Dr. Prabhat KumarDistinguished Scientist and

Chairman & Managing DirectorBharatiya Nabhikiya Vidyut Nigam Limited (BHAVINI)

Department of Atomic EnergyA Government of India Enterprise

Kalpakkam 603 102, Tamilnadu, India

BHAVINI’s NOMINATION FOR ENGINEERING EXCELLENCE AWARD - 2013

Presentation by

STAGE 1 STAGE 2 STAGE 3

U-233

ELECTRICITY

Depleted U

Pu

300 GWe, 30 Yr

Pu FUELLEDFAST BREEDERS

Th

500 GWe, 500 Yr

ELECTRICITYU-233 FUELLED

BREEDERS

Natural Uranium

ELECTRICITYPHWR

12 GWe, 30 Yr

Th

Pu

U-233

INDIA’S THREE STAGE NUCLEAR POWER PROGRAMME

BHAVINI has commenced activities on second stage

Fuel : PuO2+ UO2

Thermal Power : 1250 MWth

Electrical output : 500 MWe

Coolant : Liquid Na

Thermal Efficiency : 40%

• Prototype Fast Breeder Reactor (PFBR) is first of its kind nuclear reactor in the country

• India’s very important and prestigious project

• Advanced construction stage

Prototype Fast Breeder Reactor Flow Chart

PFBR, the only nuclear reactor in the country has secondary loop

Fukushima incident could have been avoided if passive decay heat removal system like PFBR exist in their reactor

No power required for removal of decay heat

PFBR REACTOR ASSEMBLY COMPONENTS

1 Main Vessel

2 Core Support Structure

3 Core Catcher

4 Grid Plate

5 Core

6 Inner vessel

7 Roof slab

8 Large Rotatable Plug

9 Small Rotatable Plug

10 Control Plug

11 Absorber Rod Drive Mechanism

12 Transfer Arm

13 Intermediate Heat Exchanger

14 Primary Sodium Pump

15 Safety Vessel

Man standingHuge size reactor with complex constructional

features

Stringent administrative and quality controls at every stage

Indigenous and New TechnologyMany Challenges overcome successfully and Innovations in many activitiesAchievements and high success rate in every activitiesManufacture of thin walled gigantic components for the first time in the countryHandling & Erection of over dimensional equipment without single dentDesign, Construction, Equipment fabrication and Regulatory approval in parallel

What all makes PFBR project eligible for Engineering Excellence Award 2013

First of its kind nuclear reactor in the country - Generates more Plutonium than it consumes

Manufacturing of gigantic equipment at site due to transportation constraints meeting all the stringent specification requirements

Development of special grade materials in large scale in the country never done in the past

Development of Novel equipment erection techniques

Huge quantity of highly reactive Sodium transfer without a single drop of leak- 1750 tones !!!

Few points which make PFBR project innovative

Highly reactive Liquid Sodium transfer

Largest and deepest excavated pit in Indian nuclear plants immediately next to sea

(200 meters from the sea)

National record of largest concrete pouring in single stretch ever done by any industry in India

Initially 5000 cubic meter concreting during 2005 and then surpassed BHAVINI’s own record by pouring 5800 cubic meter concrete

Off Shore Submarine Tunnel

Under sea Tunnel 567 meters length at 50 meters below the sea

Constructed for the first time in the country

15

Tsunami bund

Outfall Channel

Shore protection

Tsunami bund/Shore Protection/Outfall Channel

15

Coastal plantationCoastal plantation

Engineered sand dune

Unique method of Tsunami protection Unique method of Tsunami protection system for the reactor site system for the reactor site

INCREASE IN ELEVATIONThe nuclear island finished floor level The nuclear island finished floor level

is raised to 15.7 meters for reactor is raised to 15.7 meters for reactor protection from future Tsunami if any protection from future Tsunami if any

Fabrication of gigantic reactor components for PFBR

Fabrication of over dimensional, thin walled reactor components at PFBR site

FABRICATION OF MAIN VESSEL

Diameter achieved within 10mm tolerance for total 12900 mm dia

Great Challenge

Made for the first

time in the country

INNER VESSELPositional accuracy,

alignment and orientation has to

be maintained during fabrication

Safety Vessel with Thermal Insulation Panels

Man standing

To be lifted during erection without swing

Primary Pipe-Grid Plate assemblyPrimary Pipe-Grid Plate assembly

The Grid Plate supports all the core subassemblies of PFBR

Welding to be done in constrained space meeting

stringent specification requirements

WELDING BETWEEN

ROOF SLAB (RS) AND MAIN VESSEL (MV)

Very important joint

Weld carries about 2500 tones of weight

Welding to be carried out insitu in confined space and access

Tube to Tubesheet welding, Post Weld Heat Treatment and Micro-Focal radiography for PFBR Steam Generators

Local Heat TreatmentWelding

Micro-Focal Radiography Nuclear Clean Hall

Fabrication of 26 meters length Steam Generators in shop

FABRICATED STEAM GENERATORS

Straightness achieved within 3mm on 26,000 mm length of SG !!!!!!

