nuclear government of corporation of power india
TRANSCRIPT
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KUDANKULAM NUCLEAR POWERPROJECT
Nuclear Power Corporation ofIndia Ltd
(A Government of India Enterprises)
M.S.Suresh
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Indian NuclearProgram
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Energy Comparisons1 kg Coal 3 kw.h
1 kg Oil 4 kw.h
1 kg Uranium 50000 kw.h
(3,500,000 kw.h with closed fuel cycles)
Fuel Required for 1000 MWe Plant (annual)
Coal 2,600,000 t 2000 train of 1300 t each
Oil 2,000,000 t 10 super tanker
Nuclear 30t 10 m 3 of reactor core
(Uranium)
Land Required for 1000 MWe Plant
Fossil Nuclear Site 1-4 km2
Solar (thermal or Photovoltaic) 20-50 km2 (a small city)
Wind Field 50-100 km2
Bio Mass Plantation 4000-6000 km2
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BASICS OF NUCLEAR ENERGY
The source of Nuclear Energy lies in the
equivalence of mass and energy according to
Einsteins equation:
E = m c2,
where Eis the Energy,Joules
cis the velocity of light, m/s
m is the mass, kg
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HOW A NUCLEAR REACTOR WORKS ?
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Stage I: 10,000 MWe throughPHWRs and LWRs.
Stage- II: Fast Breeder Reactorswith plutonium as fuel and
thorium as blanket for breeding U-
233.
Stage-III: Breeder Reactors usingU-233 as fuel and thorium as
blanket.
Short term goal is to complementgeneration of electricity at
locations away from coal mines.
Indias long term nuclear energypolicy is based on recycling
nuclear fuel and harnessing the
available thorium resource.
Energy potential of three stageprogramme is placed more than 3
times the energy potential of coal
reserves.
LWR
INDIAN NUCLEAR POWER PROGRAMME
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PHWR- Pressurized Heavy water Reactor
Fuel-Natural Uranium
Moderator- Heavy Water D2O
Coolant Heavy water
PWR- Pressurized water Reactor
Fuel-Enriched Uranium
Moderator- Water
Coolant Water
FBR - Fast Breeder Reactor
Fuel - Plutonium
Coolant Liquid sodium
LWR
INDIAN NUCLEAR POWER PROGRAMME
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2x 220
2x 160, 1x540
1x 540
2x 220
1x 150
1x 2002x 220
2x 220
2x 2001x 500 (PFBR )
2x 2202x 220
Kudankulam
Kalpakkam
Narora
Rawatbhata
Tarapur
Kaiga
In Operation -15
Under Construction- 8
Kakrapar
2x 1000
INDIAN NUCLEAR POWER PLANTS
In Operation -3310 MWe Under Constn-3920MWe
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rief Background of KKN
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SITE SELECTION
Site cleared by DAE Site Section Committeefor setting of 4x500 MWe. - 1988.
Clearance from AERB for Site & High Power
Committee on Tamilnadu Government forenvironmental obtained.
Site investigation for 4x500 MWe including
Bore holes were started in 1987-88.
Site was subsequently allotted for 2x1000MWe VVER Plant.
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Tamilnadu State Environmental Committee
Clearance .
Clearance from Tamilnadu ForestDepartment.
Clearance from Ministry of Environment &Forest,
500m shoreline clearance from PMs office.
Clearance of committee on conservation ofseashore for location of Atomic PowerStation at Kudankulam from Tamilnadu Govt.
Clearance from AERB for Excavation.
Clearance from AERB for Construction of
CLEARANCES FOR KKNPP
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KKNPP
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Sea Water Intake pipeline
Breakwater dyke
Intake Structures
Fish protection facility
Sea Water Inlet pipeline
Bridge
Chlorination plant
Discharge channel
Forebay
Siphon walls
Main pump house
Part of essential load pipeline
Shoreline protection bundUZP
HYDROTECHNICAL STRUCTURES (INTAKE AND OUTFALL)
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Sr.No.
