You are on page 1of 36

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

Overseas Branches
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

DH0209
CONTENTS
INTRODUCTION 4
ORGANIZATION 6
EXPERIENCE 8
FEATURES OF PWR (KSNP) 10
- SYSTEM OF KSNP 10
- ADVANCED FEATURES OF KSNP 12
- REACTOR COOLANT SYSTEM 13
- REACTOR VESSEL AND INTERNALS 14
- REACTOR INTERNALS 15
- REACTOR VESSEL 16
- CONTROL ELEMENT DRIVE MECHANISM 18
- STEAM GENERATOR 20
- PRESSURIZER 22
- GAS STRIPPER 24
- HEAT EXCHANGER 25
- TANK 25
FEATURES OF PHWR 26
- PHWR SYSTEM 26
- CALANDRIA 27
- FEEDER HEADER ASSEMBLY 27
DESIGN ANALYSIS 28
MANUFACTURING FACILITIES 30
RESEARCH & DEVELOPMENT 32
QUALITY ASSURANCE 33
SERVICE & REPLACEMENT 34
CONSTRUCTION & INSTALLATION 35
Clean World for Our Next Generation

N
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.
NTRODUCT ON

I
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.
4
Changwon Integrated Machinery Plant

er lliittyy
ar Power Quuaa aannccee
Q
rr
le n s
suu
Nucant Ow Ass
A
Pl

iiccee &
&
SSeerrvv eem m eenntt
llaacc
RReepp
AN
N
DOOOSSA
O
D
&
tion
nstruc tion
Co talla
Ins
nngg
kkeettii
Maarr
M

ect h& t
Proj ment earc
g e Res lopmen
a e
Man Dev
&
ign ture
Des eering ufac
in an
Eng M

Currently, DOOSAN is committed to the manufacture of NSSSs and T/Gs for Ulchin Units 5&6, Shin-
Kori 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. 5
ORGAN ZAT ON
Chairman of the Board & President

Marketing & Business Technique / Production Civil & Construction


Development Group Business Group Business Group

Marketing & Business Civil & Construction


Engineering Division
Development Division Business Division

Thermal & Hydro


Power Plant Division

Nuclear
Power Plant Division
Nuclear Power
Plant Planning Corporate Quality
Industrial Machinery Control
& Plant Division Dep’t

Engine / Casting & Forging


Business Division

6
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

7
EXPERIENCE
A
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 Ulchin Nuclear Power Plant


(WSN #1,2,3,4) (UCN #1,2,3,4,5,6)

BEIJING
North Korea Nuclear Power Plant
(N. Korea #1,2)

SEOUL

Qinshan Nuclear Power Plant


(QSN #1,2)

TAIPEI

Yonggwang Nuclear Power Plant Kori Nuclear Power Plant


(YGN #1,2,3,4,5,6) (KRN #1,2,3,4)
Capacity Reactor Commercial
Project Client (MWe X Units) Type Operation
Yonggwang # 1, 2 KEPCO / Westinghouse 950 X 2 PWR 1986 / 1987
Ulchin # 1, 2 KEPCO / Framatome 950 X 2 PWR 1988 / 1989
Yonggwang # 3, 4 KEPCO 1,000 X 2 PWR 1995 / 1996
Wolsong #2 KEPCO 700 X 1 PHWR 1997
Wolsong # 3, 4 KEPCO 700 X 2 PHWR 1998 / 1999
Ulchin # 3, 4 (KSNP) KEPCO 1,000 X 2 PWR 1998 / 1999
Yonggwang # 5, 6 (KSNP) KHNP 1,000 X 2 PWR 2002
Qinshan # 1, 2 (China) QNPC / AECL 700 X 2 PHWR 2003
Sequoyah # 1 RSG TVA / Westinghouse 1,200 X 1 PWR 2003
Ulchin # 5, 6 (KSNP) KHNP 1,000 X 2 PWR 2004 / 2005
Watts Bar # 1 RSG TVA / Westinghouse 1,200 X 1 PWR 2006
N. Korea # 1, 2 (KSNP) KEDO / KEPCO 1,000 X 2 PWR 2008 / 2009
Shin Kori # 1, 2 (KSNP) KHNP 1,000 X 2 PWR 2008 / 2009
Shin Wolsong # 1, 2 (KSNP) KHNP 1,000 X 2 PWR 2009 / 2010
Shin Kori # 3, 4 (APR) KHNP 1,400 X 2 PWR 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
1400MWe

