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Costs Skyrocket as Containers Pile Up in Storage

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South African businesses are expecting a huge bill, with an estimated at R1.4-billion for storage and demurrage costs that have been accumulated during the 27 days of Level 5 lockdown, as more than 20 000 containers piled up in storage facilities across the country.

This week, the South African Association of Freight Forwarders (SAAFF) CEO David Logan expressed ‘serious concern’ at the high level of charges being invoiced by shipping lines for storage and demurrage on cargo which could not be delivered during the early stages of lockdown.

“SAAFF represents 294 South African companies in the international freight forwarding and customs broking arena managing approximately 70% of the containerised and break-bulk freight moving in and out of South Africa’s seaports, airports and land borders,” he says.

“Until recently, containers could not legally be delivered to closed importers until the appropriate lockdown level was reached. As a result, cargo was delivered and unpacked into warehouses.  In many cases the position remains the same with Level 3 only making its presence felt this week”.

“The level of charges levied by ocean carriers have been a source of concern for many years, but in normal times there was some justification for this as it was generally speaking relatively easy to clear and deliver containers within the free time allowed. Under these circumstances it was reasonable for the carriers to expect that their containers should be returned and put back into service without delay” Logan points out.

“COVID-19 has changed all that. The extended time spent in Levels 5 and 4 has meant that large numbers of containers could not be delivered with the situation only recently easing up when Level 4 allowed a limited amount of movement. The move to Level 3 will mean that a further large quantity of containers will be released for delivery, so we can expect increasing pressure in terms of exorbitant detention costs. Even at this stage, the amounts involved are very high and we are aware of invoices running into many millions of Rand already”.

Logan warns that this will not improve for some time.

Shipping line charges for delayed containers are derived from two main areas: storage (or overstay) and demurrage (or detention). The first usually involves a mark-up often running into several hundred percent of the warehouse’s charge.  The second is a direct charge for loss of use of the container. This is always charged in US Dollars at rates which bear no relation whatsoever to the actual cost of owning or leasing a container.

“In reality, these charges were designed to penalise inefficiency rather than to recover costs.  There is no logical reason why this approach should be applied in our current circumstances.

We appeal to ocean carriers to exercise restraint and moderation by recovering only their outlays, although we would accept that some reasonable administrative charge could also be imposed,” Logan concludes.

MANAGEMENTCertification and Operations Manager Appointed at the Road Freight Association

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Certification and Operations Manager Appointed at the Road Freight Association

Kevin van der Merwe a veteran Trucking industry specialist has been appointed as the Executive Manager: Certification and Operations at the Road Freight Association (RFA). He replaces Gavin Kelly, who has served as the Chief Executive since June 2019. Kevin will officially take on this role effective from the 1st of September 2020.

Kevin is no stranger to the RFA: he has been consulting for the Association for nine years, focusing on abnormal loads and vehicle loading. In January 2019 he was appointed as the Acting Executive Manager – Certification and Operations while the CEO position was being filled, to assist Gavin in ensuring members received the attention they needed.

His new role deals with certification: ensuring members are able to meet the Core Code and objectives of the RFA – from meeting compulsory standards, to elective certification of members for Road Traffic Management Systems – SANS 1395, Quality Management Systems – ISO 9001 (Integrated Freight Management Systems),  Environmental Management systems ISO 14001 (Integrated Freight Management Systems), Occupational Health and Safety – ISO 45000 and RTSMS (Road Traffic Safety Management System – ISO 39001), as well as operations: assisting with day to day challenges that members face in operating a commercial transport business in terms of the NRTA (and related legislation).

Kevin van der Merwe – Certification and Operations Manager: RFA

Solving Problems for Members

Whilst Kevin will continue with his work on abnormal loads and vehicles – “I have the support of a very experienced team who are experts in key areas that service the needs of our members”, he will now be involved in dangerous goods, green trucks, smart trucks, SMMEs, the Transport Education and Training Authority (TETA), security matters, traffic prosecutions, technological developments, operating costs, removals, couriers and recovery vehicles –  just to name a few. “My focus is to ensure that I engage with various role-players and stakeholders to solve and prevent problems that impact on the operational ability of members, as well as intervening in matters when irregularities are detected,” says Kevin.

