NUCLEAR POWER PLANT MARKETING 838, Yeoksam-dong, Gangnam-gu, Seoul 135-982, KOREA Tel: 82-2-513-6341
Fax: 82-2-513-6678 Home page www.doosanheavy.com
Doosan Heavy Industries America Corp. 140 Sylvan Avenue, Suite 3B, Englewood Cliffs, NJ 07632, USA Phone: 1-201-944-4554 Fax: 1-201-944-5022/ 5053 Doosan Heavy Industries Japan Corp. Room 307, Mita Kokusai Bldg. 1-4-28, Mita Minato-ku, Tokyo, Japan Phone: 81-3-3452-5451~3 Fax: 81-3-3452-5624 Doosan Malaysia Sdn. Bhd. (Kuala Lumpur Office) Letter Box No. 86, 22nd Floor, UBN Tower, 10 Jalan P. Ramlee, 50250 Kuala Lumpur, Malaysia Phone: 60-3-2026-8890 Fax: 60-3-2026-8891 Inkor Engineering Private Ltd. 1508, Maker Chambers 5, Nariman Point, Mumbai 400-021, India Phone: 91-22-202-6504/ 2053/ 7842 Fax: 91-22-202-6557 Beijing Office Room 1904, Landmark Bldg., 8 North Dongsanhuan Road, Chaoyang Dist., Beijing 100004, China Phone: 86-10-6590-0924/ 0109 Fax: 86-10-6590-0991 Dubai Office Office #1002, Al Moosa Tower II, Sheikh Zayed Road, P.O.Box 11859, Dubai, UAE Phone: 971-4-332-2703 Fax: 971-4-332-2714 Frankfurt Office 4th Floor, Arabella Center, Lyoner Strasse, 44-48, 60528, Frankfurt am Main, Germany Phone: 49-69-69-5004 0 Fax: 49-69-69-5004 10 Riyadh Office P.O. Box 9656, Riyadh 11423, Saudi Arabia Phone: 966-1-419-1920/ 1696/ 0397 Fax: 966-1-419-1995 Taipei Office 704, No. 51, Keelung Road Sec. 2, Taipei, Taiwan, Republic of China Phone: 886-2-2739-2255 Fax: 886-2-2739-2266 Schenectady Office Room 33-202A, General Electric Bldg., 1 River Road, Schenectady, NY 12345, USA Phone: 1-518-385-5218/ 2629 Fax: 1-518-385-4984 Windsor Office 2000 Day Hill Road, P.O. Box 500, Windsor, CT 06095, USA Phone: 1-860-731-6482/ 6479 Fax: 1-860-731-6478
INTRODUCTION ORGANIZATION EXPERIENCE FEATURES OF PWR (KSNP) - SYSTEM OF KSNP - ADVANCED FEATURES OF KSNP - REACTOR COOLANT SYSTEM - REACTOR VESSEL AND INTERNALS - REACTOR INTERNALS - REACTOR VESSEL - CONTROL ELEMENT DRIVE MECHANISM - STEAM GENERATOR - PRESSURIZER - GAS STRIPPER - HEAT EXCHANGER - TANK FEATURES OF PHWR - PHWR SYSTEM - CALANDRIA - FEEDER HEADER ASSEMBLY DESIGN ANALYSIS MANUFACTURING FACILITIES RESEARCH & DEVELOPMENT QUALITY ASSURANCE SERVICE & REPLACEMENT CONSTRUCTION & INSTALLATION 4 6 8 10 10 12 13 14 15 16 18 20 22 24 25 25 26 26 27 27 28 30 32 33 34 35
Clean World for Our Next Generation
uclear energy offers the nation and the world a clean method of generating electricity to support economic growth without polluting the atmosphere. Because nuclear power plants do not burn anything, they are non-polluting and kind to the environment. Unlike coal-, gas-, and oil-fired power plants, nuclear power plants do not emit carbon dioxide and other harmful gases into the atmosphere. Carbon dioxide is responsible for about half of any global warming caused by the greenhouse effect. Not only have nuclear power plants kept carbon dioxide out of the atmosphere, they also have lessened emissions of nitrogen oxide and sulfur dioxide. Nitrogen oxide plays a major role in the formation of ozone, which is harmful to human health. Sulfur dioxide is believed to contribute to acid rain. The increased reliance on nuclear energy throughout the world has contributed to a cleaner and healthier environment for everyone.