Pkg.No. Name of the Package Agency
1 C-1 Levelling & Grading(Completed)
M/s. SRC
2 C-2 Excavation (Completed) M/s. SRC
3 C-3 Reactor & ReactorAuxiliary Building
M/s. HCC
4 C-4 Turbine, Control &
Emergency PowerSupply Buildings
M/s.
Simplex
5 C-5 Plant Auxiliary Buildingsand Structures
M/s. L&T
6 C-6 Pump house, Sea Water M/s. HCC
CIVIL WORKS MEGA PACAKGE CONTRACTS
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Reactor Building-1K
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Fully inside lined reactor containment for KKNPP: first
time in the country
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afety Featur
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Kudankulam Reactors are Water cooled Water moderatedEnergy Reactor (VVER-1000) of Pressurized Water Reactor(PWR) technology, which is world wide proven concept.
VVER-1000 reactors, are the most advanced reactorssimilar to the PWRs of western design
21 numbers of VVER-1000 reactors are in operation withmore than 200 reactor-years of operating experience
WER-1000 plant designs were evaluated by variousagencies such as IAEA and concluded that it is safe and
advanced design.
KKNPP: ADVANCED REACTOR
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86000 m3 / hFlow rate of coolant through reactor7
6.27 MPaPressure of the steam generated at the outlet from the SG10
2 x 1000 MWe
(1111 MV.A)
Capacity of Generator11
43000 MWd/ T of UMean burn-up of the fuel9
15.7 MPaPressure of reactor primary system coolant at outlet of the core4
40 yearsDesign Life of the Plant (Reactor Pressure Vessel)1
3012 MWtRated thermal power of the reactor Plant2
ValueParameterSr. No.
3.92 to 3.84 %Average enrichment of the fuel reloads with U235
8
321 oCPrimary coolant temperature at the outlet from the reactor6
291 oCPrimary coolant temperature at the inlet to the reactor5
4No. of Circulation loops of the reactor plant3
KKNPP: Main Technical Parameters
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Safety has the overriding priority in all stages of the project i.e.
design,procurement,construction,commissing & operation.
Kudankulam reactor has futuristic engineering features for thepostulated beyond design basis scenarios.
Additional features will make reactor simple, reduction of manmachine interference, safe and reliable.
Some of the Additional features are-
Double Containment
A passive system for residual heat removal
Containment filter and venting system to protect containment
from over-pressurization Quick born injection system to ensure diversity in shutdown.
Kudankulam design shall meet all national and internationalenvironmental norms and standards.
KKNPP: SAFE REACTOR
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Airplane Crash
Tsunami Water
flood
Shock Wave
Seismic Effect
Reactor Containment design bases
All possible safety measures taken into account
in the design of the Nuclear Power Plants
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KKNPP Site: Levels
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ACTIVEAND
PASSIVESYSTEMSOF SAFETY
IN KKNPP-VVER 1000NPP
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ReactorPressureVessel
forKKNPP
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View of site Before start of worK
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Aug 25, 2000
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KKNPP site -At the startLeveling
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June 16, 2001
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KKNPP Site: After site gradingK
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Aug 15, 2001
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KKNPP Site: ExcavationK
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Nov 30, 2001
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KKNPP Site: Consolidation GroK
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Jan25, 2002
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KKNPP Site: Batching plant erecK
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Feb27, 2002
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KKNPP Site: 31st March2002
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Mar 31, 2002
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KKNPP Site: May 2002K
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May 30, 2002
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KKNPP Site: Sep 2002K
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Sept 18, 2002
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KKNPP Reactor Building: Sep 20KNP
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Sept 18, 2002
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KKNPP Site: Feb 2003K
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Feb 24, 2003
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KKNPP Site: Aug 2003K
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Aug 21, 2003
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KKNPP Reactor Building: Oct 20
OCT 21, 2003
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KKNPP Site: Feb 2004K
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Feb 02, 2004
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KKNPP Reactor Building: Feb 20
Feb 02, 2004
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KKNPP Reactor Building: Feb 20
