nuclear bill of materials specification description

PROFILE OF THE LOCAL NUCLEAR SUPPLY INDUSTRY

Generally, a Pressurized Water Reactor (PWR) Nuclear Power Plant (NPP) comprises of civil, mechanical, electrical and I&C equipment that are located in specific areas and buildings of the power plant and are classified as safety and non safety related depending on the system and application

This equipment can be categorized based on the industries and sub-industries that typically manufacture or supply these types of items. The main equipment categories specified and typically required to construct a 2x 1000 MW unit NPP is summarised in the following presentation.

Main equipment categories

Mechanical Equipment:

· Pressure Vessels· Tanks· Valves· Pumps· Compressors· Fans (HVAC)· HVAC ( Chillers, Heating Coils)· Heat Exchangers· Filters· Ion Exchangers· Turbines· Pipes· HVAC Ductworks· Cranes


Electrical Equipment:(Note: conversion to SA electrical voltage usage has not been done for

this exercise)· Generators· Transformers· Motors· Switchgears· Motor Control Center (MCC)· Electrical Panels· Cables


I&C Equipment· DCS· Transmitters· Gauges/Indicators· Sensors/Elements

Civil part· Civil Concrete· Forms· Rebar· Tendons· Structural and Reinforcing Steel· Containment Assemblies (Electrical Penetrations, Piping

Penetrations, Hatch Assemblies)

4

NPP equipment and services Safety and Non Safety Equipment

Equipment in every category can further be divided into safety and non-safety groups that are important especially for equipment with special quality requirements.

Plant equipment that belong to the items important-to-safety are those whose malfunction or failure could lead to unacceptable radiation exposure of the site personnel or members of the public. Important-to safety items include components that prevent anticipated operational occurrences from leading to accident conditions. Safety systems are provided to ensure the safe shutdown of the reactor, or the removal of residual heat from the core, or to limit the consequences of anticipated operational occurrences and design basis accidents.

5

NPP equipment and services

The task of ensuring a high level of safety of NPPs and achieving excellent safety performance means that safety-related equipment delivered to NPPs must meet special qualifications.

Every vendor or manufacturer that delivers or would like to deliver equipment or components to a NPP has to comply with the qualification requirements depending on the type, function and location of the equipment.

Manufacturers have to complete not only QA/QC documentation and calculations but also to perform some of the following tests for a specific number of their production: thermal aging test, mechanical aging test, operational radiation aging test, vibration and seismic test, analysis of standardized tests, manufacturer performance input test, electromagnetic compatibility test.

6


The above conditions are important for local industry assessment and decision making for consideration of which equipment or components to manufacture and deliver to the NPP.

The manufacturers and vendors need to consider the fabrication of nuclear equipment or components along with the volume and number of equipment or components that are needed for the NPP project in order to determine the viability of their production costs.

7

NPP equipment and services- Quantity Descriptions

Mechanical Equipment:

Pressure Vessels· There are more than 30 safety-related pressure vessels and more

than 30 non-safety-related pressure vessels. The scope includes the reactor, pressurizer, accumulator, air dryer, high-pressure cylinders for compressed gasses, etc.

· For example , the reactor has a volume of approximately 110 m3, the pressurizer approximately 70 m3 and accumulators approximately 50 m3.

· Nuclear vessels are typically from steel material Nickel –Chromium – Iron –Alloy (Alloy 690 ) clad by stainless steel (with Chromium, Nickel ). In the case of stainless steels, only austenitic and martensitic stainless steels are used.

8


Tanks· There are more than 150 safety related tanks and more than 350

non safety related tanks. Scope includes components such as air accumulators, air receivers, sampling system tanks, gas decay tanks, chemical feed tanks, expansion tanks, surge tanks, large yard tanks etc.

· Material for these components is usually a form of carbon steel or stainless steel depending on the chemistry or radioactive material of the contained volume.

9


Example of some tanks that belong to the largest size category

· FILTERED WATER STORAGE TANK 3800 m3· AUXILIARY BOILER FUEL OIL STORAGE TANK 1900 m3· CONDENSATE STORAGE TANK 1900 m3· DEMINERALIZED WATER STORAGE TANK 1900 m3· REFUELING WATER STORAGE TANK 1700 m3

10

Client logoSlide 11


Valves· There are more than 5800 safety related valves and more than

11 800 non-safety-related valves · Specification is done based on type and DN of valve

11


Pumps· There are more than 120 safety-related pumps with voltage up to

0,48 kV , more than 30 safety-related pumps with voltage above 0,48 kV, more than 480 non-safety-related pumps with voltage up to 0,48 kV and more than 20 non-safety-related pumps with voltage above 0,48 kV.

Compressors· There are approximately 8 safety-related compressors and more

than 30 non-safety related compressors. · All compressors are 480 V or less

12


Fans (HVAC)· There are more than 60 safety-related fans and more than 300 non-

safety-related fans. · All fans are 480 V or less.