n proportion to the rapid development of Korea’s economy, the demand for electricity has increased just as quickly. As a leading supplier of Korean nuclear equipment, it has been DOOSAN’s responsibility to meet this demand. DOOSAN is a major player in the nuclear power plant business, and was chosen as sole manufacturer of heavy components for the Nuclear Steam Supply System at Yonggwang Units 1&2 and Ulchin Units 1&2 (including Reactor Vessel, Steam Generators, Pressurizer and Primary Piping). The company was then selected as prime contractor for Yonggwang Units 3&4 (1,000 MWe each), and demonstrated its superior capability through exceptional equipment quality and plant performance. Based on extensive experience and continued efforts to further develop a sturdy technological base, DOOSAN successfully contributed to the design and construction of Ulchin Units 3&4 (1,000 MWe each) – two flagship units designated as the Korean Standard Nuclear Power Plant (KSNP). The on-site construction of the Ulchin project was completed successfully under the careful direction of DOOSAN. DOOSAN has supplied NSSS and T/G for Yonggwang Units 5&6 (1,000 MWe each), and also provided the Replacement Steam Generator (RSG) at Kori Unit 1 in Korea and four RSGs for Sequoyah Unit 1 in the U.S.A. In addition to its increased involvement in the Korean Pressurized Water Reactor (PWR) program, DOOSAN also is fully capable of supplying the complex equipment required for Pressurized Heavy Water Reactors (PHWR). Thus, the high-quality equipment demanded by Wolsong Units 2,3&4 was supplied by DOOSAN. The company also supplied Steam Generators, a Feeder/Header and related equipment for Qinshan CANDU Units 1&2 in China.
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Currently, DOOSAN is committed to the manufacture of NSSSs and T/Gs for Ulchin Units 5&6, ShinKori Units 1&2 and Shin-Wolsong Units 1&2 (1,000 MWe each) in Korea, as well as NSSS for KEDO Units 1&2 in North Korea and four RSGs at TVA Watts Bar Unit 1 in the U.S.A. Moreover, DOOSAN has been designated as prime contractor for the supply of NSSS and T/G for Shin-Kori Units 3&4 (1,400 MWe each) in Korea. DOOSAN is prepared to supply safe and reliable Nuclear Power Plants to any customer, anywhere in the world.
ORGAN ZAT ON
Chairman of the Board & President
Marketing & Business Development Group
Technique / Production Business Group
Civil & Construction Business Group
Marketing & Business Development Division
Engineering Division Thermal & Hydro Power Plant Division Nuclear Power Plant Division Industrial Machinery & Plant Division Engine / Casting & Forging Business Division
Civil & Construction Business Division
Nuclear Power Plant Planning Dep’t
Corporate Quality Control
Nuclear Design & Production Nuclear Design Dep’t Nuclear BOP Design Dep’t Next Generation Reactor Team NSSS Engineering Dep’t Nuclear Manufacturing Engineering Dep’t Nuclear Component Fabrication Shop
Nuclear Production Control Dep’t Customer Services Younggwang #5,6 PM Ulchin #3,4 PM Ulchin #5,6 PM Wolsong PM KEDO PM Ulchin Construction Site
s a leading supplier of nuclear equipment in Korea, HANJUNG has taken a leading role in nuclear power plant construction since it supplied main components to Kori units 3 & 4 in 1981. Based on the technology accumulated over the past twenty years, HANJUNG has proven its capability by constructing 1,000 MW-class nuclear power plants as the prime contractor of the Yonggwang units 3, 4, 5 & 6 and Ulchin units 3, 4, 5 & 6.