Challenges in header pullout to bend tubes welding for Sodium to Air Heat Exchangers

Extremely Difficult

Header Welding - Needs highly qualified and skilled welders

Header Welding- Extremely difficult

Challenge

Reactor equipment erection

Erection of PFBR equipment without single dent

Main Vessel

ERECTION OF MAJOR COMPONENTS

Safety Vessel Thermal Baffle

Safety Vessel is being lowered into Reactor Vault in a constrained space without swing

Erection of Thermal BaffleErection of Thermal Baffle

Inner Vessel

ERECTION OF MAJOR COMPONENTS

Grid Plate Roof Slab

Massive Argon Buffer Tank

erection

STEAM GENERATOR (SG) ERECTION

SPECIAL ARRANGEMENT FOR SHIFTING SG (25 METER LONG

COMPONENT)PLACING SG IN SPECIAL

TILTING MECHANISM

LOWERING OF SG IN STEAM GENERATOR

BUILDING

POSITIONING & ALIGNMENT

TILTING FOR ERECTION

CONNECTION OF LIFTING

SLINGS

SG LIFTED WITH HEAVY DUTY CRAWLER CRANE

FIXING OF HEATERS

ON SG

Meticulous planning and Management Technical aspects Finance Human Resources Contracts and Material Management Safety & Security Adjust as per design No damage/dent on any equipment during

erection Financial Management NIL report during the CIG audits Awards

Operational excellence of the project

“Industrial Safety Award” by Atomic Energy Regulatory Board

“Suraksha Puraskar” by National Safety Council of India

INDUSTRIAL SAFETY AWARDS

High performance in safety in the construction sector !!!!!

“Best HR Practices–2012 Award” by National Institute of Personnel Management (NIPM)

AWARDS - HUMAN RESOURCES

Development and inspiration of true potential of human capital

“ICI (TNCC) - Ultratech Award” by Indian Concrete Institute

Award for outstanding Concrete Structure

How PFBR project has added to the self reliance of India in the chosen sector

Excellences by young team with an average age of 30 years

Documentation/Technical Papers - More than 300 papers in National/International

Conferences/Journals by young company

Visit of 23,000 students at PFBR project site as a part of outreach programme

Sustainability Improvement in the quality standards Creation of new and indigenous technological

capability in terms of machining, welding, fabrication, testing, handling and erection

First Time right approach Neighborhood Development• Indirect employment• Education• Infrastructure• Health & hygiene• Water supply• Outreach programme• Sports

Key impacts which PFBR project has made

Vocational Training courses II batch commenced on 02.10.2006

Donation of Personal computers to the schools

Vocational Training Programme for Neighborhood village youth from 27.09.2005

Donated PC and books to Govt. Higher Sec. School, Pudupattinam on 28.04.2008

Water Pump & Pump room for Panchayat Union Primary School Meiyur

Construction of Compound Wall- Panchayath Union Primary School Sadhrangapattinam

Water Tank & Hand Wash Facility Panchayath Union Primary School Sadhrangapattinam

Science Lab Apparatus & Models donated to Annamalai Middle School, Desumughipet, Thirukalukundram

`

Sadras Primary Health Centre – Maternity Ward

Sprayed mosquito repellant in the surrounding villages as preventive measure for chickengunia

In co-ordination with Dr.M.S.Swaminathan Research Foundation, Chennai, action has been initiated to set up

Village Knowledge Centre Bio-shieldHatchery – Self Help Groups

One R.O. Plant has been installed at Sadras Meyyur kuppam, Kalpakkam

Epidemiological Health Survey with Assistance from BHAVINI

Robust feedback system for-Knowledge management-Sharing of experiences with industry and academia-Win Win situation for all

Training, qualification & capability development Strengthening of Industries

-Tools/fixtures- Facilities- Techniques- Manufacture - Inspection

Standardized design and manufacturing Modular concept to the possible extent

Few points which illumine more on the future readiness of the project

Over all Night View

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PFBR the pride of nation

Thank Thank YouYou