Feb 02, 2004
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KKNPP -RB containment linerK
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Aug 18, 2004
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KKNPP -RB containment linerK
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Aug 18, 2004
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KKNPP -RB internal
structure
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Aug 2004
Aug 18, 2004
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KKNPP Site: Sep 2004K
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Sept 16, 2004
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KKNPP Site: Dec 2004K
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Dec 20, 2004
Si b 200K
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KKNPP Site: Feb 2005K
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Feb 10, 2004
KKNPP RB d 1K
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KKNPP RB dome part-1K
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Containment Dome First part being lifted in TAPP
China, a similar design of KKNPP
challe
ngeahead
KKNPP RB d 2K
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KKNPP RB dome part-2K
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challenge
ahead
Containment Dome Second part being lifted in TAPP
China, a similar design of KKNPP
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Major equipment erecti
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Core Catcher Erection inRB-1
Latest safety feature in Nuclear Reactors- Core melt
catcher at KKNPP: first of its kind in the world
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T C il
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Truss CantileverErection in RB-1
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E ti f L Pl t
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Erection of Lower Platein RB-1
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Erection of SupportTruss in RB-1
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Erection of Thrust Trussin RB-1
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Equipment Transportation
RPV being rolled off from barge at Mini port at KKNPP
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Sea Water Intake pipeline
Breakwater dyke
Intake Structures
Fish protection facility
Sea Water Inlet pipeline
Bridge
Chlorination plant
Discharge channel
Forebay
Siphon walls
Main pump house
Part of essential load pipeline
Shoreline protection bundUZP
HYDROTECHNICAL STRUCTURES (INTAKE AND OUTFALL)
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Off h t tK
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Offshore structuresNP
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~5 lakh cu.m . was dewatered from the temporary dyke
to facilitate construction of offshore structures in the sea
KK
C i i i S h d l
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Commissioning Schedule
As per sanction from Government:
Unit-1 : Dec 2007
Unit-2 : Dec 2008
As per Internal Target:
Unit-1: : Mar 2007
Unit-2 : Sep 2007
KKNPP: HONOURS & ACHIEVMENTS
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Excellent rating for Memorandum Of Understanding
(MOU) targets for the year 2002-03 and 2003-04.
All milestones of Ministry Of Statistics & Program
Implementation (MOSPI), for the year 2002 and 2003,
completed within schedule.
NPCIL Safety award for the year 2002 among the
construction projects
Greentech Silver award for Industrial Safety for year
2003 AERB Safety Award for year 2004 among the
construction projects
Highest accident free period among construction
projects (>30,000,000 man-hours)
KKNPP: HONOURS & ACHIEVMENTS
KKNPP Civil Engineering
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KKNPP- Civil EngineeringFeatures
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KKNPP Ci il E i i F t
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KKNPP- Civil Engineering Features
PCC B20
B20 SCREED CONCRETE 20 MM THICK
TWO LAYERS SBS WATER PROOFING MEMBRANE
B20 SCREED CONCRETE 30MM THICK
Membrane water proofing
KKNPP Ci il E i i F t
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KKNPP- Civil Engineering Features
SBS WATERPROOFING MEBARANE LAYING BELOW FOUNDATION
Membrane water proofing
KKNPP Civil Engineering Features
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KKNPP- Civil Engineering Features
Screed Concrete over Membrane
Membrane water proofing
KKNPP Civil Engineering Features
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KKNPP- Civil Engineering Features
Membrane Water proofing at Foundation sides
Membrane water proofing
KKNPP Ci il E i i F t
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KKNPP- Civil Engineering Features
SCREW COUPLERS
KKNPP Civil Engineering Features
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KKNPP- Civil Engineering Features
Fabrication UnitUniversally accepted Process of extensionof Rebar
Rebar congestion due to lap can be avoided
and effective concrete placement
Available in dia of rebar 16mm & above
Reduces the construction time
Very much handy at temporary openings
which are to be closed later
Screw couplers
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KKNPP- Civil Engineering Features