Wolsong Nuclear Power Plant (WSN #1,2,3,4)
Ulchin Nuclear Power Plant (UCN #1,2,3,4,5,6)
BEIJING North Korea Nuclear Power Plant (N. Korea #1,2)
Qinshan Nuclear Power Plant (QSN #1,2)
Yonggwang Nuclear Power Plant (YGN #1,2,3,4,5,6)
Kori Nuclear Power Plant (KRN #1,2,3,4)
Project Yonggwang # 1, 2 Ulchin # 1, 2 Yonggwang # 3, 4 Wolsong #2 Wolsong # 3, 4 Ulchin # 3, 4 (KSNP) Yonggwang # 5, 6 (KSNP) Qinshan # 1, 2 (China) Sequoyah # 1 RSG Ulchin # 5, 6 (KSNP) Watts Bar # 1 RSG N. Korea # 1, 2 (KSNP) Shin Kori # 1, 2 (KSNP) Shin Wolsong # 1, 2 (KSNP) Shin Kori # 3, 4 (APR)
Client KEPCO / Westinghouse KEPCO / Framatome KEPCO KEPCO KEPCO KEPCO KHNP QNPC / AECL TVA / Westinghouse KHNP TVA / Westinghouse KEDO / KEPCO KHNP KHNP KHNP
Capacity (MWe X Units) 950 X 2 950 X 2 1,000 X 2 700 X 1 700 X 2 1,000 X 2 1,000 X 2 700 X 2 1,200 X 1 1,000 X 2 1,200 X 1 1,000 X 2 1,000 X 2 1,000 X 2 1,400 X 2
Reactor Type PWR PWR PWR PHWR PHWR PWR PWR PHWR PWR PWR PWR PWR PWR PWR PWR
Commercial Operation 1986 / 1987 1988 / 1989 1995 / 1996 1997 1998 / 1999 1998 / 1999 2002 2003 2003 2004 / 2005 2006 2008 / 2009 2008 / 2009 2009 / 2010 2010 / 2011
TYPE / YEAR 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07
Shin KRN-4 Shin KRN-3 Commercial Operation Under Site Installation Under Shop Fabrication Planned Shin WSN- 2 Shin WSN- 1 Shin KRN-2 Shin KRN-1 N.Korea-2
1000 MWe CLASS
N.Korea-1 UCN-6 UCN-5 YGU-6 YGU-5 UCN-4 UCN-3 YGU-4 YGU-3
950 MWe CLASS
UCN-2 UCN-1 YGU-2 YGU-1 QSN-2
700 MWe CLASS
QSN-1 WSN-4 WSN-3 WSN-2
Sequoyah-1 Watts Bar-1 KRN-1
TYPE / YEAR 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07
Practical Period to Manufacture in Nuclear Shop
FEATURES OF PWR (KSNP)
SYSTEM OF KSNP
Turbine Bldg. Main Steam Stop Valve High Pressure Turbine Low Pressure Turbine Generator Moisture Separator Reheater Condenser Circulating Water Pipe H.P.Feedwater Heater Deaerator Deaerator Storage Tank L.P.Feedwater Heater 25-Ton Bridge Crane 250-Ton Bridge Crane
Primary Aux. Bldg. Main Control Room Main Steam Pipe Feedwater Pipe Main Steam Safety Valve Emergency Diesel Generator Charging Pump Shutdown Cooling Heat Exchanger High Energy Line Area Supply A.H.U. Containment Spray System H/EX Fire Water Storage Tank Aux. Feedwater Pump (Motor Driven)
Aux. Feedwater Pump (Turbine Driven) Component Cooling Water Pump Press. Htr. 480 Volt Load Center 480 Volt Dist. Cab. Press Htr. Elec. Penet. Area Cubicle Cooler C.E.D.M. System Cabinet
SNP (Korean Standard Nuclear Power Plant) is a standard design which has been and will be applied to Korean 1,000 MWe Nuclear Power Plants. KSNP is an improved design based on Yonggwang units 3 & 4. Ulchin units 3 & 4 are the first plants to use the KSNP design. Yonggwang units 5 & 6, Ulchin units 5 & 6 and North Korean units 1 & 2 are also being constructed using this design. Future Korean 1,000 MWe class units including Shin Kori units 1 & 2 and Shin Wolsong units 1 & 2 will be constructed using the advanced KSNP design.