Member and Industry Engagement Crucial

Interactions and engagements with RFA members are key in his new role: “The operational challenges and developments of members also form part of the responsibility of the position,” continues Kevin. “It enables me to engage with various role-players within the road freight and logistics industry:  including members, government departments, suppliers, Original Equipment Manufacturers (OEMs), equipment developers and academia. The position is responsible for driving engagement with our members through its various interest groups to ensure that the specific industry segments we represent have a conduit to effect the changes they want to see and ensure that the regulatory authorities do not lose sight of the fact that they must engage with industry on all matters that impact on it.”

Unlocking Membership Value

Kevin is excited at the opportunities his new position offers to unlocking membership value: “It is great to be part of such a dynamic group of capable people who understand the importance of putting our members first. The RFA has a great reputation as an effective industry representative body that takes direction from its members and is committed to unlocking membership value. The “reset” of the Association under the new leadership and focus on the needs of members is critical to the continued success of the RFA”.

COVID-19 and Consultation Cutbacks

Commenting on the myriad of challenges currently facing road freight operators, Kevin says: ”The COVID-19 pandemic has provided regulatory authorities with an ideal excuse not to engage with industry on a regular basis on matters such as the high cube container height limit issues, and the true meaning and purpose of “consultation” when engaging with interested parties for the purposes of introducing new legislation. I am however positive that we will get matters back on track as soon as the restrictions on movement and industry are lifted.”

The RFA is not opposed to regulatory authorities, because their role is to support industry and bring about a conducive operating environment. “As an Association we must endeavour to always put the needs of members first and continually find ways to unlock member value,” concludes Kevin.

6 Invaluable Tips for Trucking Operators

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With what may be a new-normal which includes uncertainty, disruptions, and a dynamic environment, here a several practical steps road freight operators could take to ensure some stability in their operations.

Gavin Kelly, Chief Executive of the Road Freight Association (RFA) offers some valuable advice for all road freight operators during these challenging and unpredictable times:

  1. Follow the COVID-19 Health Protocols published by the RFA: your business needs to follow these as a start.
  2. Ensure that you are registered with the National Bargaining Council for the Road Freight and Logistics Industry (NBCRFLI) so that you can benefit from the huge assistance packages the RFA has made possible. This helps you pay workers and will keep your business going during the dry spell.
  3. Look at your expenses: Make sure that you cover the important aspects of your business. Cutting maintenance costs for example is not a wise approach.
  4. Ensure you play a role in identifying corrupt practices.
  5. Join the RFA so that we can tackle corruption and other challenges together.
  6. Transport efficiently and safely and refuse to operate in non-sustainable circumstances. Ask a decent price for a decent service offered – don’t accept anything that is sub-standard.

There is a long, rough road ahead and those operators that survive and thrive are going to be those that are adaptable and agile.

China Export Boom Fades as Supply Chains Shift

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After two years of record exports, Chinese manufacturers are turning downbeat as consumers in their biggest markets curb spending and Covid lockdowns drive customers to competitors in the region.

With most of the world now living with the coronavirus and travel and other leisure activities resuming, consumers are cutting back on spending on Chinese-made laptops, phones and other work-from-home goods that propelled the nation’s exports and fueled the economy’s recovery from its pandemic slump in 2020.

On top of that, soaring inflation in the U.S. and Europe means households are tightening their belts, while costs of raw materials and logistics remain excessive, eating into exporters’ profits.

Those are just some of the challenges that businesses like Shenzhen Teanabuds Electronics Co. have been grappling with. An exporter of wireless earbuds, headsets and speakers to the U.S., Europe and the Middle East, the company has seen orders plunge by about 50% compared with last year.

“They will only continue to decline in the rest of this year because we are losing our advantage,” said Zhang Wanli, the company’s global marketing director.

Some of Teanabuds’ clients have recently shifted their orders to Southeast Asian countries as suppliers there offered lower prices given their supply chains are less stressed, Zhang said. High raw material and shipping costs have narrowed the company’s profit margin to 15% from 30% in 2019, he said.

