Proper management of Design and Working Documentation is one of the main tasks in the construction of any nuclear power plant. The preparation of Design Documentation (D.D.) of a nuclear power plant is started after site selection. On the other hand, a Working Documentation (W.D.) is derived from the Design Documentation before starting the field construction work. Design Documentation is produced by considering the aimed nuclear technologies chosen for the plant, site characteristics, and the International Atomic Energy Agency’s recommendations and safety standards for the protection of health and to minimize the danger to life and property. The Working Documentation is formed by maintaining the working stages and by providing a detailed drawing of each stage required to implement the Design Documentation at the site. Moreover, there are some other documents used in a Nuclear Power Plant (NPP) such as Work Execution Plan (WEP), Technical Solution (T.S.) and Design Changes etc. that have different functions and are required as the subsidiary of Working Documentation. The developers of the documents may be the same organization or different organizations. If different organizations are involved in the preparation of different documents, good coordination and communication between different organizations are required for maintaining the objective of the Design Documentation. Rooppur Nuclear Power Plant is the largest project in Bangladesh and the challenges behind the development of the Design Documentation and the Working Documentation along with other subsidiary documents are discussed.
1. Introduction
The Rooppur Nuclear Power Plant (Rooppur NPP) is being constructed under the legal basis of the Inter-Governmental Agreement, the General Contract between JSC Atomstroyexport, Russia and Bangladesh Atomic Energy Commission.
The Design Documentation is a bunch of documents that fulfill all the aspects and the objectives of the establishment of a Nuclear Power Plant. This type of documentation should include information on the customer's technical specification of preferred reactor technology, electricity production capacity, site information, all essential implementation detail and design decisions from different types of design analyses. On the other hand, Working Documentation (WD) describes the working stages, amount of materials along with their normative documents and the detailing of construction procedures on the basis of Design Documentation. The implementation of the Design and Working Documentation of the Rooppur Nuclear Power Plant is a challenging job.
As per International Atomic Energy Agency (IAEA), inadequate completion of design and engineering work prior to the start of construction is detrimental to the implementation of the project as per the target schedule. According to IAEA Nuclear Energy Series, NP-T-2.7, lack of details in the design documentation leads to:
— Delays in the start of construction activities at full speed;
— Continuous pressures to all involved organizations;
— Attempts to reschedule the manufacturing and construction steps, thus further complicating project management;
— Reduced quality due to time pressure and often corrections and reassessment.
The procedure that was followed to implement Design Documentation and Working Documentation in Rooppur Nuclear Power Plant is described in this paper in detail. Also, the importance and challenges to meet the requirements for approval and acceptance are discussed here.
2. Design Documentation
Design Documentation means all documentation including technical assignments, reports, analyses, descriptions, specifications, calculation results, maps, drawings, schedules, and other types of technical information developed by the Contractor and approved by the Customer which shall be used for order, manufacture, and tests of systems and Equipment including LTME, and development of Working Documentation. A contract between Bangladesh Atomic Energy Commission and JSC ASE has been conducted for the development of Design Documentation and the performance of survey for the design stage of the RNPP project in Bangladesh which is Contract No. 77-258/1308800 dated 02.10.2013.
2.1 General Designer of Rooppur NPP
ASE Joint Stock Engineering Company (JSC ASE EC), previously known as JSC NIZNY NOVOGOROD ENGINEERING COMPANY <<ATOMENERGOPROEKT>> (JSC NIAEP) is the General Designer of Rooppur NPP according to State Corporation <<ROSATOM>> Order No. 1/463-Π dated 20.05.2014. (QAP(D)). Production activity of JSC ASE EC as the General Designer of Rooppur NPP includes the development and revision of Design Documentation.
2.2 Functions and Responsibility of General Designer, JSC AEP
The functions and responsibilities of the General Designer, JSC AEP are described below as per the Quality Assurance Program for Design (QAP(D)): -
i. Availability of licenses, certificates and other documents permitting the activities,
ii. Quality Assurance of the Design Works,
iii. Compliance of the issued Documentation with the nuclear safety norms & rules,
iv. Uniformity of presentation and format of design documentation,
v. Development and Implementation of QAP (D) to guarantee the quality of the works performed and to ensure safety and reliability of the facility under construction,
vi. Approval of QAP (D) by the Customer,
vii. When developing the design JSC ASE EC works with the Customer according to the procedure stated in contract No. 7764/13756 dated 25.03.2014, the internal procedures and the procedures of the customer.