Containment Bldg. Containment Spray Header Polar Crane C.E.A. Change Platform Personnel Access Air Lock Main Steam Pipe Containment Liner Plate Pressurizer R.C.F.C Steam Generator C.E.D.M. Air Handling Unit Safety Injection Tank
Steam Generator Shield Wall C.E.A. Drive Mechanism Refueling Machine Reactor Vessel Reactor Coolant Pump Reactor Vessel Support Column Equipment Hatch In-Core Instrumentation Refueling Canal Fuel Transfer Tube Emergency Exit Air Lock
Fuel Bldg. Fuel Handling Overhead Crane Spent Fuel Handling Machine Spent Fuel Storage Pool Cask Loading Pit New Fuel Storage Pit Cask Decontamination Pit New Fuel Inspection Area Loading Area Fuel Transfer System Shipping Cask Refueling Water Tank Reactor Make-up Water Storage Tank Hold-up Water Storage Tank Normal Supply Air Handling Unit
A D VA N C E D F E AT U R E S O F K S N P
Enhanced Plant Safety
- Safety Depressurization System for rapid depressurization of the RCS - Reinforced monitoring function for Residual Heat Removal System - High pressure piping for Shutdown Cooling System - Plant Protection System equipped with automatic inspection function - Established priority order for alarm - Utilization of Core Protection Calculator and Core Operating Limit Supervisory System to improve Core monitoring function
Enhanced Availability and Capacity Factor
- Classified some part of CVCS (Chemical and Volume Control System) as Non-safety related components - Improved Shutdown Cooling System - Centrifugal Charging Pump - Improved Letdown Line - Consideration of Human Factor in the MCR design - Expanded use of Plant Computer - Utilization of Core Protection Calculator and Core Operating Limit Supervisory System to secure the safety margin of reactor operation
Enhanced Design Margin
- Application of improved seismic analysis method - Application of Leak-Before-Break design concept - Improved evaluation method for heat generation rate in the RVI
Improved Control System
- Considered Human Factors in the design - Established priority order for alarm - Minimized Alarm Indications and Instruments by applying Discrete Indication and Alarm System - Digitalized signals - Use of Optical Fibers and Multiplexer
Simplified Operating Procedure
- Separate Heat Exchanger for Containment Spray System - Simplified Chemical and Volume Control System - Expanded use of Plant Computer
- Reduced cost by classification of non safety related CVCS - Minimized pipe whip restraints and snubbers by application of Leak-Before-Break design concept - Reduced cable cost by using Multiplexer - Minimized Alarm Indications and Instruments by applying Discrete Indication and Alarm System
REACTOR COOLANT SYSTEM
KSNP is a Pressurized Water Reactor type system that uses two discrete coolant loops (Primary and Secondary) to supply steam to the turbine generator. Since the nuclear fuel assemblies, used to generate heat, are located within the boundaries of the Primary Coolant Loop, it contains coolant that is radioactive. The Primary Coolant Loop transfers heat to the Secondary Coolant Loop through the Steam Generator thereby isolating the Secondary Coolant Loop from the radioactivity of the Primary Coolant Loop. The Primary Coolant Loop (Reactor Coolant System) consists of one Reactor Vessel, two Steam Generators, one Pressurizer, and four Reactor Coolant Pumps (RCPs).
Electrical Output Thermal Output Design Pressure Normal Operating Pressure Design Temperature 1,000 MWe 2,825 MWt 2,500 psi 2,250 psi 650 F
REACTOR VESSEL AND INTERNALS
The Reactor Internals are designed to provide support structures for the core and to provide a flow path within the Reactor Vessel to guide the primary coolant through the core.
Guide Structure Support System
The Guide Structure Support System (GSSS) is designed to provide lateral support for the Control Element Assembly (CEA). The CEAs can be installed or removed without removing the GSSS.
Lower Support Structure
The Lower Support Structure (LSS) has a grid shape to provide maximum support to the fuel assemblies.
Upper Guide Structure
The Upper Guide Structure (UGS) contains individual guide tubes for each CEA rod. These tubes provide lateral and azimuthal constraint to the CEAs. In addition, the lower end of these tubes interface with the upper end of each fuel assembly, limiting vertical motion of the fuel during plant conditions when an upward load is placed on the core.
The Reactor Vessel is designed to withstand high pressure and temperature. It contains nuclear fuel and internals. The Closure Head is removable to reload the fuel.
CEDM Nozzle Closure Head Closure Stud Closure Nut & Washer
Surveillance Capsule Holder
Core Stabilizing Lug & Shim
Core Stop Lug
The Reactor Vessel is fabricated from ringforged shells. These ring-forged shells eliminate the need for longitudinal seam welds thereby reducing production and inspection time. Materials of the Reactor Vessel are carefully selected to withstand high pressure, temperature, and radiation.
The Reactor Vessel Assembly is supported by four columns located under the vessel inlet nozzles. These columns are designed to flex, permitting horizontal expansion, and thus allowing unrestrained heatup and cooldown of the vessel.
The shell of the Reactor Vessel, including the integral hemispherical lower head and the upper closure head, is automatically clad with stainless steel using an Automatic Cladding Machine to prevent corrosion.