The slump in demand for Chinese goods is a blow to the economy, which is already forecast to grow at the slowest pace in decades this year due to a property market slump and the government’s aggressive Covid-related restrictions.
After surging 30% in 2021, exports are likely to grow just 1.6% this year, according to Nomura Holdings Inc. Exports accounted for more than a third of China’s growth last year and 20% in 2020, the bank estimates.

Trade will likely get a temporary boost as Shanghai reopens from its two-month long Covid lockdown — economists expect data Thursday to show exports grew 8% year-on-year in May, up from 3.9% in April. Still, the trend for the rest of the year is down.

“The export boom caused by Covid is behind us,” said Larry Hu, head of China economics at Macquarie Group Ltd.

Exports may contract this year in volume terms even if nominal growth could be positive due to price increases, said Thomas Gatley, a senior analyst at Gavekal Research Ltd. A drastic slowdown would put Beijing’s economic growth target of about 5.5% further out of reach.

“This is really not a good time for exports to weaken as well,” said Gatley. “This is why policy makers are increasingly panicking.”

Even though global consumers remain cashed up, fading government fiscal support and rising interest rates are impacting their disposable income. And with shoppers pivoting their spending back to services from goods, demand is sliding.

Vice Commerce Minister Wang Shouwen also acknowledged the pressures facing China’s trade, saying Wednesday that “we must be soberly aware that there are still a series of uncertainties in foreign trade.” A fragile global economic recovery, high inflation internationally, and logistics bottlenecks within China all cause uncertainties for the trade outlook for the rest of the year, he said at a press conference in Beijing.

Major U.S. retailers like Walmart Inc. and Target Corp. are also sitting on inventories of $45 billion, up 26% from a year ago, which they bulked up during the pandemic to overcome shipping delays. That means they’re under no pressure to place new orders.

Guangzhou GL Supply Chain Co., which makes everything from gardening products like watering cans and table cloths to Christmas-themed storage bags, says orders from U.S. and European customers have declined by half from the same period last year.

Even products for the Christmas season are selling poorly compared with 2021, “perhaps because people have to spend more money on basic necessities” because of higher inflation, said Chen Zijian, the sales manager.

“Last year, the pandemic was more serious,” he said. “But we sold gardening products, and the business wasn’t impacted much, perhaps because people stayed at home and gardened.” Compared with last year, “our orders have declined quite a lot,” he said.

Losing Out

More broadly, analysts say that a shift in supply chains for cheaper manufacturing in Southeast Asia is accelerating after a brief pause in the past two years. About 7% of Chinese orders for furniture were lost to countries like Vietnam between September 2021 and March 2022, as well as 5% for textile products and 2% for electronics, according to an estimate by Everbright Securities Co.

That challenge is being compounded by elevated raw material prices and freight rates. The raw materials subindex under China’s producer price index surged 17.4% in April, keeping costs elevated. The Shanghai containerized freight index is still at over four times pre-pandemic levels despite a retreat of 17% so far this year.

Even those exporters that are doing well are worried about what’s ahead as the Federal Reserve and other central banks raise interest rates.

Hermann Zhai, general manager of Shandong-based Kinghike Vehicle Co., which exports electric golf carts to the U.S., is enjoying a surge in orders thanks to more clients switching to electric instead of gasoline-powered carts in the face of skyrocketing energy prices.

“I hope the measures the Fed is taking will be effective to contain inflation,” Zhai said. “If it worsens and becomes hyperinflation, that could damage our sales significantly.”

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LA Port Braces for Early Peak Cargo Season as Consumers Keep Buying

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The Port of Los Angeles, the U.S.’s busiest, is preparing for the early arrival of the 2022 peak season for cargo as retailers stock up on back-to-school and fast-fashion products despite high inventory levels, Executive Director Gene Seroka said.

“The upstream orders coming from Asia — getting ready for an early arrival of peak-season goods — look strong; the June numbers will be very healthy,” Seroka said in an interview on Bloomberg Television Friday. He added that the port handled just under 970,000 units of cargo in May, making it the operation’s third-busiest month on record.