2.3 Design Organizations
General Designer, JSC AEP has involved itself to develop the Design Documentation of Basic Rooppur NPP. The designer’s quality activities are carried out based on Quality Assurance Program QAP (D) for performing in Rooppur NPP. Following are the work scope of design organizations:
|
Scope of Work |
Designer |
|
General Designer |
JSC Atomenergoproekt |
|
Services of Chief Designer of Reactor Plant |
JSC OKB GIDROPRESS |
|
Services of Scientific Supervisor of the Project |
National Research Center “Kurtchatovsky Institute” |
|
Services of the System Integrator-Chief I&C Designer |
JSC VNIIAES |
|
Services of Chief Designer of turbine island equipment |
JSC “Power Machines” |
2.4 Responsibilities of the Sub-Contractors
The responsibilities of the designer’s Sub-Contractors are mentioned below: -
• Availability of licenses, certificates and other documents permitting the activities,
• Quality Assurance of the Design Works,
• Compliance of the issued Documentation with the nuclear safety norms & rules,
• Uniformity of presentation and format of design documentation,
• Implementation of QAP (D) to guarantee the quality of the works performed and to ensure the safety and reliability of the facility under construction.
2.5 Main Participants of Designing for Rooppur NPP
As per QAP(D), the main participants of Designing for Rooppur NPP are:
§ The Engineering Survey Department
§ Bureaus of Comprehensive Design (BCD): BCD-1, BCD-2 & BCD-3.
The Engineering Survey Department provides the design Engineering Departments of JSC ASE EC with findings of Engineering Surveys and Investigations. The details of the three BCDs are following:
BCD-1 is a process engineering department. The main task of BCD-1 is to develop the design and estimate documentation for the mechanical section.
BCD-2 is a civil engineering department that develops design and estimates documentation for the architectural and building section, hydraulic facilities, water conduit and sewerage systems, fire-fighting plants, railway and motor transport, general layout plans, and construction organization plans.
BCD-3 is an electrical engineering department that develops design and estimates documentation for the electrical and I&C section.
2.6 Other Participants of Designing for Rooppur NPP
Scientific Research Laboratory for Radioactive Water Treatment and Water Chemistry provides scientific support for the design with regard to general chemistry. The Computer-Aided Design System Department provides automatization of the design process, technical support of the computer-aided design systems used to issue the design documentation, and calculation programs system support. The Metrological Examination Department is in charge of the metrological examination of the developed design documentation. The Economic Planning Department and The Quality Management Department of General Designer also take an important part in the development of Design Documentation.
2.7 Coding of Design Documentation
The code of any document is an object that summarizes information associated with it. In the case of coding of Design Documentation, it shall be understood as a physical, functional or logical unit of the project, e.g., a building (structure), functional system, equipment unit, section (subsection, part) of Design Documentation. Classification and coding systems used in the Rooppur NPP are described in the design materials RPR-QM-AEB0001 (Agreement on Using the KKS Coding System) and RPR-QM-ADC0002 (Design Documentation Identification Guide).
2.8 Technical Requirements for the Systems of Rooppur NPP
Technical requirements considered for designing the systems of Rooppur NPP are described as follows: -
a. Safety Class according to NP-001 (PNAEG-01-011-97),
b. By Quality Assurance Categories,
c. Seismic Resistance Category according to NP-031-01,
d. Groups depending on the degree of impact on Nuclear facility safety according to PNAE G-7-008-89,
e. Application and Operation Conditions according to NP-068-05,
f. Category of the functional group depending on the degree of impact on Nuclear Facility Safety according to NP-026-04,
g. Lifting Cranes by Group of influence on Nuclear facility safety according to NP-043-11.
h. Engineering Structures and Building elements classification according to Pin AE-5.6 and NP-031-01.
2.9 Approval & Acceptance of Design Documentation from the Customer Side
The acceptance criteria for Design Documentation of Rooppur NPP have been discussed in the contract agreed upon between BAEC & JSC ASE. The clauses of this contract that elaborated the acceptance process of D.D. are given here.
All Documentation developed and approved by the Contractor shall be reviewed and agreed upon with the Customer.
If there are any Customer comments on the Documentation considered, the Customer shall send the comments with an appropriate justification of each comment to the Contractor within 30 calendar days from the date of documentation receipt.
the Contractor shall send the relevant response to the Customer within 30 calendar days from the receipt of the Customer’s written notification.
if the Customer doesn’t provide within 30 calendar days any written notifications of the comments on the documentation received from the Contractor, the documentation shall be considered as agreed upon with the Customer.
