Diesel d'ultime secours
On March 11, 2011, at 2:46 pm local time, an earthquake of magnitude 9 on the Richter scale shook the Pacific coast of Tohoku, Japan. Less than an hour later, a tsunami hit part of the eastern coast of Japan, causing waves up to 10 meters high.
The nuclear power station of Fukushima, located 90 miles (145 km) from the epicenter, suffered irreparable damage, leading to the explosion of the reactor buildings. Flooded by the tsunami, the Emergency Backup Generators were unable to take over from the main power supply. As a result, there was no longer any cooling system available.
In the following months, the Autorité de Sûreté Nucléaire (French nuclear safety authority) asked EDF to equip French nuclear power stations with Emergency Backup Generators to withstand extreme cases, thus guaranteeing the integrity of reactors in all situations.
In response to the initial post-Fukushima feedback, EDF launched a consultation in Q1 of 2013 to equip the 56 French reactors. A year later, in April 2014, Ortec joined forces with Clemessy and ABC to win the largest of the 2 lots for the manufacture and installation of 36 Emergency Backup Generators.
On this basis, a meticulous organization was set up within the Group to form an engineering team close to the customer, in line with the upcoming execution phase, and prepared to start work at the “lead” project site of Saint-Laurent-des-Eaux, mid-2016.
Used to joining forces and coordinating the best of its skill set, notably during major unit shutdowns, Ortec brought together a team capable of meeting these challenges.
a dedicated organization
Known for its ability to manage large-scale projects, the Ortec Group has unique know-how in bringing together, organizing and getting the best from its skill set.
To steer the Emergency Backup Generator project, Ortec established a new department: the Major Energy Projects division aimed, much like a catalyst, at gathering and coordinating within a single entity the best skills in the Ortec Group, from design to execution, in order to build a team capable of addressing the issues.
As a backdrop, the group, as part of a consortium, won a contract to equip 36 of the 58 French reactors with Emergency Backup Generators.
All of SOM’s design expertise (detailed preliminary project, processes, hydraulic calculations), SOM Calcul’s precision, mechanical and piping calculations, and reviews by Orys (an Ortec subsidiary specializing in nuclear works) of studies and design were set in motion to keep up with the pace. The Major Energy Project division ensured, for its part, the steering and monitoring of design.
The major phases of the project
An alchemy of research & design skills
In all, some hundred or so engineers and designers were involved in the research and design phase for a total of 120,000 hours of studies.
Services provided by the study panel:
- Design and implementation studies
- Qualification follow-up (seismic, shock wave, tornado, radiation, extreme temperatures, fire, etc.)
- Control of costs, lead time, risks, performance, quality, documentation and configuration.
- Drafting of technical requirement specifications, general specifications, contractor consultation files
- Drafting of assembly and testing procedures
- Risk analyses (works and operation)
- Management of outsourcing
- Production, works and testing follow-up and control
In addition, the expert design offices at headquarters (Lifting, Logistics & Welding, Control, Inspection) and the Industrial Purchasing department also took part in the design, supply and works contracting phase.
Innovation to serve performance
A 3D mock-up
A dedicated team summarized all the digital data gathered as they went, as well as data sent by everyone working on the project. This provided them with the same version of the updated model at all times.
The verification of interfaces between civil engineering and the equipment to be fitted, i.e. 1,500 interfaces per structure, is carried out through a point cloud survey process with a 3D laser using an algorithm for automatic recognition. This algorithm is used to superimpose the installations defined on the virtual mock-up with the exact dimensions, to highlight any discrepancies and manage any nonconformities before work begins. Similarly, the Ortec Group used a laser plotter to calculate and position, with extreme precision, the places where brackets were to be fixed. This saved time and proved to be extremely efficient, especially given the number of brackets to be fixed. Whereas for 200 piping elements, it used to take the teams two weeks with conventional measuring tools, only 3 days are needed with the laser plotter.
A lot of precious time was saved with this technology. Scaffolding was no longer needed to check a position located 5 meters high, nor was a topographer. Everything was automated and simplified for an accurate result and optimum efficiency.
A 4-dimensional project !
To carry out the same type of construction 36 times, within a limited time frame, the Major Energy Project division not only standardized and industrialized the process, but also the working method. Thanks to a tool designed specifically to deal with the issues involved with the Emergency Backup Generators: 4D planning
Within the consortium, it was Ortec’s job to define the scope and timing of operations for each operator. By setting up the 4D assembly scenario, which combined the digital 3D mock-up and the operations schedule, Ortec was able to build and optimize different construction scenarios, adjusted to planning over time. This tool made it possible for teams to clearly visualize the different project phases, by half-day, location by location, but also to manage the various co-activities between each operator, thus improving safety conditions on site.
The 4D planning was the principal indicator of project site preparation. A development “Made in Ortec”, hailed by all, and a point of pride for those who conceived it.
Indeed, only minor discrepancies were observed between the design and the finished construction at the first project site at Saint-Laurent-des-Eaux. The assembly scenario was compliant and was even improved on the following project sites, due to effective experience feedback.
coordination, method and rigor
in the works phase
Orys’ scope of works:
- Pipework processes
- Handling and metalwork equipment
- Ventilation / Heating / Explosion protection
- Fire extinguishing
- Assembly of the backup generator
- Assembly of auxiliary equipment
- Assembly of electrical cabinets
- Plugging of fireproof and exterior hoppers
Key figures
32 miles of piping
50 000 weldings including
6500 brackets fitted
1800 valves fitted
700 tests performed
180 pickling and passivation operations
Key figures
Total mass of equipment installed by Orys
6000 metric tons
1000 Electrical Cabinets
700 Process skids and mechanical equipment
300 Fans
72 Air coolers
36 Motor / Alternator Units 5600 Hoppers to be plugged
Handling operations orchestrated from beginning to end
As one of the Group’s core activities, handling operations require great expertise and proven know-how. To introduce a 62-metric ton backup generator inside the building, all the skills of the Ortec teams were mobilized.
From the design phase onwards, all the Ortec handling and lifting experts were fully involved in the preparation of this key stage: the installation of the backup generator. All of this, in close cooperation with ABC, the engine manufacturer. Ever the innovator, Ortec set up logistics for handling operations by designing and manufacturing a series of customized tools for extreme-precision positioning (hydraulic jacks, shifting paths, lifting beams, platforms).
Before the kick-off of the project site at Saint-Laurent-des-Eaux, a number of tests were carried out under real conditions in order to test the performance of the tools. Conclusive tests, successfully renewed upon successive operations.
Five years after the call for tenders on the power station at Saint-Laurent-des-Eaux, the Ortec Group finalized installation of the first Emergency Backup Generators. For this project of exceptional scale, the Ortec Group implemented work methods that were every bit as exceptional.
All of the Group’s resources played a role in meeting the project’s growing momentum and carrying out the various projects in parallel.
Deploying skills in parallel, the ultimate challenge
After having completed the reference worksite on the 2 units for Saint-Laurent-des-Eaux, a multiple challenge awaited the teams in charge of the Emergency Backup Generator project: to improve the methods used at Saint-Laurent-des-Eaux and to replicate them another 34 times (including 10 times in parallel at the height of operations), in less than 18 months!
This meant a project site launched every week, for 10 weeks, mobilizing 600 people from the Ortec Group alone, for a total of more than 1 million hours of work, with one objective: zero accidents.
This rhythm was maintained at a sustained pace by the Ortec teams, all the while respecting quality and safety standards, and deadlines, in order to meet the commitments made by its customer EDF to the Autorité de Sûreté Nucléaire.
Discover the Grand Angle files