Retailers have been building up inventories amid soaring consumer demand and transportation bottlenecks, but many including Target Corp. and Walmart Inc. are trying to figure out how to sell all their products as people shift to spending more on services over goods.

“The cargo keeps going because the consumer keeps buying. Those inventory levels have to be built up across a wide spectrum of retailers and importers,” he said. The shipments due to arrive are not necessarily the product that is going to be looked at for discounting and pushing out, but are instead seasonal goods specific to the second half of the year, such as back-to-school items.

“What we’ll also see is cost-minded consumers looking for the necessary bargains to put food on the table for dinner. We may be buying hamburger instead of steak, beer instead of fine wines. We’re going to keep buying; our savings accounts are fairly high.”

President Joe Biden visited the port Friday to highlight the White House’s push to smooth out the supply chain crunches that have stoked the hottest inflation since 1981.

The president and his administration have helped since last year to reduce massive backlogs at the twin ports of Los Angeles and Long Beach, which handle 42% of containerized trade with Asia. The gateways have been bracing for an earlier-than-normal peak season in shipping, which usually starts in July ahead of the holiday season.

The easing of port congestion in Shanghai is expected to unleash a wave of containers on the U.S. West Coast that could clog supply chains further.

This year, it’s likely to coincide with what some port chiefs say will be an increase in cargo arrivals that had been held back from the U.S. because of the lockdowns in Shanghai and surrounding areas, as well as the expiration of labor contracts for 22,000 dockworkers across 29 ports in California, Oregon and Washington.

Read more: What West Coast Ports’ Labor Negotiations Mean for Supply Chains

“What we’re going to see here in the next month or two is an accelerated number of calls for the volume that did not come during the ‘zero policy’ lockout slowdown,” Long Beach Executive Director Mario Cordero told Bloomberg Television in a separate interview, citing disruptions in transportation and labor shortages across the Pacific. “While it’s fair to say that the ports in China were not closed, it’s also fair to say that the supply chain there was rather chaotic.”

Seroka has said cargo flows from China have been consistent despite the lockdowns, with freight moving through the Yangshan and Ningbo while Shanghai operations were shuttered.

Los Angeles “did not see the precipitous drop in cargo that some observers had called for — the ports and central government had prioritized this long haul cargo coming to Los Angeles, the southern California ports,” Seroka said. “And now we’re starting to see just a little bit of an uptick, which are the peak-season goods.”

The Los Angeles port chief said dockworkers and employers are unlikely to reach a new contract by the expiration of the current one on July 1, but both sides have committed to keep operations running.

“They’re going to continue to work as hard as they can at the table while everyone is out moving cargo,” Seroka said, adding he doesn’t see a strike on the cards. “We don’t want any disruptions to the American supply chain.”

Canada’s OPG and Czech Republic’s ČEZ Partner to Advance SMR and Other Nuclear Technology

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Ontario Power Generation (OPG) and Czech Republic-based ČEZ are collaborating to advance deployment of nuclear technology, including small modular reactors (SMRs). The companies said they signed a memorandum of understanding (MOU) on Oct. 11, with an aim to “reduce financial, technical and schedule risk to both parties on their respective future projects.”

OPG is Ontario’s largest electricity generator. The company has 75 generating stations in the province with a combined capacity of more than 18 GW. In addition to 66 hydroelectric facilities, its fleet includes two nuclear stations—the 3.5-GW Darlington facility and the 3.1-GW Pickering station (Figure 1). OPG says nuclear power provides about 60% of Ontario’s power today.

1. Pickering Nuclear Generating Station is a power plant located on the north shore of Lake Ontario. It consists of eight CANDU reactors. Since 2003, two of the units have been defueled, while the other six units remain operational. Courtesy: OPG

“Ontario Power Generation is a world-class nuclear operator, with decades of experience in providing safe, clean, reliable nuclear power,” OPG President and CEO Ken Hartwick said in a statement. “Working together with entities like ČEZ, we can leverage our combined experience to develop and build the new technology needed to power the future and meet decarbonization goals.”