HVAC (Chillers, Heating Coils)· There are 10 safety-related HVAC Chillers and 8 non-safety-

related HVAC Chillers. There are 20 safety-related-heating coils and more than 160 non-safety-related heating coils.

· All HVAC chillers and heating coils are 480 V or less.

13


Heat Exchangers· There are more than 45 safety-related heat exchangers and 70

non- safety-related heat exchangers · HVAC cooling units with filters are included under Filters tab as

HVAC, FILTERS. Filters

· There are more than 25 safety-related water filters and more than 130 non-safety-related water filters, more than 15 safety-related air filters and more than 120 non-safety-related air filters, more than 185 safety-related HVAC filters and more than 25 non-safety- related HVAC filters, more than 110 safety-related strainers filters and more than 260 non-safety-related strainer filters and more than 30 non-safety-related oil filters.

14


Ion Exchangers· There are approximately 8 safety-related ion exchangers and more

than 50 non-safety-related ion exchangers Turbines

· In US types NPP, usually, there are 2 high-pressure turbines, 6 low-pressure turbines and 6 feed water turbines. In addition, there are 2 turbines for auxiliary feed water pumps in a 2 x 1000 MWe PWR NPP.

Pipes· More than 900 000m of piping of various material types, namely;

stainless steel, carbon steel, chrome moly

15


HVAC Ductworks· There are approximately 1400 tons safety-related HVAC ductworks

from Stainless Steel and approximately 600 tons non-safety-related HVAC ductworks from galvanized material

Cranes· There are more than 40 different types of cranes.

16


Electrical Equipment: Generators

· Usually, there are 2 main generators , 2 generator excitors and 2 generator suppressors and up to 8 diesel generators in the 2 x 1000 MWe PWR NPP.

Transformers· There are more than 25 safety-related transformers and more than 430

non-safety-related transformers. Motors

· This list includes only motors for valve operators. Other motors are specified together with the pumps, compressors, fans, and chillers.

· There are more than 470 safety-related valve operators and more than 230 non-safety-related valve operators.

17


Switchgears· There are more than 350 safety-related switchgears and more than

540 non-safety-related switchgears. Motor Control Centre

· There are more than 820 safety-related MCC and more than 2200 non-safety-related MCC

Electrical Panels· There are more than 820 safety-related electrical panels and more

than 1500 non-safety-related electrical panels.

18


Cables· There are more than 6500 kms of different types of cables . · Currently, it is anticipated that the total amount of cable can be

reduced by up to 30% by using fibreoptical cables.

I&C Equipment· There is equipment in I & C systems that are part of the DCS. · The scope of equipment in the DCS and instrumentation systems

depends on the specific NPP design and DCS supplier and cannot be generalized.

19


Civil part Civil Concrete

· The quantity of concrete depends on the specific NPP design and it is not appropriate to generalize it.

· Usually, there are concrete structures with a range of compressive strength classes from pressures of 20 MPa up to 40 MPa and with volume weights from 2000 kg/m3 up to 3500 kg/m3.

Forms· The quantity of forms depends on the specific NPP design and it is

not appropriate to generalize it.

20


Rebar· The quantity of rebar depends on the specific NPP design and it is

not appropriate to generalize it. Tendons

· The quantity of tendons depends on the specific NPP containment design and it is not appropriate to generalize it.

Structural and Reinforcing Steel· The quantity of structural and reinforcing steel depends on the

specific NPP design and it is not appropriate to generalize it.

21


Containment Assemblies (Electrical Penetrations, Piping Penetrations, Hatch Assemblies)· There are included as electrical penetrations, piping penetrations

and hatch assemblies in the attached list of equipment.

22


Generally, there is additional equipment /components in the NPP that are not mentioned in the attached List of Equipment with respect to their uniqueness or difficulty to categorize into the frame quantity. These equipment / components should be considered for local industry involvement in construction of the NPP. Note that for the items below estimated quantities for the equipment for 2 x 1000 MWe are provided. The quantity of this equipment depends on the specific design of the NPP.

23


Usually, costs on equipment make up approximately 40 % to 45% of all NPP total construction costs. Equipment costs are broken further as follows:· Heavy components as Turbogenerator, Reactor Vessel and Steam

Generator 39 % (35 – 45%)· Mechanical equipment 38 % (35 – 45%)· I & C equipment 11 % ( 8 – 15%)· Piping / Valves 7 % (5 – 10%)· Electrical equipment 5 % (4 – 6%)

Detail costs on equipment are changing in time based on the equipment offer and demand , energy prices and requirements of the NPP project.

24

nuclear bill of materials specification description

Business

npp equipment

safetyrelated equipment

plant equipment

number of equipment

safety related tanks

applicationthis equipment

safety items

services safety