All the Documentation delivered by the Contractor to the Customer shall be authorized and approved by the Contractor
2.10 Change Management of Design Documentation
Development, inspection, coordination, approval, making changes, and archiving of design documents shall be regulated by STO 8841271.291.039.2 “Corporate standard. Integrated Management System. Procedure for development of design products”. All changes introduced in design documentation shall be inspected and approved as well as input design documentation. If changes in one document influence another then this document shall be also updated. The procedure of making changes is regulated by STO 8841271.291.039.2.
3. Working Documentation (W.D.)
Working Documentation means documentation developed on the basis of Design Documentation approved by the Customer which shall ensure the level of detailing and certainty required for the development of engineering documentation and as-built documentation, order, manufacture, and tests of systems and equipment, and performance of the Works under the contract.
3.1 Developer of Working Documentation (W.D.) of Rooppur NPP
As per Clause 10.1 & 10.2 of General Contract No. 77-258/1414800 between JSC ASE and BAEC, JSC ASE will develop Working Documentation within the frame of the design works and will elaborate the Working Documentation for the construction of Rooppur NPP Units in accordance with the Design Documentation developed under Contract No. 2 and agreed by the Customer as well as in compliance with the Contract terms and conditions.
3.2 Coding System of Working Documentation (W.D.)
Classification and coding systems used for Working Documentation in the Rooppur NPP are described in the design materials Agreement on Using the KKS Coding System and Design Documentation Identification Guide. A sample coding of Working Documentation is shown below:
RPR.0120.10.XXX.YYY.BB.TB.0001
Where, RPR – Rooppur NPP Project Code
0120 – Code of the Designer
10 – The Unit Number
XXX – Code of a Building
YYY – Code of a system (Sprinkler System)
BB – Area of Works Code (Mechanical Solution)
TB – Code of the Document type (Working Drawings)
0001 – Registration Number.
3.3 Acceptance of Working Documentation from the Customer Side
The approval and acceptance criteria of Working Documentation are conducted as per General Contract (GC) No. 77-258/1414800 signed between BAEC & JSC ASE. The procedures of acceptance in accordance with the Clauses of G.C. are elaborated below:
- Documentation shall be packaged and submitted to the Customer.
- Each Documentation package specified in this sub-clause shall be delivered in quadruplicate in 4 (four) hard copies in English and in duplicate -1 copy in English, 1 copy in Russian as soft copies allowing to read and copy only (without editing), in .pdf or. tif format, having the scanning resolution parameters not less than 300 dpi for text and 600 dpi for pictures (if required).
- All Documentation developed and approved by the Contractor shall be reviewed and agreed upon (if there are no comments from the customer) with the customer in the part related to its quantity, completeness, and quality of formatting / drawing up.
- Should there be any customer comments, when reviewing the documentation as per clause 19.10, the Customer shall send the comments with an appropriate justification of each comment to the Contractor within 15 calendar days from the date of documentation receipt on the terms and conditions of the Contract.
- The Contractor shall send the relevant response to the Customer within 15 calendar days from the receipt of the Customer’s written notification.
- If there is no written notification to be provided from the customer relative to comments to the documentation received from the contractor, the documentation shall be deemed agreed upon with the customer.
- All the documentation delivered by the Contractor to the Customer, shall be authorized and approved by the Contractor
- Parties can resolve existing issues of disagreements at the periodic quarterly coordination meetings or specially arranged meetings
A Schematic presentation of acceptance of W.D. is shown in Figure-1.
Figure-1: Schematic presentation of acceptance of Working Documentation (W.D.)
4. Design Changes During the Construction Period of Rooppur NPP
IAEA Specific Safety Guide, SSG-38 has described that a process should be established to address proposals from the contractor(s) for changes to the design. And if a proposal has an implication for safety during commissioning, operation or decommissioning, the design organization(s), licensee and regulatory body, as appropriate, should be involved in its resolution. It also mentioned that arrangements for communication should be established between the design organization(s) and the construction organization, and between the construction organization, its contractor(s) and the licensee, where appropriate, to deal with queries concerning the design.