CONTROL ELEMENT DRIVE MECHANISM
The reactivity of the core is controlled by inserting or withdrawing the Control Element Assembly (CEA) from the core. The Control Element Drive Mechanism (CEDM) is an electromechanical device which provides controlled linear motion to a CEA through an Extension Shaft Assembly (ESA) in response to operating signals received from CEDM control system. The CEDM is operated by applying localized magnetic fields which activate the Motor Assembly located within the primary water pressure boundary. Linear motion within the CEDM motor causes latching devices to transmit this motion to the ESA. The ESA is in turn connected to the CEA within the core. CEA motion occurs when power is sequentially applied to the series of electrical coils external to the primary water pressure housing. In an emergency shutdown, the CEAs are inserted into the core by gravity upon initiation of a scram signal.
UPPER PRESSURE HOUSING ASSEMBLY
UPPER SHROUD ASSEMBLY
MOTOR HOUSING ASSEMBLY
COIL STACK ASSEMBLY
EXTENSION SHAFT ASSEMBLY
Concept of Drive Mechanism (Double Step)
STATIONARY MAGNET-UPPER UPPER LIFT COIL UPPER LIFT MAGNET UPPER LATCH COIL
UPPER LATCH MAGNET UPPER LATCH HOUSING STATIONARY MAGNET-LOWER LOWER LIFT COIL LOWER LIFT MAGNET LOWER LATCH COIL
The Motor Assembly is an integral unit which fits into the motor housing and provides linear motion to the CEA. Both upper latches and lower latches are used to perform the stepping of the CEA and, by proper sequencing, perform a load transfer function which minimizes latch and extension shaft wear. Total CEA motion per cycle is 3/4 inch.
- Withdraw, insert or hold the position of CEA - Release CEAs by gravity into the reactor core - Operable for cumulative travel of minimum 100,000 feet - Lubricated by primary coolant - Operate at 2500 psig at 650 F - 30 inches per minute at normal operation - Consists of seven separate subassemblies which are interchangeable between drives
LOWER LATCH MAGNET EXTENSION SHAFT ASSEMBLY LOWER LATCH HOUSING
Plasma Coating on Latch Guide Tube
The Latch Guide Tube is given an accelerated life test of at least 30,000 feet of travel at a nominal drive speed of 30 inches per minute and 300 full-height gravity drops at simulated reactor operating conditions and ambient external conditions. The Latch Guide Tube of the Motor Assembly is chrome oxide plasma coated to prevent wear.
S T E A M G E N E R AT O R
The Steam Generator is a type of heat exchanger which provides steam to drive the turbine generator. While heat is exchanged from the Primary Coolant Loop to the Secondary Coolant Loop within the Steam Generator, the coolant within each loop is isolated from the other.
- Evaporator with integral economizer - Enhanced flow induced vibration mechanism - Double feed line - Double steam line - High capacity separators - High efficiency dryers - Inconel 690 thermal treated tubing - 409 stainless steel tube supports - Flow distribution plate - High capacity blowdown - Improved bend region tube supports - Improved feedwater distribution system - Integral retention ring for single nozzle dam - Permanently marked tubesheet hole
HANJUNG is the only manufacturer who can perform both explosive expansion (explansion) and hydraulic expansion in tube-to-tubesheet joints which must provide a tight seal between tube and tubesheet, and provide sufficiently high strength to support the axial tube load. Also, the joining technique must lend itself to mass production and to uniformity of quality.
RANKING OF EXPANSION METHOD
Expansion Rate Microstructure Test Pull-Out Test Hydraulic Leak Test Residual Stress SCC (Stress Corrosion Cracking) Simulation Test Uniformity of Quality Mass Production
Ranking : 1 = Best, 3 = Worst
Ranking * Mechanical Roll
2 2 1 1 3 3 2 3
1 1 2 2 2 2 1 1
1 1 1 1 1 1 1 2
Axial Residual Stress after Expansion
Tube Expansion (Explosive)
- Equipment : Primer Cord, End Cap, Sheath, Trunk Line - Transition Length : Max. 0.75 in. - No Crevice
Primer Code End Cap
Polyesthylene Sheath Secondary Side After Explansion Before Explansion
Primary Side Explansion Charge
Circumferential Residual Stress after Expansion
Tube Expansion (Hydraulic)
- Equipment : Hydraulic Power, Mandrel, Holder, Intensifier - Fluid : Grade "B" Water - Depth of Crevice : 0.125 to 0.25 in
Mandrel O-Ring O-Ring Urethane Metal Ring
Clad = 0.25 in.
