BHAVINI’s NOMINATION FOR ENGINEERING
EXCELLENCE AWARD - 2013

Presentation by

Dr. Prabhat Kumar
Distinguished Scientist a...
INDIA’S THREE STAGE NUCLEAR
POWER PROGRAMME

12 GWe, 30 Yr

Natural
Uranium

Th

E LE CT RI CIT Y

PHWR

Depleted U
Pu

30...
• Prototype
Fast
Breeder
Reactor (PFBR) is first of its
kind nuclear reactor in the
country
• India’s very important and
p...
Prototype Fast Breeder Reactor Flow Chart
Fukushima incident could have been avoided if passive
decay heat removal system ...
PFBR REACTOR ASSEMBLY COMPONENTS
Huge size reactor with
complex constructional
features

Man standing

1

Main Vessel

2

...
Stringent administrative and quality
controls at every stage
What all makes PFBR project eligible for
Engineering Excellence Award 2013
Indigenous and New Technology
Many Challenges...
Few points which make PFBR project
innovative
 First of its kind nuclear reactor in the country
- Generates more Plutoniu...
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 mete...
Off Shore Submarine Tunnel
Under sea Tunnel 567 meters
length at 50 meters below the sea

Constructed for the first time in the country
Tsunami bund/Shore Protection/Outfall Channel

Tsunami bund

Shore
protection

Outfall Channel

15

15
Coastal plantation

Engineered sand dune

Unique method of Tsunami protection
system for the reactor site
INCREASE IN ELEVATION
The nuclear island finished floor level
is raised to 15.7 meters for reactor
protection from future ...
Fabrication of gigantic reactor
components for PFBR
Fabrication of over dimensional, thin
walled reactor components at PFBR site
FABRICATION OF MAIN VESSEL
Great
Challenge
Made for
the first
time in the
country

Diameter achieved within 10mm tolerance...
INNER VESSEL
Positional accuracy,
alignment and
orientation has to
be maintained
during fabrication
To be lifted during
erection without swing

Man standing

Safety Vessel with Thermal Insulation Panels
Primary Pipe-Grid Plate assembly

The Grid Plate supports all the
core subassemblies of PFBR

Welding to be done in
constr...
WELDING
BETWEEN
ROOF SLAB
(RS) AND MAIN
VESSEL (MV)

Very important joint
Weld carries about
2500 tones of
weight
Welding ...
Tube to Tubesheet welding, Post Weld Heat Treatment and
Micro-Focal radiography for PFBR Steam Generators

Welding
Nuclear...
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
ERECTION OF MAJOR COMPONENTS

Safety Vessel

Main Vessel

Thermal Baffle
Safety Vessel is being lowered into Reactor Vault
in a constrained space without swing
Erection of Thermal Baffle
ERECTION OF MAJOR COMPONENTS

Grid Plate

Inner Vessel

Roof Slab
Massive
Argon
Buffer
Tank
erection
STEAM GENERATOR (SG)
ERECTION

SPECIAL ARRANGEMENT FOR
SHIFTING SG (25 METER LONG
COMPONENT)

PLACING SG IN SPECIAL
TILTIN...
Operational excellence of the project
 Meticulous planning and Management






Technical aspects
Finance
Human Reso...
INDUSTRIAL SAFETY AWARDS
High performance in safety in
the construction sector !!!!!