General Contract (G.C.) of Rooppur NPP, the customer shall be entitled to make a proposal in writing regarding particular changes at any time within the period of contract performance. On the other side, the contractor is entitled to propose any amendments to the customer, which are desirable or required in his opinion. The customer is entitled to his discretion to approve or reject any amendment proposal of the contractor’s proposal within thirty (30) days from obtaining the contractor’s proposal by sending a notification with reasons to the contractor in accordance with sub-clause 24.6 of G.C.
Usually, General Contractor, JSC ASE has requested for approval of any design change issue via a notification letter. This change of design can be related to Design Document Changes, Working Documentation Changes, Work Execution Plan Changes, Material Changes etc. any types of changes that creates the conflict with the design of the construction work. In accordance with clause 10.5 of G.C., the contractor shall submit to the customer the developed or updated Working Documentation with “approved for construction” stamp after the customer’s approval as per Clause 19.2 before the start of the relevant type of work and/or stage of work. Mostly, General Contractor submits the new revision of Working Documentation to BAEC officials for approval with a notification letter.
The most challenging part of the construction of Nuclear Power Plant is to prepare the final revision of Design Documentation and Working Documentation including all the changes performed during the construction period. The changes can be occurred due to the change of working procedures, change of amount and type of construction material, lack of experiences in sub-contractor’s side, correction in the design documentation, deviation in the performed work from requirements etc.
5. Conclusion
International Atomic Energy Agency’s (IAEA) Nuclear Energy Series, NP-T-2.7 has given importance on good coordination and good communication for a successful outcome if design work is conducted by different organizations and in different places even in different countries. It has also mentioned that the design must be matured, and the licensing issues must be resolved prior to start of construction. Moreover, IAEA Safety Series SSR-2/2 states: “During construction and commissioning, a comparison shall be carried out between the as built plant and its design parameters. A comprehensive process shall be established to address non-conformities in design, manufacturing, construction and operation. Resolutions to correct differences from the initial design and non-conformities shall be documented.” IAEA Specific Safety Guide, SSG-38 has described that the licensee should control the drawings, the use of design codes and the construction documentation that describe the basis for licensing the construction, commissioning and operation of the nuclear installation in order to maintain control of the design. Hence, it is clearly understood that the implementation of Design Documentation and Working Documentation is a dynamic process and it is required not only in the construction stage of a Nuclear Power Plant, but also in the commissioning and operation period of a nuclear power plant.
References
[1] INTERNATIONAL ATOMIC ENERGY AGENCY, Safety of Nuclear Power Plants: Commissioning and Operation, IAEA Safety Standards Series No. SSR-2/2, IAEA, Vienna (2011) (Revision of this publication in preparation).
[2] INTERNATIONAL ATOMIC ENERGY AGENCY, Safety Standards for protecting people and the environment, Construction for Nuclear Installations, IAEA Specific Safety Guide No. SSG-38, IAEA, Vienna (2015).
[3] INTERNATIONAL ATOMIC ENERGY AGENCY, Project Management in Nuclear Power Plant Construction: Guidelines and Experience, IAEA Nuclear Energy Series No. NP-T-2.7, IAEA, Vienna (2012).
[4] Quality Assurance Program for Designing for Rooppur NPP, QAP(D), RPR-AQA0001, Revision B03.
[5] General Contract No. 77-258/1414800 between Bangladesh Atomic Energy Commission (BAEC) and Atomstroyexport Joint-Stock-Company (JSC ASE) for Rooppur Nuclear Power Plant Construction.
[6] Contract No. 77-258/1308800 between Bangladesh Atomic Energy Commission (BAEC) and Joint-Stock-Company Atomstroyexport (the Russian Federation) for development of design documentation, first-priority working documentation and engineering survey for the Design stage of Rooppur NPP in the People’s Republic of Bangladesh.
[7] RPR-QM-AEB0001, Agreement on Using the KKS Coding System for Construction of Rooppur Nuclear Power Plant.
[8] RPR-QM-ADC0002, Design Documentation Identification Guide for Construction of Rooppur Nuclear Power Plant.
[9] STO 8841271.291.039.2 “Corporate standard. Integrated Management System. Procedure for development of design products”.
Md. Zakir Hossain, Engineer, Construction of Rooppur Nuclear Power Plant Project (CRNPP); Assistant Manager (Civil Engineering), Nuclear Power Plant Company Bangladesh Limited (NPCBL); Md. Yeasin Arafat Khan, Principal Engineer, Construction of Rooppur Nuclear Power Plant Project (CRNPP); Manager, Nuclear Power Plant Company Bangladesh Limited (NPCBL).