Tubesheet Thickness = 21.5 in
Depth of Expansion Depth of Crevice
The Pressurizer is designed to maintain the Reactor Coolant System operating pressure, such that the minimum pressure observed during an operating transient is above the setpoint for the safety injection actuation signal and below the maximum pressure setpoint which would initiate a high pressure reactor trip. The Pressurizer contains sufficient water volume to prevent draining the Pressurizer during a reactor trip and to keep the heaters from being uncovered by the outsurge of water during a decrease in turbine load.
- Sufficient water volume - Sufficient steam volume - Minimized total reactor coolant mass change - Sufficient heat capacity - Improved internal support system
SAFETY VALVES OPEN
Pressure Control Program
A number of heaters are connected to proportional controllers, which adjust the heat input to account for steady-state losses and to maintain the desired steam pressure in the Pressurizer. The remaining heaters are connected to on-off controllers. These heaters are normally de-energized but are automatically turned on by a low-pressurizer-pressure signal or a high-level error signal. The Chemical and Volume Control System (CVCS) acts to restore coolant level, resulting from a transient pressure decrease below normal operating pressure.
PRESSURIZER PRESSURE, PSIA(kg/cm2 A)
HIGH PRESSURE ALARM
2300 (161.7) 2275 (159.9) 2250 (158.2) 2225 (156.4) 2200 (154.7) 2160 (151.9)
BOTH SPRAY VALVES FULLY OPEN ABOVE2 2300 PSIA (161.7 kg/cm A) BOTH SPRAY VALVES FULLY CLOSED 2 BELOW 2275 PSIA (159 9 kg/cm A) AND PROPORTIONAL HEATER GROUP “OFF” NORMAL SETPOINT PROPORTIONAL HEATERS GROUP “ON” ALL BACKUP HEATERS “OFF” ABOVE 2225 2PSIA (156.4 kg/cm A) ALL BACKUP HEATERS “ON” BELOW 22002PSIA (154.7 kg/cm A) LOW PRESSURE ALARM
NET HEAT IN
NET HEAT OUT
Heater & Support System
SLEEVE BOTTOM HEAD
Individually replaceable electric heaters are installed in heater sleeves through the bottom head. The electric heaters are straight tubular sheath type for direct immersion, ungrounded, with a sealed connector at the electrical terminal. The heaters are designed to be replaceable by a heater weld cutter. Sleeve assemblies are welded to the internal clad of the vessel bottom head and the heaters are welded to the sleeves. Each heater is internally supported for seismic loading and vibration by heater support plates at two elevations.
Safety Depressurization System (SDS)
The Safety Depressurization System is included to provide a manual means of rapidly depressurizing the Reactor Coolant System for the highly unlikely event of a total loss of feedwater to both Steam Generators. The SDS is not required to operate during normal power operation, therefore, power is removed from the globe valves to prevent inadvertent opening. Upon restoring power to the globe valves from the auxiliary electrical equipment rooms, all required SDS manipulations can be performed from the main control room.
The Gas Stripper is designed to automatically remove dissolved radioactive krypton and xenon, as well as hydrogen gases from the primary coolant. It has the capability of producing a minimum Decontamination Factor (DF) of 1X103. The Gas Stripper system employs countercurrent mass transfer between steam and water to deplete dissolved noncondensable gases. The Gas Stripper consists of a process unit, an instrument rack and a control panel. The process unit includes gas stripper column, heat exchangers, pumps, valve, I&C associated piping and a steel structure made of structural square tubing that supports all components in the unit.
Influent Operating Conditions
Mode 1 (Max. Operating) Flow Rate (gpm) Temperature ( F) Pressure (psig) 140 120 - 170 30 - 60 Mode 2 (Norm. Operating) 30 - 135 40 - 120 30 - 60 Mode 3 (Min. Operating) 20 40 - 120 30
H E AT E X C H A N G E R
The Regenerative Heat Exchanger is installed in series with a letdown heat exchanger to continuously circulate a portion of the reactor coolant for purification. The reactor coolant passes from the Reactor Coolant System through the tube side and is cooled by purified water pumped back to the Reactor Coolant System through the shell side.
Shell Side Normal Operating Temperature (In/Outlet) Normal Operating Pressure Design Temperature Design Pressure 120 / 479 F 2485 psig 550 F 3025 psig Tube Side 564.5 / 293 F 2235 psig 650 F 2485 psig
SHELL OUTLET U-BEND TUBE TYPE 304 STAINLESS STEEL
TA N K
The Safety Injection Tanks are part of the Safety Injection System and are located in the containment building. They provide a means of rapidly reflooding the core following a large break LOCA, and keeping the core covered until flow from the safety injection pumps becomes available.