“Industrial Safety Award” by Atomic ...
AWARDS - HUMAN RESOURCES
Development and inspiration of
true potential of human capital

“Best HR Practices–2012 Award” by...
Award for outstanding Concrete Structure

“ICI (TNCC) - Ultratech Award”
by Indian Concrete Institute
How PFBR project has added to the self
reliance of India in the chosen sector
 Excellences by young team with an average
...
Key impacts which PFBR project has made
 Sustainability
 Improvement in the quality standards
 Creation of new and indi...
Science Lab Apparatus & Models donated to Annamalai Middle School,
Desumughipet, Thirukalukundram

Donated PC and books to...
Epidemiological Health Survey with
Assistance from BHAVINI

One R.O. Plant has been installed at Sadras Meyyur
kuppam, Kal...
Few points which illumine more on the future
readiness of the project
 Robust feedback system for
-Knowledge management
-...
Over all Night View

PFBR the pride of
nation
53
Thank
You
Bharatiya nabhikiya vidyut nigam limited (bhavini)
Bharatiya nabhikiya vidyut nigam limited (bhavini)
Bharatiya nabhikiya vidyut nigam limited (bhavini)
Bharatiya nabhikiya vidyut nigam limited (bhavini)
Bharatiya nabhikiya vidyut nigam limited (bhavini)
Bharatiya nabhikiya vidyut nigam limited (bhavini)
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Bharatiya nabhikiya vidyut nigam limited (bhavini)