ČEZ is one of Europe’s largest energy companies. Both OPG and ČEZ have committed to achieving net zero goals by 2040, and they believe advanced reactor technology can help in that mission.

Darlington SMR

Under the MOU, OPG and ČEZ will share information related to the deployment of new nuclear projects. OPG has said new nuclear generation, including SMRs, is “an essential part of the electricity mix needed to decarbonize the energy sector and broader economy.” OPG is in the process of deploying an SMR at its Darlington site and has already received approval of an Environmental Assessment.

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In December 2021, OPG said it would work with GE Hitachi Nuclear Energy on the Darlington SMR project. GE Hitachi’s BWRX-300 (Figure 2) is a 300-MWe water-cooled, natural circulation SMR with passive safety systems. It is the 10th evolution of GE’s boiling water reactor (BWR). The company says the BWRX-300 represents the simplest and most innovative BWR design since it began developing nuclear reactors in 1955.

2. An artist’s rendition of a GE-Hitachi BWRX-300 nuclear unit. The BWRX-300 is a 300-MW boiling water reactor (BWR) that derives from the Gen III+ 1,520-MW ESBWR, which the Nuclear Regulatory Commission certified in 2014. Courtesy: GEH

On March 10 this year, OPG announced it had awarded a $32 million contract to E.S. Fox Limited for the first phase of site preparation and support infrastructure for the Darlington SMR project. Among the infrastructure work expected to be completed under the contract is bringing water, electrical power, information technology, and roads to the site. The Darlington SMR is expected to be operational by the end of this decade.

ČEZ’s Nuclear Fleet

ČEZ is no stranger to nuclear power either. It currently operates two nuclear power plants (NPPs) in the Czech Republic. The four-unit Dukovany site (Figure 3) was the first NPP built on Czech territory, and, according to the company, it is “one of the largest, most reliable, and economically advantageous energy sources” in ČEZ’s fleet. Dukovany is located 30 kilometers (km) southeast of Třebíč. It produces about 20% of the total electricity consumption in the Czech Republic.

3. The Dukovany Nuclear Power Plant, with an installed capacity of 2,040 MW, is the second-largest nuclear power plant in the Czech Republic. Courtesy: ČEZ

The Dukovany plant has four VVER 440 model V 213 pressurized water reactors (PWRs). The individual units were put into operation between 1985 and 1987. The original total installed electrical capacity was 1,760 MW, but output has been gradually increased through turbine upgrades, efficiency programs, and technical improvements. Today, the power plant has an installed capacity of 2,040 MW.

ČEZ also operates the dual-unit Temelin NPP, which is situated about 24 km from the South Bohemian capital České Budějovice. Temelin has two VVER 1000 Type V 320 PWRs. The units entered operation in 2000 and 2003, respectively. The station generates roughly the same electricity annually as the Dukovany plant.

A Partnership with Potential

Like OPG, ČEZ has taken first steps toward expanding its nuclear fleet at both Temelin and Dukovany. “As a company, we are focused on developing new energy solutions and technologies,” Tomáš Pleskac, member of the Board of Directors and chief of the New Energy Division with ČEZ, said in a statement. “We are preparing for the construction of a new nuclear unit in Dukovany and the upcoming allocation of space at Temelín, where the first SMR could be built in the first half of the next decade. The collaboration with OPG is therefore, for us, a logical step forward.”

“Ontario is proud to lead the way on clean nuclear technologies,” Ontario’s Energy Minister Todd Smith, said in a statement. “With our robust nuclear supply chain and talented workforce, we are ready to support the global deployment of our nuclear expertise that will help reduce emissions while delivering energy security to the world.”

Transnet opens port capacity for emerging manganese mining companies

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Transnet plans to open up capacity allocation for emerging miners through the Ports of Gqeberha and Saldanha from April, 2023 when its current long-term contracts come to an end.

In a statement, Transnet said it had issued a formal communique to all 10 manganese exporters recording the expiry of current contracts, which are set to wrap up on March 31, 2023.