Normal Operating Temperature Normal Operating Pressure Design Temperature Design Pressure (Int./ Ext.) 120 - 200 F 610 psig 200 F 700/ 100 psig
FEATURES OF PHWR
ANJUNG also supplied the major components of the PHWR (Pressurized Heavy Water Reactor) plants at Wolsong units 2,3 & 4 and Qinshan CANDU units 1 & 2 in China. PHWR uses natural uranium which is simpler to handle and easier to process into fuel assemblies than enriched uranium. Instead of H2O, which is used in a PWR, a PHWR uses heavy water (D2O) as the moderator and coolant. The system can be refueled during full-power operation. HANJUNG successfully supplied the Calandrias, Feeder/Headers Pressurizer, Major Heat Exchangers and Steam Generators to Wolsong units 2,3 & 4. The Feeder/Headers Pressurizer, Major Heat Exchangers and Steam Generators for use in Qinshan CANDU units 1 & 2 in China are currently being fabricated.
Wolsong Nuclear Power Plant units 1,2,3 & 4
1. MAIN STEAM PIPES 2. PRESSURIZER 3. STEAM GENERATORS 4. HEAT TRANSPORT PUMPS 5. HEADERS 6. CALANDRIA 7. FUEL 8. MODERATOR PUMP 9. MODERATOR HEAT EXCHANGER 10.FUELING MACHINES
LIGHT WATER STEAM LIGHT WATER CONDENSATE HEAVY WATER COOLANT HEAVY WATER MODERATOR
The core of the Nuclear Steam Supply System of a PHWR is a large cylindrical vessel called the Calandria which houses 380 horizontal tubes loaded with natural uranium fuel bundles.
F E E D E R H E A D E R A S S E M B LY
The Feeder consists of several hundred pipes which transmit heated heavy water from the Calandria to the Steam Generator. The Header merges and distributes the coolant.
DES GN ANALYS S
ANJUNG performs structural analysis to verify component integrity. ANSYS, I-DEAS and other recognized codes are used to compute stresses. HANJUNG’s Stress Analysis Team has extensive expertise in the interpretation and application of requirements and guidelines contained in well known industry standards. Thermal stresses in a structural member are induced by temperature changes and their associated dimensional changes. A restrained structural member subject to a change in temperature will develop thermal stresses. Thermal-hydraulic and computational fluid dynamics are used for heat exchanger sizing and performance evaluation. They are also used in the development and conceptual design of the components, especially in the design of the Steam Generators, which are characterized by complicated single and two phase flow heat transfer. Structural analysis is essential to ensure the structural integrity of components against the most severe loads imposed under postulated accident and normal operating conditions. The analysis includes calculations of the temperature distribution in the metal and thermo-elastic behavior, mechanical stress evaluations, low cycle fatigue evaluations, and provisions to safeguard against brittle fracture.
The Reactor Vessel inlet nozzle and vessel support are analyzed together to consider the interaction effects and to get accurate stresses at the intersection between the two components. The inlet nozzle and support assembly is modeled using the three dimensional techniques of the ANSYS program. The analytical model consists of three-dimensional (3-D) isoparametric solid elements. The stresses are calculated for unit pressure and unit external loads and then combined together to get the stresses for each actual load condition. The HANJUNG program "AFPOST" is used for calculating stress intensity ranges and performing fatigue evaluations.
ATHOS is a three-dimensional two-phase flow distribution code with both steady state and transient capabilities. Homogeneous and axial flow algebraic slip models are available. A typical geometric model includes approximately 1000 cells but more detailed models are possible.
Secondary flow distribution results include velocity vector components in the three coordinate directions, pressure, temperature, quality and density in each cell. The corresponding heat flux, tube wall temperatures, primary temperatures and the circulation ratio are also calculated. Vector and scalar plotting are available.
In transient calculations, water level and steam flow are calculated as a function of time. The code has been verified by comparison of analytical results with measured data from small scale experiments, model steam generators and full-scale steam generators.
