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ASQ 2006 Energy and Environmental Conference Nuclear Power Initiatives and Quality Perspectives

ASQ 2006 Energy and Environmental Conference Nuclear Power Initiatives and Quality Perspectives. Jack B. Allen Senior Vice President – Operational Excellence Westinghouse Electric Company. Overview. World Nuclear Snapshot U.S. Plan New Plants Opportunities QUALITY Foundation.

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ASQ 2006 Energy and Environmental Conference Nuclear Power Initiatives and Quality Perspectives

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  1. ASQ 2006 Energy and Environmental ConferenceNuclear Power Initiatives and Quality Perspectives Jack B. Allen Senior Vice President – Operational Excellence Westinghouse Electric Company

  2. Overview • World Nuclear Snapshot • U.S. Plan • New Plants Opportunities • QUALITY Foundation

  3. World Electricity Demand Growth (bkWh) 63% Increase Needed in Next 20 Years Source: EIA International Energy Outlook - Updated 07/05

  4. Forecast Electricity Demand by Region (Billion KWh) Source: EIA Annual Energy Outlook 2004 Asia Europe U.S Rest of World Extensive expansion of installed generating capacity needed!

  5. Nuclear…A Major Role in Global Generation 441 Operating Commercial Nuclear Power Plants Worldwide Percentage New Construction in Progress Source: International Atomic Energy Agency & World Nuclear Association Database

  6. Anticipated Global Nuclear Capacity Demand GWe Ref: The Future of Nuclear PowerAn Interdisciplinary MIT Study (2003) and Westinghouse Analysis 477 200 175 91 46 68 62 17 49 39 37 32

  7. The Nuclear Renaissance New plants under construction or strong consideration: Canada South Africa China South Korea Czech Republic Switzerland Finland Taiwan France Turkey India U.K. Russia U.S. Vietnam

  8. New Plant Markets Present Significant Growth Opportunities - Asia • China: 9 operating units; 2 under construction • Demand growth of 250% over 15 years • Evaluating AP1000 - 4 plant bid • Plan to build 35 – 40 new plants • South Korea: Commitment to balanced energy policy • Will award two additional orders in 2006 / 2007 • Japan: Toshiba ownership expands Westinghouse name/market • India: Establishing U.S. nuclear relationship

  9. Growth Opportunities – Europe and South Africa Opening of markets in European Union provides opportunities for U.S. companies • Finland: New reactor under construction • Belgium, Germany, Sweden: Future energy policy under review; owners investing in upgrades • Eastern Europe (EU): Evaluating energy needs;more new nuclear build programs likely • United Kingdom: Gap looming with old nuclear units retiring soon. Energy review includes nuclear • Republic of South Africa: 1-2 units needed, PBMR later

  10. Drivers of Global Market for Nuclear Plants • Rapidly growing economies in Asia • Coal transport limits • Need for fuel supply security, price stability - Russia cuts natural gas deliveries (contract dispute) • Kyoto Accords (reduce greenhouse gas emissions) • Old plants retiring • IAEA projection of nuclear by 2030: - Low estimate: 54 GW more than 2005 capacity (about 45 plants) - High estimate: 309 GW more (about 257 plants)

  11. Impact to U.S. Resources • Lessons learned for design, manufacture and construction of new plants • Potential to move focus from current plant upgrade, maintenance and operation • Step change demand to a consolidated infrastructure • Call to arms for knowledge transfer

  12. Vermont Yankee (1) Columbia (1) FitzPatrick (1) Monticello (1) Nine Mile Point (2) Seabrook (1) Kewaunee (1) Fermi (1) Pilgrim (1) Ginna (1) Palisades (1) Millstone (2) Prairie Island (2) Point Beach (2) Indian Point (2) (2) Susquehanna Limerick (2) Oyster Creek (1) Cook (2) Peach Bottom (2) Perry (1) Duane Arnold (1) Byron (2) Salem (2) Beaver Valley (2) Davis-Besse (1) Ft. Calhoun (1) Quad-Cities (2) Hope Creek (1) Dresden (2) Three Mile Island (1) Braidwood (2) Calvert Cliffs (2) La Salle (2) Cooper (1) North Anna (2) Clinton (1) Callaway (1) Surry (2) Wolf Creek (1) Diablo Canyon (2) Harris (1) McGuire (2) Watts Bar (1) Brunswick (2) Oconee (3) Sequoyah (2) H. B. Robinson (1) Vogtle (2) Browns Ferry (3) San Onofre (2) ANO (2) Catawba (2) Palo Verde (3) Summer (1) Hatch (2) Comanche Peak (2) Grand Gulf (1) Farley (2) River Bend (1) Waterford (1) South Texas (2) Crystal River (1) St. Lucie (2) Turkey Point (2) 103 Nuclear Power Plants Totaling 97,018 MWe (Number of operating units per site shown in parenthesis) Nuclear Power - 20% of U.S. Electricity Production