“New contracts will be entered into with new and existing miners, effective from April 1, 2023,” it said.

According to Transnet, new contracting and capacity allocation processes have commenced, with the intent to enable the emerging miner to ramp up.

“Transnet hopes to increase the current number of emerging miners that have access to rail and port capacity from the current four to 11, through introducing seven new entrants by the beginning of the next financial year,” it said.

Transnet said currently, the emerging miner allocation was 2 million tons per annum (mtpa).

“Transnet seeks to make an additional minimum of 2mtpa available for emerging miners, thereby creating 100% growth to a minimum of 4mtpa in this sector by April, 2023. This constitutes a 25% share of total available capacity,” the group said.

The company said part of its strategy to enable emerging miners was to look at ways of easing its business processes.

“Some of these include the following: easing the burden of funding bank guarantees as a requirement for doing business for emerging miners; an arrangement where underwriters cover the risk of a guarantee by up to 50%; and Transnet covers the remaining 50% is currently being finalised with underwriters,” it said.

Transnet said it further commits to continue supporting emerging miners with loading capacity in the manganese space.

“Transnet would also like to reaffirm its commitment to its long-term expansion project, which includes enabling capacity growth from the current 16mtpa to 22mtpa by 2027. This ramp-up will further enable emerging miner growth,” the company said.

Meanwhile, Transnet Port Terminals, an operating division of Transnet, declared a force majeure to all its customers following the strike action declared by two recognised unions within Transnet.

The United National Transport Union (Untu) and the South African Transport and Allied Workers (Satawu) embarked on a strike against the offered wage increases by Transnet for the new financial year, as well as the fact that no wage increases were approved for the current financial year.

Transnet said it anticipated that portions of its operations will be scaled down.

“However, and to the extent possible, we will invoke contingency plans and source external stand-in or temporary resources to ensure that the operations continue across the various terminals.

“Should the strike extend beyond the anticipated period of one week, Transnet will assess the impact of the strike on its operations and the force majeure event declaration. Further communication in this regard will be forthcoming from Transnet Port Terminals,” it said.

China Will Add Two More AP1000 Nuclear Reactors

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China’s State Council has approved two AP1000 nuclear reactor units for State Power Investment Corp.’s (SPIC’s) Lianjiang Nuclear Power Plant in Zhanjiang, Guangdong province, reactor technology supplier Westinghouse said on Oct. 12.

If built, the units will become ninth and tenth reactors based on Westinghouse’s Generation III+ advanced reactor technology in China. Four AP1000 units are already currently operating in China: Sanmen 1 and 2 in Zhejiang province and Haiyang 1 and 2 in Shandong province. The four reactors were commissioned in 2018.

The Lianjiang Nuclear Power Project is located in Tianluoling, Cheban Town, Lianjiang City, Zhanjiang City, Guangdong province, 48 kilometers away from Lianjiang City and 65 kilometers away from Zhanjiang City. This image envisions what the six-unit plant will look like when completed. Courtesy: SPIC

Another four CAP1000 reactors—China’s licensed adaptation of the AP1000—are under construction at the Sanmen and Haiyang plants. Sanmen 3 and 4. China National Nuclear Corp. (CNNC) kicked off construction of the second phase at Sanmen in June 2022, while Shanghai Nuclear Engineering Research and Design Institute (SNERDI), a SPIC affiliate, poured first concrete for Haiyang’s second phase in July 2022. The State Council approved the two projects in April. By Sept. 25, SNERDI, a general contractor for both projects, reported it had separately hoisted in place containment vessels at Haiyang 3 and Sanmen 3.

SNERDI is also building CAP1000s at Lianjiang 1 and 2. The company on Sept. 28 announced it began excavation for the Lianjiang plant’s first phase. The site is designed to host a total of six 1.2-GW reactors, said SNERDI.

Speeding Toward ‘Nth-of-a-Kind’

Westinghouse in a statement congratulated SPIC on adding the AP1000-derived plants to its growing fleet. It said the AP1000 plant “is the only operating Generation III+ advanced reactor with fully passive safety systems, modular design, and has the smallest footprint per MWe on the market.” The reactors at Sanmen and Haiyang “utilize the most advanced, proven technology and have set industry records with their outstanding startup, availability, and operational performance. One unit at the Haiyang site is generating both electricity and steam for district heating,” it noted.

