
all 442 reactors worldwide – in electric generation in 2007. In addition, STP’s
Unit 2 had the third highest production nationally and ranked number 14
globally despite a refueling and maintenance outage last year.
Dec. 12, 2007 -- Power Engineering magazine presented a 2007 Project of
The Year Award to the STP Nuclear Operating Company for excellence in
replacing the low pressure turbines in both STP units. The publication
honored STP's turbine replacement effort as the Best Nuclear Project
worldwide.
September 17 -- STP reports lowest production cost among U.S. nuclear
plants, 1.356 cents per kilowatt-hour in 2006.
Process, Power & MarineSTP Accomplishments
2007 (Cont’d)
April 20 -- The low pressure turbines and main generator rotor in Unit 2 werereplaced in 28 days, setting a new world record.
March 26 -- STP completes a second, and consecutive, breaker-to-breakerproduction run. Unit 2 operated continuously for 508 days between scheduledrefueling outages.
2006
October 27 -- The low pressure turbines in Unit 1 were replaced in 26.5 days,establishing a new world record.
October 1 -- STP completes the first breaker-to-breaker production run in theplant's history. Unit 1 operated continuously for 532 days between scheduledrefueling outages.
STP Unit 2 led all 103 reactors nationwide in production, operatingcontinuously all year and generating 11.22 billion KwH. Its output was the thirdhighest of the 442 reactors worldwide.
STP Unit 1, which was routinely shut down 34 days last year for refueling andmaintenance, generated 10.14 billion KwH. Despite the outage, the unit stillranked sixth in the country and seventeenth globally.
Process, Power & MarineThe Outlook For Our Earth?
1.6 billion people – one quarter of the world’s population,
have no access to electricity.
The demand for electricity in developed countries
continues to grow.
29,028 ft29,028 ft
Process, Power & MarineElectricity Around the World
Process, Power & MarineForecast Electricity Demand
Process, Power & Marine
Coal:
49.9%
3%
Oil
18.6%
Natural
Gas
19.4%
Nuclear
6.4%
Hydro
2.7%
Renewables
US Portfolio
Process, Power & Marine
2009TBDTBDTBDFPL
TBD (ESP in review)TBDTBDClintonExelon *
20082APWRComanche Peak
(TX)
Texas Utilities
20081EPRCallowayAmeren/UniStar
20082EPRAmarillo (TX)Amarillo Power/UniStar
20072ABWRSouth Texas
Project (TX)
STPNOC
20081-4EPRCalvert Cliffs (MD)
Nine Mile (NY)
Constellation/Unistar
2008 (ESP in
review)
2AP 1000Vogtle (GA)Southern Co.
20072AP 1000V.C. Summer (SC)SCE&G/Santee
Cooper
20082TBDLocation TBD (FL)Progress Energy
20072AP 1000Harris (NC)Progress Energy
20072AP 1000Bellefonte (AL)TVA/Southern
20081ESBWRRiver Bend (LA)Entergy
20071ESBWRGrand Gulf (MS)Entergy
20072AP 1000Cherokee (SC)Duke Power *
20071ESBWRNorth Anna (VA)Dominion
COL Application
Filing Date
Number of
Reactors
DesignSiteCompany
16
US Nuclear Industry Plans
Process, Power & Marine
Performance of existing fleet
Energy Policy Act of 2005
Predictable and economic
Clean and low emissions
Why Build Nuclear?
Process, Power & Marine
New Build Opportunities – Units
3&4
Process, Power & Marine
Existing design certified by the Nuclear Regulatory Commission
Established supply chain
Construction track record
Four similar plants operating
successfully in Japan
Additional plants under
construction
Leading versus bleeding edge
The ABWR
Process, Power & MarineNew Build Objectives – Units 3&4
Complete the project within established schedule and budget
parameters.
Achieve the Energy Policy Act benefits.
Support the U. S. nuclear renaissance.
Deploy an integrated IMS to facilitate state of the art project
management tools through design, construction, commissioning and
data handover to operations and maintenance.
New build data and systems flange with operating and maintenance
system being developed in existing units.
Configuration management environment is highly transparent.
Process, Power & Marine
Safe and reliable operation of existing units
Total project approach
COLA
Contracts and procurement
Modularisation plan
Long-term staffing and training
Challenges
Project Focus
Process, Power & Marine
Safe and reliable operation of existing units
Total project approach
COLA
Contracts and procurement
Modularisation plan
Long-term staffing and training
Challenges
Project Focus
Process, Power & Marine
Standard construction techniques
Hard copy drawings and specifications
Limited Information Technology
Schedules not electronically linked
to design & procurement data bases
Integration through communication
and collaboration skills
Site specific design
Overlap in design and construction
schedules
Previous Nuclear Construction Projects
Process, Power & Marine
Project management finesse
STP’s facilitative culture
High standards of excellence
Planning mentality
Strong communications
Collaboration & decision making
Teamwork
Project management tools
Project Culture – Key Success Factors
Process, Power & MarineData Handover Paradigm
Information organisation in the project execution phase is
different than for the operational facility.