  13. Key Developments Renewed U.S. Interest in Nuclear • Natural gas prices soar • Focus on greenhouse gas emissions • Existing nuclear plants operating safely and economically • NRC new licensing process (avoid another Shoreham) • Energy Policy Act 2005 • Electricity demand growth • Advanced plant designs

  14. U.S. Needs by 2030… 45 % More Electricity Source: Energy Information Administration

  15. U.S. New Nuclear Plant Activity Source: Nuclear Energy Institute, Washington, DC (February 23, 2006)

  16. Currently Planned New U.S. Units

  17. Leaders forCombined Operating License Process • NuStart Energy Development • Companies engaged: 11 • Reactor designs: Westinghouse AP1000 and GE ESBWR • Dominion-led • Companies engaged: 4 • Reactor design: GE ESBWR • TVA-led • Companies engaged: 6 • Feasibility study to site GE Advanced BWR

  18. Operating Plant Uprate Activities • Replacement of Reactor Vessel Head • Replacement Steam Generators • Weld Overlay of Nozzle Penetrations • Upgrades to Instrumentation and Control Systems

  19. Supply Base Shrinking…Pump and Valve Suppliers for Example Copes-Vulcan SPX Valves & Controls Tyco Flow Control Curtiss-Wright Crosby Byron Jackson Limitorque Actuators Dezurik Anderson-Greenwood Anderson-Greenwood Target Rock Copes-Vulcan Crosby Dezurik K-Flo Tricentric Daniel Valve Target Rock Edward EMD Keystone EMD Hopkinsons Mueller Steam Worthington Keystone Flowserve Weir Valves & Controls Valtek Durco Pacific Pumps Daniel Valve Durco Edward Voght Pacific Pumps Atwood & Morrill Voght Valtek Flowguard Limitorque Actuators Atwood & Morrill Anchor-Darling Nordstrom Hopkinsons United Centrifugal United Centrifugal Durco Blakeborough Mueller Steam K-Flo Nordstrom Blakeborough Anchor-Darling Tricentric Byron Jackson Worthington Flowguard

  20. Some Emerging Issues and Trends • Major/Replacement Hardware Quality and Schedule Failures • Manufacturing, machining and special process controls errors • Materials and supplier qualifications • Supply Base Shrinkage and Lost Quality “Pedigree” • Transition to Digital Instrumentation & Controls • Critical Non-Safety Related Equipment Performance • Reactor coolant pump motors and non-safety transformers

  21. Industry Perceptions • Lacking Confidence in Supply Base • Issues, outage delays and lost expertise and knowledge • Migration from ASME Nuclear to ISO-9001 or Commercial Quality Assurance Programs • Commercial dedication of components • Compensatory measures - inspection, oversight • Active Customer Engagement (INPO – Institute of Nuclear Power Operations) • Human Performance, Corrective Action Programs, Operating experience and Nuclear Safety Conscious Work Environment • Active Regulator Engagement

  22. New Techniques: Construction Modularization • Large components • Alternative fabrication and assembly locations • Assembly transport • Sub-assembly and test practices

  23. Supplier Base Demands and Expectations • Step Change Growth – Multiple Plants • Competitiveness • Sub-Supplier Performance Assurance • Continuous Improvement Behaviors • Quality and Human Performance • Waste Elimination • Product and Technology Development • Alliance Relationships

  24. Thoughts …“What keeps us up at night” • Commitment to Sub-supplier Oversight • Achievement of Customer Expectations • Zero Tolerance for Error • Implementation of Human Performance Tools • The Big Picture • Step Change for Pace and Volume of Business • New Personnel Knowledge Transfer • Re-instilling Rigor and Discipline of “Nuclear QA” • An INCIDENT Anywhere … Affects EVERYONE !

  25. Timing and Impact of Attention and Influence Hayes - Wheelwright Model

  26. Westinghouse “Critical to Success” Objectives Achieve Sustainable Growth by Contributingto Our Customers’ Success CustomerIntimacy OperationalExcellence TechnologyLeadership • Behavioral • Differentiation • Create Success • for Customers • World-class • Environmental, • Health and Safety • Flawless Execution • Cost • Competitiveness • Develop / Maintain • Critical Skills • Develop Leading • Technology • Solutions • Innovation Customer 1st Management System • CFL Training • Project Outcome • Customer 1st Project • Reviews • Behavioral Modification FY2007

  27. Tools Enable Improvement Quality of Execution Ease of Doing Business Lean Enterprise Six-Sigma Human Performance Behavioral Differentiation Design for Six-Sigma

  28. Call to Arms for QUALITY Professionals • Respond to lessons learned for design, manufacture and construction of nuclear equipment • Restore Nuclear Quality Programs and Rigor • Implement Continuous Improvement Plans • Rapidly Initiate Knowledge and Experience Transfer • Maintain Industry QUALITY Conscience

  29. New Opportunities Require Re-building … a Strong Quality Foundation and Team which … Starts with YOU

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