Shin KRN-4
CLASS

Shin KRN-3

Shin WSN- 2
Commercial Operation
Shin WSN- 1
Under Site Installation
Shin KRN-2
Under Shop Fabrication
Planned Shin KRN-1

N.Korea-2
1000 MWe CLASS

N.Korea-1

UCN-6

UCN-5

PWR YGU-6

YGU-5

UCN-4

UCN-3

YGU-4

YGU-3

UCN-2
950 MWe CLASS

UCN-1

YGU-2

YGU-1

QSN-2
700 MWe CLASS

QSN-1

PHWR WSN-4

WSN-3

WSN-2

Sequoyah-1
1200 MWe

RSG Watts Bar-1


600 MWe

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 7


FEATURES OF PWR (KSNP)
SYSTEM OF KSNP

Turbine Bldg. Primary Aux. Bldg.


Main Steam Stop Valve Main Control Room Aux. Feedwater Pump
High Pressure Turbine Main Steam Pipe (Turbine Driven)
Low Pressure Turbine Feedwater Pipe Component Cooling Water Pump
Generator Main Steam Safety Valve Press. Htr. 480 Volt Load Center
Moisture Separator Reheater Emergency Diesel Generator 480 Volt Dist. Cab. Press Htr.
Condenser Charging Pump Elec. Penet. Area Cubicle Cooler
Circulating Water Pipe Shutdown Cooling Heat Exchanger C.E.D.M. System Cabinet
H.P.Feedwater Heater High Energy Line Area Supply A.H.U.
Deaerator Containment Spray System H/EX
Deaerator Storage Tank Fire Water Storage Tank
L.P.Feedwater Heater Aux. Feedwater Pump
25-Ton Bridge Crane (Motor Driven)
250-Ton Bridge Crane

8
K
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. Fuel Bldg.


Containment Spray Header Steam Generator Shield Wall Fuel Handling Overhead Crane
Polar Crane C.E.A. Drive Mechanism Spent Fuel Handling Machine
C.E.A. Change Platform Refueling Machine Spent Fuel Storage Pool
Personnel Access Air Lock Reactor Vessel Cask Loading Pit
Main Steam Pipe Reactor Coolant Pump New Fuel Storage Pit
Containment Liner Plate Reactor Vessel Support Column Cask Decontamination Pit
Pressurizer Equipment Hatch New Fuel Inspection Area
R.C.F.C In-Core Instrumentation Loading Area
Steam Generator Refueling Canal Fuel Transfer System
C.E.D.M. Air Handling Unit Fuel Transfer Tube Shipping Cask
Safety Injection Tank Emergency Exit Air Lock Refueling Water Tank
Reactor Make-up Water Storage Tank
Hold-up Water Storage Tank
Normal Supply Air Handling Unit

9
A D VA N C E D F E AT U R E S O F K S N P

- Safety Depressurization System for rapid depressurization of the RCS


- Reinforced monitoring function for Residual Heat Removal System
Enhanced - High pressure piping for Shutdown Cooling System
Plant - Plant Protection System equipped with automatic inspection function
Safety - Established priority order for alarm
- Utilization of Core Protection Calculator and Core Operating Limit
Supervisory System to improve Core monitoring function

- Classified some part of CVCS (Chemical and Volume Control System) as


Non-safety related components
- Improved Shutdown Cooling System
Enhanced - Centrifugal Charging Pump
Availability and - Improved Letdown Line
Capacity Factor - 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

- Application of improved seismic analysis method


Enhanced Design
- Application of Leak-Before-Break design concept
Margin
- Improved evaluation method for heat generation rate in the RVI

- Considered Human Factors in the design


- Established priority order for alarm
Improved
- Minimized Alarm Indications and Instruments by applying Discrete
Control
Indication and Alarm System
System
- Digitalized signals
- Use of Optical Fibers and Multiplexer

Simplified - Separate Heat Exchanger for Containment Spray System


Operating - Simplified Chemical and Volume Control System
Procedure - Expanded use of Plant Computer

- Reduced cost by classification of non safety related CVCS


- Minimized pipe whip restraints and snubbers by application of
Economization Leak-Before-Break design concept
- Reduced cable cost by using Multiplexer
- Minimized Alarm Indications and Instruments by applying Discrete
Indication and Alarm System

12
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).