Excellent Planning and Focus on Safety Lead to Successful Feedwater Heater Replacement Project

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Nuclear power plant outages are filled with intense work and tight schedules. A feedwater heater replacement project at Duke Energy’s Oconee station in South Carolina shows how teamwork coupled with excellent planning and a focus on safety can lead to success.

Feedwater heaters (FWHs) are an integral part of a nuclear power plant’s thermodynamic cycle. Depending on a plant’s design, there may be low-pressure FWHs installed between the unit’s condenser and deaerator, while high-pressure FWHs are often installed between the deaerator and steam generators. The number of FWHs installed is designed to optimize thermal efficiency. Each FWH typically utilizes steam from an extraction point placed at various stages of the plant’s steam turbines.

1. The new feedwater heater (FWH) is shown here staged on the turbine deck prior to the outage. The next step was to remove the shipping caps over the nozzle connections and add insulation. Courtesy: ARC Energy Services Inc.

Over time, the tubing in FWHs can erode, so it’s not uncommon for the components to eventually require repair or replacement to ensure long-term efficient plant operations. In May 2022, Oconee Nuclear Station replaced two vertical 60-ton FWHs in Unit 3 (Figure 1). ARC Energy Services Inc., Sarens Nuclear & Industrial Services Inc., 3SPACE Inc., and Structural Integrity Associates Inc. teamed up to complete the job in just 12 days and one hour. The project required 700 welds and more than 42,400 total hours of work, including planning, pre-outage, and outage activities, all completed safely.

Project Responsibilities

3SPACE performed laser scanning and created a point cloud to capture all interferences requiring removal before the feedwater heaters could be replaced. ARC then generated a 3D model animation to visualize the process during planning. ARC also engineered a sliding rail system, controlled by hydraulic pumps, which was installed in the heater bay crane aisles to mobilize needed rigging equipment for the FWH replacements, including:

2. The old FWH is shown here being removed with the temporary lift device. Courtesy: ARC

The old FWHs were removed with the TLD (Figure 2), down-ending onto the rock-over tailing cart and trunnion cart while maintaining control with the hydraulic sliding rail system. The new FWHs were up-ended using the same equipment and set into location so 3SPACE could perform metrology to align the 24-inch inlet and outlet nozzles (Figure 3).

3. The new FWH is shown here being aligned to the pedestal. Courtesy: ARC

Once all alignment was completed the team installed all piping and interferences per new design drawings. Structural Integrity performed phased array ultrasonic testing (PAUT) on all 24-inch nozzle welds before and after post-weld heat treatment with no rejections.

Teamwork and Innovation Overcomes Challenges

One of the biggest challenges was keeping the team safe and healthy. Several work groups had people out due to COVID-19. The team minimized that potential issue by practicing good hygiene and following COVID protocols that were in place.

4. The new FWH is shown here as it’s being lowered, with the knuckle boom crane pictured in the foreground. Courtesy: ARC

Another challenge involved crane use because two major projects were ongoing on Unit 3, which limited crane availability. Conflicts were avoided through effective communication and scheduling with Duke Energy work groups. ARC also provided an alternate option of using the knuckle boom crane (Figure 4) in some situations.

The project team utilized special engineered equipment to remove and replace the two 60-ton FWHs in the limited space and time available. The work was done safely with no injuries or first aid incidents, even while COVID-19 was a widespread threat. The success of the project demonstrates to the industry that with proper planning and focused execution jobs can be accomplished effectively and efficiently. The FWH project was completed below budget and ahead of schedule with zero injuries in 42,400 hours worked.

An Effective Safety Program

As a contractor for Duke Energy, ARC works closely to mirror the client’s safety culture and protocols. The company believes that all injuries can be avoided and promotes a safety-conscious environment on the job and off the clock. ARC says safety is 24-7 and it demonstrates that in all engagements with clients and staff.