Not all the information generated during the project is
required in O&M – we intend to identify this early and not
leave until the end.
Provide clear and precise guidelines as to what we receive
and when we receive it and incorporate it into the EPC
contract.
Ensure that the information provided is consistent with our
configuration and change management strategies and is
readily transferable into our new company operations and
maintenance system.
Process, Power & Marine
EPC“where time TOTO market
is imperative”
Engineering data in Execution is stateful, volatile, temporal
and spread across disparate sources & owners
Progress
Management
Instrumentation
Design
Project
Management
Instrument
Data Sheets
Process
Simulation
Specifications
& Standards
P&ID
Contracts
Mechanical
Equipment
Design
Electrical Design
Line
Lists
Valve
Lists
GA’s and ISO’s
Civil & Structural
Cabling &
Lighting
Hook up &
Installation
Document
Control
Project
Portal
Time allocation
& measurement
PFD
Automation &
Control Design
Hazop
Requisitioning
Equipment
Data Sheets
Plant 3D
Modeling
SLD’s &
Schematitcs
HVAC
Procurement
Cost Controls
Equipment
Lists
EDMS
Supplier
Gateway
Shipping
Construction
Sequencing
Test &
Commissioning
planning logic connectivity layout actual completion
Process, Power & Marine
Process
Control
SPC
Work Order
Execution
Engineering data in Operations spreads across multiple
plant operational systems & time domains
ERP
Product / plant
Lifecycle
mgmt
EDMS
Specialty
Quality
Admin
Product
Specs
Plant
Centric
ERP
Chemistry
MgtBatch
Mgt
SCADA
SPC / Trends
Process
Planning
Optimisation
Data
Historian
MES
LIMS
FCP
Factory Schedule
AutomationControl
Logic
Data Capture
Procurement
Financials
CRM
Trading
Exchange
Supply
Chain
Machine
LogicProcess
Mgt
Plant
Operations
Production
Schedule
Business
Process
Supply
Chain
Customer
Plant
Supply
Chain
Extended
Supply
Chain
Process
Automation
In Process
Testing
Enterprise
Production
Unit
Production
Process
Machine
Reliability monitoring
& optimisation
Original diagram source courtesy: AMR Research
OO“where time ININ market
is imperative”
Process, Power & MarineConfiguration Management
AssetAsset
(inventoried item)(inventoried item)
TagTag
(functional location)(functional location)
P-101
11
11
“and, if it breaks, where are the
spares or where can we find a
similar model?”
N N
Logical or Functional
Location“what are the characteristics to
fulfill the process need”
Engineering
Domain = logical
ModelModel
(standard equipment)(standard equipment)
Pump Catalog
Centrifugal
Model # CP-C-4020
Specifications:RPM: 1500
Material: Cast Steel 316
Model or Std Equipment“what we can purchase
to fulfill the process need”
Purchasing
Domain = typical
Actual or Physical“what we have installed
to fulfill the process need”
Operations
Domain = actual
Process, Power & Marine
Units 1&2 – Another Opportunity
Process, Power & MarineUnits 1&2 Introduction
South Texas Project 1
Palacios, Texas, United States
Pressurised Water Reactor (PWR)
Westinghouse Electric Corp.
Net Output: 1250 MWe
Operable. Initial criticality: 03/1988; Commercial start: 08/1988
South Texas Project 2
Palacios, Texas, United States
Pressurised Water Reactor (PWR)
Westinghouse Electric Corp.
Net Output: 1250 MWe
Operable. Initial criticality: 03/1989; Commercial start: 06/1989
Process, Power & MarineUnits 1&2 Success – Why Change?
Commitment to operational and financial excellence
Texas is a deregulated market
Future financial improvements will largely come fromtechnology and process improvements
Attaining “fleet like” economies of scale is a key element ofour Business Plan and requires common processes andsystems for all 4 units
Process, Power & MarineUnits 1&2 Objectives
Develop a strategic plan to capture relevant legacy data
Paper
Mylar
CAD Files
Raster Files
Individual databases
Evaluate commercial technologies to replace current in-housedeveloped applications - i.e. master equipment database
Integrate with new Operations and Maintenance system
Provide a harmonised and integrated IT infrastructure and supportingtechnologies across Units 1&2, consistent with Units 3&4
Capitalise on 3-D modeling for continued outage and modificationexcellence
Process, Power & MarineQuestion/Answer
Owner Challenges & Expectations to Build the Next
Generation of Power Plants
Callum Ford
21-22 August 2008
Hilton Opera Hotel
Hanoi, Vietnam