Type of Screw Coupler
Connecting Bar is RotatedType- A
Screw couplers
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KKNPP- Civil Engineering Features
Type of Screw Coupler
Coupler is rotatedType- B
Additional Threading
Screw couplers
KKNPP Civil Engineering Features
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KKNPP- Civil Engineering Features
Type of Screw Coupler
Coupler is rotated & locked with Lock nutType- C
Additional Threading
Lock Nut
Screw couplers
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KKNPP- Civil Engineering Features
Type of Screw Coupler
Coupler welded To structural element & Bar is
rotatedType- W
Welding
Screw couplers
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KKNPP- Civil Engineering Features
Cutting Metric Threads
Screw couplers
KKNPP- Civil Engineering Features
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KKNPP- Civil Engineering Features
Screw splicing with Coupler
Screw couplers
KKNPP- Civil Engineering Features
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KKNPP- Civil Engineering Features
Temp. Opening with Coupler
Screw couplers
KKNPP Civil Engineering Features
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KKNPP- Civil Engineering Features
HEAVY CONCRETE
KKNPP- Civil Engineering Features
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KKNPP- Civil Engineering Features
Concrete prepared with Hematite aggregate
% of Iron- more than 60%
Specific Gravity- above 4.65
Chemical composition Fe2O3
Properties of Heavy aggregate
Hematite is raw iron ore
Heavy concrete
% of Iron Oxide - more than 90%
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KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
Heavy Concrete
Heavy Concrete
KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
Properties of Serpentine concrete
Concrete density not less than 3650Kg / Cum
Less thickness of structural element than of normal concrete
Heavy Concrete
Radiation Shielding (Gamma)
KKNPP- Civil Engineering Features
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KKNPP- Civil Engineering Features
SERPENTINE CONCRETE
KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
Concrete prepared with Serpentine aggregate
% of Chemically bound water-13%
Compressive strength- 300Mpa
Specific Gravity-2.5 to 2.8
Chemical composition - 3MgO.2SiO2.2H20
Properties of Serpentine aggregate
Metamorphic mineral occurring as small pockets in
Magnesium Dolomite
Heat conductivity coefficient- 0.895 W/(m.K)
Specific Heat- 84 KJ/(Kg.K)
Serpentine Concrete
KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
Serpentine Aggregate
Serpentine Concrete
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KKNPP Civil Engineering Features
Properties of Serpentine concrete
Radiation Attenuation
Thermal Insulation
Cooling effect to the surrounding
Serpentine Concrete
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KKNPP Civil Engineering Features
GREEN CUTTING
KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
Preparation of Construction Joint (side)
Top laitance to be removed
after final setting of Concrete
for effective bonding
Surface roughness +/- 5mm
Surface retarder Application
Just after final setting time
wash with Air Water jet
Green cutting
KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
Preparation of Construction Joint (Top)
Green cutting
KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
PRE-STRESSING
KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
What is pre-stressing ?
Concrete is weak in Tension but can withstand more compression
Relatively high compressive strength concrete is used
Pre- compression induced by pre-stressing with HT steel wire
Net effect after the loading is only compression
KKNPP- Civil Engineering Features
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KKNPP Civil Engineering Features
Principle of Pre-stressing
W
PP
+
P/A+M/Z
=
- M/Z
P/A +M/Z
P/A - M/Z
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g g
Why pre-stressing is need for the Containment?
.Containment is the Cylindrical house for Reactor
.It is the Ultimate barrier to contain accident releases
In case of hypothetical accident the pressure inside containment may
raise to 0. 4MPa
.To with stand the pressure during accident (no part of the containmentshould be in tension)
Pre-stressing
.To contain the radiation release with in the containment
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g g
Pre-stressing system For KKNPP- Freyssinet 55C15
Technical Parameter of Pre-stressing system
Greased cable un-bonded post tension Pre-stressing system
Net pre-stressing per Tendon -11.5MN
Friction coefficient -0.05 per Rad.
Pre-stressing Jack 3C1500F (15MN)
Wobble coefficient - 0.001 per M
Number of strands in one tendon - 55 Nos
Number of tendons U - 60Nos (every 3 degree)
H - 68 Nos (34 pairs at every 1.4m)
This system is adopted first time in the World for NPP
Pre-stressing
KKNPP- Civil Engineering Features
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g gPre-stressing
KKNPP- Civil Engineering Features
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g g
Pre-stressing system For KKNPP- Freyssinet 55C15
Technical Parameter of HDP Coated Pre-stressing Strand
Breaking load-279KN
Cross sectional area -150 Sqmm
Ultimate strength -1860MPa.