STEEL FOUNDRY SHOP
(1) Electric Arc Furnace : 100/ 120 tons (1) Electric Arc Furnace : 20/ 35 tons (1) Vacuum Ladle Refining & Holding Furnace : 30/ 155 tons (1) Vacuum Stream Degassing Equipment : 30/ 465 tons
(1) Forging Press : 10,000/ 13,000 tons (1) Forging Press : 4,200 tons (1) Forging Press : 1,600 tons (3) Forging Manipulator : Max. 400M tons
(10) Horizontal Lathe : 1,000 Dia x 4,000 L x 5 tons (8) Vertical Boring Machine : 2,800 Dia x 2,500 x 3,200 H x 25 tons (4) Horizontal Boring Machine : 125 Dia x 1,250 x1,600
HEAVY MACHINE SHOP
(11) Horizontal Lathe : 3,000 Dia x 18,000 L x 250 tons (11) Vertical Boring Machine : 10,000 Dia x 2,200 H x 400 tons (11) Horizontal Boring Machine : 400 Dia x 3,800 x13,000 (9) Plano Miller Machine : 7,100 x 7,000 x 500 tons
(2) Plate Bending Roll : 160 Thk. x 3,600 W (7) SAW Strip Cladding Machine : 4",2",1" (1) 3 Spindle Deephole Drilling Machine : 6,000(X) x 3,600(Y) x1,100(Z) (1) Vertical Boring Machine : 22,000 Dia x 8,000 H x 160 tons (1) Horizontal Boring Machine : 220 Dia x 8,000 x 15,000
RESEARCH & DEVELOPMENT
hrough sustained investments in research and development, HANJUNG has been able to supply equipment for nuclear power plants with a high degree of quality, safety and reliability.
Major R & D Teams
- Structure and Strength Research Team - Thermo and Fluid Dynamics Team - Fatigue Failure Research Team - Material Development Team - Life Evaluation Research Team - Welding Technology Development Team - Product Development Team - Production Engineering Team - Control System Research Team - Energy and Environment Research Team
ANJUNG is dedicated to providing equipment which meets or exceeds applicable codes, standards and customers' specific demands. To attain a high degree of quality control, HANJUNG is well equipped with X-ray generator, magnetic particle examination equipment, pressure testing equipment, wear tester and emission spectrometer. HANJUNG also performs chemical analysis, physical test, precision measurement, electrical measurement, non-destructive examination and material analysis. As a strong testimony to its outstanding quality control system, HANJUNG was awarded with ISO 9001 certification for all its power generation facilities and industrial plants. In addition, HANJUNG has received 12 certificates of authorization from the American Society of Mechanical Engineers to use the applicable ASME code symbol stamps for various types of manufacture operation.
TITLE N NA NPT NA NPT A PP S U U2 H MO CERT. NO. N-2765 N-2766 N-2767 N-2779 N-2780 17602 17603 17604 17605 17606 20200 QSC- 481 DESCRIPTION Manufacture of Nuclear Component Sec.III Shop Assembly of Nuclear Comp. & Part Sec.III Manufacture of Nuclear Part Sec.III Installation of Nuclear Comp. & Part Sec.III at site Manufacture of Nuclear Part Sec.III at site Power Boiler Assembly (Sec. ) Pressure Piping Power Boilers (Sec. ) Pressure Vessels (Sec.VIII Div. 1) Pressure Vessels (Sec.VIII Div. 2) Heating Boilers except Cast Iron MM of Ferrous Castings & Forgings MS of Ferrous Covered Electrodes
SERVICE & REPLACEMENT
ANJUNG strives to provide the highest quality technical service to power plant owners. HANJUNG solves problems with owner full satisfaction. HANJUNG supplied the Replacement Steam Generators at Kori unit 1 using advanced design and technology. Fields of the technical services provided by HANJUNG are : Periodic Monitoring and Control of Equipment Inspection and Evaluation of Equipment Maintenance & Refurbishment of Equipment Fabrication & Replacement of Equipment Warranty Maintenance Installation & Supervision Spare Part Control All site experience information is fed back to the design department where it is incorporated into the design development process for use in future projects.
Stuck Stud Repair Machine
Inspection Service of Reactor Internals at the Ulchin Unit 3 Site, Prior to Plant Operation
Installation of Reactor Vessel
ANJUNG has been responsible for installing both mechanical and electrical equipment Since Ulchin units 1 & 2.
HANJUNG has developed technology and accumulated experience in nuclear power plant technology that has been used to satisfy owner’s requirements. HANJUNG strives to enhance itself and its reputation as a quality nuclear power plant constructor dedicated to providing safe reliable nuclear power plants.
Installation of Steam Generator
CONSTRUCTION & INSTALLATION