Pressurizer

Steam
Generator

RCP

Reactor
Vessel

TECHNICAL DATA

Electrical Output 1,000 MWe

Thermal Output 2,825 MWt

Design Pressure 2,500 psi

Normal Operating Pressure 2,250 psi

Design Temperature 650 F

13
REACTOR VESSEL AND INTERNALS

14
REACTOR 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.

15
REACTOR VESSEL
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 Guide Stud

Closure Head

Closure Stud

Closure Nut & Washer

Inlet Nozzle Outlet Nozzle

Support Pad

Surveillance Capsule Holder

Core Stabilizing Lug & Shim

Core Stop Lug

Shear Lug Instrument Nozzle

16
Material

The Reactor Vessel is fabricated from ring-


forged 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, temper-
ature, and radiation.

Support Columns

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.

Cladding

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.

17
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

COOLING SHROUD

MOTOR ASSEMBLY

MOTOR HOUSING ASSEMBLY

COIL STACK ASSEMBLY

EXTENSION SHAFT ASSEMBLY

18
Concept of Drive Mechanism (Double Step)
STATIONARY MAGNET-UPPER
The Motor Assembly is an integral unit which
UPPER LIFT COIL fits into the motor housing and provides linear
motion to the CEA. Both upper latches and
UPPER LIFT MAGNET
lower latches are used to perform the stepping
UPPER LATCH COIL
of the CEA and, by proper sequencing, perform
a load transfer function which minimizes latch
UPPER LATCH MAGNET and extension shaft wear. Total CEA motion per
cycle is 3/4 inch.
UPPER LATCH HOUSING

STATIONARY MAGNET-LOWER

LOWER LIFT COIL

LOWER LIFT MAGNET


LOWER LATCH COIL Advanced Features

- Withdraw, insert or hold the position of CEA


LOWER LATCH MAGNET
- Release CEAs by gravity into the reactor core
EXTENSION SHAFT ASSEMBLY - Operable for cumulative travel of minimum
LOWER LATCH HOUSING
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

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.

19
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.

Advanced Features
- 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

20
TUBE EXPANSION RANKING OF EXPANSION METHOD
Ranking *
Method
HANJUNG is the only manufacturer Description Mechanical Explosive Hydraulic
Roll
who can perform both explosive
Expansion Rate 2 1 1
expansion (explansion) and hydraulic
expansion in tube-to-tubesheet joints Microstructure Test 2 1 1
which must provide a tight seal Pull-Out Test 1 2 1
between tube and tubesheet, and
Hydraulic Leak Test 1 2 1
provide sufficiently high strength to
support the axial tube load. Residual Stress 3 2 1
Also, the joining technique must lend SCC (Stress Corrosion
3 2 1
itself to mass production and to Cracking) Simulation Test

uniformity of quality. Uniformity of Quality 2 1 1

Mass Production 3 1 2
Ranking : 1 = Best, 3 = Worst

Axial Residual Stress after Expansion Tube Expansion (Explosive)


- Equipment : Primer Cord, End Cap, Sheath, Trunk Line
- Transition Length : Max. 0.75 in.
- No Crevice
End Cap
Primer Code

Trunk Line
Polyesthylene Sheath

Secondary
Side Primary
After Side
Explansion
Explansion
Charge
Before
Explansion

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

O-Ring O-Ring
Mandrel Urethane
Metal Ring

Primary Secondary
Side Clad = 0.25 in. Tubesheet Thickness = 21.5 in Side

Depth of Expansion

Depth of
Crevice

21
PRESSURIZER
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.

Advanced Features
- Sufficient water volume
- Sufficient steam volume
- Minimized total reactor coolant
mass change
- Sufficient heat capacity
- Improved internal support system

22
2500 SAFETY VALVES OPEN
Pressure Control Program
(175.8)