The ARC safety program used at Oconee—and on all of the company’s projects—is designed to educate and guide employees and subcontractors toward a safe and healthy working environment. In addition to a comprehensive Environmental Health and Safety (EH&S) policy and procedure, and required training for compliance with all applicable safety and health standards, employees participate in a weekly safety training session designed to cover the latest best safety practices pertaining to the power industry.

Training and risk assessments include regulatory standards and applicable behavioral-based safety developments. Management’s commitment to safety is the foundation of the ARC program. Managers lead by example and guide crews to perform at the highest level of safety consciousness. At the beginning of each shift, teams complete a job hazard analysis to identify the assigned tasks, associated risks, and how to mitigate those risks and execute the work without incident.

Construction Quality and Craftsmanship

Using ARC’s robust Quality Management Program (QMP), managers set solid expectations and plans months before project initiation. Project quality requirements—from implementation to final offloading of the FWHs—were set and followed precisely.

The project’s quality team included four non-destructive test (NDT) and quality control inspectors (QCIs), who monitored every detail of the code, plans, and procedures used. Structural Integrity provided highly qualified PAUT specialists, who performed flawlessly and with precision.

5. Workers are shown here welding one of the 24-inch pipe connections to the FWH. Courtesy: ARC

Quality went beyond welding. It encompassed the development of quality plans, document controls, filler material controls, professionalism of each team member and their willingness to get things done right the first time, training, and following each element of the QMP. The team successfully completed the project making almost 700 welds with each being inspected, documented, and tracked (Figure 5).

Just like safety, quality takes a team effort. Without the amazing team ARC formed, quality would have suffered. Each team member contributed to the elevated quality of this project in the following ways:

Bespoke pit fan motors with fin cooling

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Menzel Elektromotoren has designed and manufactured three powerful 6600 V squirrel cage motors as integral components for pit fans. The customer specified cylindrical motor casings as compact as possible. The greatest challenge was to implement the required rated power of 1700 kW in cylindrical casings. Menzel therefore designed fin-cooled motors (cooling type IC 411) in frame size 630, an extremely unusual design for motors this large. The manufacture is complex but the result is optimal for the constricted installation conditions. In order to save additional space, all connection cables are routed out of the motors and the terminal boxes are mounted outside the fans. Since the driven fan wheels are mounted directly on the motor shafts, the motor bearing must compensate additional high loads: radial loads up to 20700 N and axial loads up to 27000 N. For the required bearing service life of 100,000 hours, Menzel implemented a special rolling bearing setup. In addition, the motors have a second shaft end for a holding brake. The three-phase squirrel cage motors are designed for operation on a frequency converter (duty type S9) with speed changes and reversal of the rotation direction. This allows the pit fans not only to ventilate the mine, but also to extract dangerous firedamp if necessary.

Surface-cooled motors from Menzel: https://www.menzel-motors.com/slip-ring-motor/ic411/

About Menzel ElektromotorenBased in Berlin, Menzel Elektromotoren GmbH has been manufacturing and distributing electric motors since 1927. The medium-sized company specializes in the delivery of large electric motors, including special models, within the shortest possible time. The product range comprises high and low voltage motors, DC motors, transformers, and frequency inverters. Services include motor production and short-term adaptation of stocked motors to application-specific requirements. In order to ensure fast deliveries to the customer at all times, the company maintains a very extensive inventory including more than 20,000 motors with a maximum performance of up to 15,000 kW. Qualified engineering, experienced staff, and state-of-the-art production and testing facilities help Menzel provide excellent reliability. Menzel operates subsidiaries in the UK, France, Italy, Spain, and Sweden, and cooperates with numerous partners worldwide.
Contact:Menzel Elektromotoren GmbHMathis MenzelNeues Ufer 19 – 2510553 BerlinGermanyPhone: +49 . 30 . 349 922-0Email: info@menzel-motors.comInternet: www.menzel-motors.comgii die Presse-Agentur GmbHImmanuelkirchstr. 1210405 BerlinGermanyPhone: +49 . 30 . 538 9650Email: info@gii.deInternet: www.gii.de