Modulus of Elasticity 1.95MPa
Yield strength 1600Mpa
Relaxation loss 1000hrs 2.5% at 200C
3.5% at 400C
Weight per M -1.17Kg
Pre-stressing
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HDP coated Pre-stressing strands
Pre-stressing
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g g
Pre-stressing system For KKNPP- Freyssinet 55C15
Technical Parameter of Trumplate
Weight - 140 Kg
Overall dimensions - 420 mm X 510 mm X 516 mm
Brinnel HBW hardness - 170 to 230
Pre-stressing
KKNPP- Civil Engineering FeaturesPre-stressing
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Trumplate Erection for U Cable
Pre stressing
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Pre-stressing system For KKNPP- Freyssinet 55C15
Technical Parameter of Cable Duct
Spiral sheath (formed from steel strip of 78mm)
Dia-200mm (206 for Coupler)
Steel Tube
Dia-219mm (OD)
Thickness -0.6mm
Weight -17.04Kg/m
Weight -3.66Kg/m
Thickness -3.2mm
Pre-stressing
KKNPP- Civil Engineering FeaturesPre-stressing
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Bell mouthing Steel pipes
Pre stressing
KKNPP- Civil Engineering Features
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Pre-stressing system For KKNPP- Freyssinet 55C15
Technical Parameter of Anchor Block
Overall dimensions -300mm (dia) X 160mm(thick)
Weight - 65 Kg
Nominal tensile strength - 650 MPa
Roughness 12.5 m
Pre-stressing
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Pre-stressing system For KKNPP- Freyssinet 55C15
Technical Parameter of Wedges
Segments (parts) - 3
Steel grade - 16 Mu Cr5
Overall dimensions- 26.5 mm X 45 mm
Pre-stressing
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Pre-stressing system For KKNPP- Freyssinet 55C15
Mock up for Threading & Grouting (H Cable)
Pre-stressing
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Pre-stressing system For KKNPP- Freyssinet 55C15
Cross section of the grouted Cable
Pre-stressing
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Pre-stressing system For KKNPP- Freyssinet 55C15
Advantage of Pre-stressing system
Low friction coefficient hence less friction loss & less tendons
Since grouting is done before stressing, the influence of one stand over
other during stressing is avoided.
Single strand replacement if necessary is possible
Re-stressing in future if necessary is possibleCable is coated with grease & more resistant to corrosion
(Un bonded -0.05 per Rad as against 0.24 Per rad for bonded )
Pre-stressing
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Modulus of Elasticity - 39000MPa
Density - 2200 to 2500Kg/Cum
Water impermeability - W6 or W8
Design Requirement for B30 grade concrete
Concrete
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The concrete for KKNPP is designed for Water
impermeability of W6 or W8 as per GOST12730.05-84
Specimen specification
Dia -150mm
Height-150mm ( 40mm)
Dia -100mm (20mm)
Age -28days
Top laitance to be removed
Number of sample - 6
Concrete
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Mold with Air tight
gas- cut
Concrete
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Specimen is placed
inside the mold.
Gap between the mold
& specimen is sealedwith resin
Concrete
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The mold with specimen
closed with rubber gas-cut and connected to
the testing M/c
Concrete
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Pressurized to 0.2MPa
Retention period
16Hrs for 40mm
Pressure increment-0.2MPa
12Hrs for 20mm
Final pressure
0.6MPa for W6
0.8MPa for W8
Concrete
Criteria Nowater should leak
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Lift Height -2.8m
Grade of concrte-B50 Steel liner
Placement Temp- 190
C
Containment Concrete
Doka Self climbing
form
Fluid pressure on liner
Less than 0.015MPa
Layer-1
Layer-2
Layer-3
CIVIL WORKS: CONCRETING PROGRESS
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0
5000
10000
15000
20000
25000
30000
35000
40000
45000
Jan-04
Feb-04
Mar-04
Apr-04
May-04
Jun-04
Jul-04
Aug-04
Sep-04
Oct-04
Nov-04
Dec-04
Total concreting done as of Mar 16, 2005 :7.01 lakh cu.m.
Concreting done in Year 2004 : 4.01
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