A number of heaters are connected to


proportional controllers, which adjust the heat
PRESSURIZER PRESSURE, PSIA(kg/cm2 A)

input to account for steady-state losses and to


2350
(165.2)
HIGH PRESSURE ALARM maintain the desired steam pressure in the
BOTH SPRAY VALVES FULLY
OPEN ABOVE2 2300 PSIA
Pressurizer. The remaining heaters are connected
2300 (161.7 kg/cm A)
(161.7)
2275
BOTH SPRAY VALVES FULLY CLOSED
2
BELOW 2275 PSIA (159 9 kg/cm A)
to on-off controllers. These heaters are normally
(159.9) AND PROPORTIONAL HEATER
GROUP “OFF”
2250
(158.2) NORMAL SETPOINT PROPORTIONAL
HEATERS GROUP “ON”
de-energized but are automatically turned on by
2225
(156.4) ALL BACKUP HEATERS “OFF”
ABOVE 2225 2PSIA
(156.4 kg/cm A)
a low-pressurizer-pressure signal or a high-level
2200
(154.7) ALL BACKUP HEATERS “ON”
BELOW 22002PSIA
(154.7 kg/cm A) error signal. The Chemical and Volume Control
2160 LOW PRESSURE ALARM
(151.9)
System (CVCS) acts to restore coolant level,
resulting from a transient pressure decrease
NET HEAT IN NET HEAT OUT
below normal operating pressure.

Heater & Support System


SUPPORT
PLATE 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
SLEEVE terminal.
BOTTOM HEAD 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.
HEATER

Safety Depressurization System (SDS)

The Safety Depressurization System is included


to provide a manual means of rapidly
SDS
NOZZLE 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
SDS NOZZLE
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.

23
GAS STRIPPER
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 Mode 2 Mode 3


(Max. Operating) (Norm. Operating) (Min. Operating)
Flow Rate (gpm) 140 30 - 135 20
Temperature ( F) 120 - 170 40 - 120 40 - 120
Pressure (psig) 30 - 60 30 - 60 30

24
H E AT E X C H A N G E R
The Regenerative Heat Exchanger is installed Shell Side Tube Side
in series with a letdown heat exchanger to Normal Operating
Temperature (In/Outlet) 120 / 479 F 564.5 / 293 F
continuously circulate a portion of the reactor
coolant for purification. The reactor coolant Normal Operating Pressure 2485 psig 2235 psig
passes from the Reactor Coolant System through
the tube side and is cooled by purified water Design Temperature 550 F 650 F
pumped back to the Reactor Coolant System Design Pressure 3025 psig 2485 psig
through the shell side.

SHELL INLET

TUBE OUTLET

TUBE INLET

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 120 - 200 F


Normal Operating Pressure 610 psig
Design Temperature 200 F
Design Pressure (Int./ Ext.) 700/ 100 psig

25
FEATURES OF PHWR
H
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

PHWR SYSTEM

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

26
CALANDRIA
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.

27
DES GN ANALYS S

H
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.

28
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 Secondary flow distribution In transient calculations, water


two-phase flow distribution code results include velocity vector level and steam flow are
with both steady state and components in the three calculated as a function of time.
transient capabilities. coordinate directions, pressure, The code has been verified by
Homogeneous and axial flow temperature, quality and density comparison of analytical results
algebraic slip models are available. in each cell. with measured data from small
A typical geometric model The corresponding heat flux, scale experiments, model steam
includes approximately 1000 cells tube wall temperatures, primary generators and full-scale steam
but more detailed models are temperatures and the circulation generators.
possible. ratio are also calculated. Vector
and scalar plotting are available.

29
MANUFACTURING FACILITIES
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

FORGE SHOP
(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

MACHINE SHOP
(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

30
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

NUCLEAR SHOP
(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

FABRICATION SHOP

31
RESEARCH & DEVELOPMENT

T
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

32
QUALITY ASSURANCE
H
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.

ASME CERTIFICATE

TITLE CERT. NO. DESCRIPTION


N N-2765 Manufacture of Nuclear Component Sec.III
NA N-2766 Shop Assembly of Nuclear Comp. & Part Sec.III
NPT N-2767 Manufacture of Nuclear Part Sec.III
NA N-2779 Installation of Nuclear Comp. & Part Sec.III at site
NPT N-2780 Manufacture of Nuclear Part Sec.III at site
A 17602 Power Boiler Assembly (Sec. )
PP 17603 Pressure Piping
S 17604 Power Boilers (Sec. )
U 17605 Pressure Vessels (Sec.VIII Div. 1)
U2 17606 Pressure Vessels (Sec.VIII Div. 2)
H 20200 Heating Boilers except Cast Iron

MO QSC- 481 MM of Ferrous Castings & Forgings


MS of Ferrous Covered Electrodes

33
SERVICE & REPLACEMENT
H
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

34
CONSTRUCTION & INSTALLATION
Installation of Reactor Vessel

H
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

35