  1. 1. BHAVINI’s NOMINATION FOR ENGINEERING EXCELLENCE AWARD - 2013 Presentation by Dr. Prabhat Kumar Distinguished Scientist and Chairman & Managing Director Bharatiya Nabhikiya Vidyut Nigam Limited (BHAVINI) Department of Atomic Energy A Government of India Enterprise Kalpakkam 603 102, Tamilnadu, India
  2. 2. INDIA’S THREE STAGE NUCLEAR POWER PROGRAMME 12 GWe, 30 Yr Natural Uranium Th E LE CT RI CIT Y PHWR Depleted U Pu 300 GWe, 30 Yr Pu FUELLED FAST BREEDERS Th E LE CT RI CIT Y 500 GWe, 500 Yr Pu U-233 U-233 FUELLED BREEDERS E LECTRICITY U-233 STAGE 1 STAGE 2 STAGE 3 BHAVINI has commenced activities on second stage
  3. 3. • 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 Fuel : PuO2+ UO2 Thermal Power : 1250 MWth Electrical output : 500 MWe Coolant : Liquid Na Thermal Efficiency : 40%
  4. 4. Prototype Fast Breeder Reactor Flow Chart Fukushima incident could have been avoided if passive decay heat removal system like PFBR exist in their reactor PFBR, the only nuclear reactor in the country has secondary loop No power required for removal of decay heat
  5. 5. PFBR REACTOR ASSEMBLY COMPONENTS Huge size reactor with complex constructional features Man standing 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
  6. 6. Stringent administrative and quality controls at every stage
  7. 7. What all makes PFBR project eligible for Engineering Excellence Award 2013 Indigenous and New Technology Many Challenges overcome successfully and Innovations in many activities Achievements and high success rate in every activities Manufacture of thin walled gigantic components for the first time in the country Handling & Erection of over dimensional equipment without single dent Design, Construction, Equipment fabrication and Regulatory approval in parallel
  8. 8. Few points which make PFBR project innovative  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 !!!
  9. 9. Highly reactive Liquid Sodium transfer
  10. 10. Largest and deepest excavated pit in Indian nuclear plants immediately next to sea (200 meters from the sea)
  11. 11. 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
  12. 12. Off Shore Submarine Tunnel
  13. 13. Under sea Tunnel 567 meters length at 50 meters below the sea Constructed for the first time in the country
  14. 14. Tsunami bund/Shore Protection/Outfall Channel Tsunami bund Shore protection Outfall Channel 15 15
  15. 15. Coastal plantation Engineered sand dune Unique method of Tsunami protection system for the reactor site
  16. 16. INCREASE IN ELEVATION The nuclear island finished floor level is raised to 15.7 meters for reactor protection from future Tsunami if any
  17. 17. Fabrication of gigantic reactor components for PFBR
  18. 18. Fabrication of over dimensional, thin walled reactor components at PFBR site
  19. 19. FABRICATION OF MAIN VESSEL Great Challenge Made for the first time in the country Diameter achieved within 10mm tolerance for total 12900 mm
  20. 20. INNER VESSEL Positional accuracy, alignment and orientation has to be maintained during fabrication
  21. 21. To be lifted during erection without swing Man standing Safety Vessel with Thermal Insulation Panels
  22. 22. Primary 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
  23. 23. 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
  24. 24. Tube to Tubesheet welding, Post Weld Heat Treatment and Micro-Focal radiography for PFBR Steam Generators Welding Nuclear Clean Hall Local Heat Treatment Micro-Focal Radiography
  25. 25. Fabrication of 26 meters length Steam Generators in shop
  26. 26. FABRICATED STEAM GENERATORS Straightness achieved within 3mm on 26,000 mm length of SG !!!!!!
  27. 27. Challenges in header pullout to bend tubes welding for Sodium to Air Heat Exchangers Extremely Difficult
  28. 28. Header Welding - Needs highly qualified and skilled welders
  29. 29. Header Welding- Extremely difficult Challenge
  30. 30. Reactor equipment erection
  31. 31. Erection of PFBR equipment without single dent
  32. 32. ERECTION OF MAJOR COMPONENTS Safety Vessel Main Vessel Thermal Baffle
  33. 33. Safety Vessel is being lowered into Reactor Vault in a constrained space without swing
  34. 34. Erection of Thermal Baffle
  35. 35. ERECTION OF MAJOR COMPONENTS Grid Plate Inner Vessel Roof Slab
  36. 36. Massive Argon Buffer Tank erection
  37. 37. STEAM GENERATOR (SG) ERECTION SPECIAL ARRANGEMENT FOR SHIFTING SG (25 METER LONG COMPONENT) PLACING SG IN SPECIAL TILTING MECHANISM TILTING FOR ERECTION CONNECTION OF LIFTING SLINGS LOWERING OF SG IN STEAM GENERATOR BUILDING SG LIFTED WITH HEAVY DUTY CRAWLER CRANE POSITIONING & ALIGNMENT FIXING OF HEATERS ON SG
  38. 38. Operational excellence of the project  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
  39. 39. INDUSTRIAL SAFETY AWARDS High performance in safety in the construction sector !!!!! “Industrial Safety Award” by Atomic Energy Regulatory Board “Suraksha Puraskar” by National Safety Council of India
  40. 40. AWARDS - HUMAN RESOURCES Development and inspiration of true potential of human capital “Best HR Practices–2012 Award” by National Institute of Personnel Management (NIPM)
  41. 41. Award for outstanding Concrete Structure “ICI (TNCC) - Ultratech Award” by Indian Concrete Institute
  42. 42. 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
  43. 43. Key impacts which PFBR project has made  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
  44. 44. Science Lab Apparatus & Models donated to Annamalai Middle School, Desumughipet, Thirukalukundram Donated PC and books to Govt. Higher Sec. School, Pudupattinam on 28.04.2008 Donation of Personal computers to the schools Vocational Training Programme for Neighborhood village youth from 27.09.2005 Water Pump & Pump room for Panchayat Union Primary School Meiyur Vocational Training courses II batch commenced on 02.10.2006 Construction of Compound Wall- Panchayath Union Primary School Sadhrangapattinam Water Tank & Hand Wash Facility Panchayath Union Primary School Sadhrangapattinam
  45. 45. Epidemiological Health Survey with Assistance from BHAVINI One R.O. Plant has been installed at Sadras Meyyur kuppam, Kalpakkam ` 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-shield Hatchery – Self Help Groups
  46. 46. Few points which illumine more on the future readiness of the project  Robust feedback system for -Knowledge management -Sharing of experiences with industry and academia -Win Win situation for all  Training, qualification & capability developmen  Strengthening of Industries -Tools/fixtures - Facilities - Techniques - Manufacture - Inspection  Standardized design and manufacturing  Modular concept to the possible extent
  47. 47. Over all Night View PFBR the pride of nation 53
  48. 48. Thank You

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