The document outlines NPCIL's plans to build nuclear reactors in India in a "fleet mode" whereby 10 reactors of 700MWe each will be constructed simultaneously over the next 10-12 years, presenting challenges for standardized engineering, establishing a robust supply chain, and developing adequate human resources for the nuclear industry to support the rapid expansion.

1. INDIAN STRUCTURAL INTEGRITY SOCIETY
Workshop on Structural Integrity
Assessment of Nuclear Energy Assets
9th – 10th May 2018
AERB Auditorium, Niyamak Bhavan-B,
Mumbai

2. Business opportunities opening
up in NPCIL PHWR programs and
technical Preparedness expected
from vendors…….
P V Philipkutty
Associate Director
(Nuclear & Mechanical Systems),
Procurement Directorate
Nuclear Power Corporation of India
Limited

3. Present Nuclear power scenario in India
• 22 Reactors operating under NPCIL- an
installed capacity of 6780 MWe (TAPS 1-4, RAPS 2-6,
MAPS 1&2, NAPS 1&2, KAPS 1&2, KGS 1-4 & KKNPP 1&2)
• 8 Reactors are under construction
• 2X700 MWe at KAPP 3&4 Gujarat
• 2X700 MWe at RAPP 7&8 Rajasthan 6700 MWe
• 2X700 MWe at GHAVP 1&2 at Haryana
• 2X 1000 MWe at KK NPP 3&4 Tamilnadu

5. Performance-Electrical generation …

6. Rapid growth- Expectation of GOI-People…
• Government of India has sanctioned plants to be built
in fleet mode - pressing speed button
• Government of India has also sanctioned large size
additional LWRs
• Government of India has also laid down expectations
in the form of 24 LWRs through import route

7. Fleet mode construction of plants
• 10 PHWR type Reactors 700 MWe each –
7000 MWe
• 2 LWR type reactors at Kudankulam NPP of
1000 MWe each – 2000 MWe
Total of 9000 MW nuclear capacity sanctioned

8. Future Nuclear capacity addition planned
• 24 Reactors of LWR technology as
additionality through import route –
• 6X 1650 MWe at Jaitapur, Maharashtra
• 6X 1208 MWe at Kovada, Andhra Pradesh 29.000 MWe
• 6X 1000 MWe at Mithivirdhi, Gujarat
• 6X 1000 MWe at Haripur West Bengal
Total of 29,000 MW nuclear capacity

9. Nuclear Power Plant Sites in India

10. Procurement Strategy for GHAVP-1&2
• GHAVP-1&2 will be similar to KAPP-3&4/
RAPP-7&8
• All major Nuclear Components will be directly
procured by NPCIL
• There will be approx. 25 nos. of Supply Packages
• EPC Packages will be approx. 10 nos.
• Major Site Contracts will be 03 nos.

11. Procurement Strategy for GHAVP-1&2
• 25 nos. of Supply Packages.
□ End Shield Package
□ Calandria Assembly
□ End Fittings and Associated Components
□ C.V Top Hatch Beams & Deck Plate Assembly
□ Air Lock Doors (MAL & AAL)
□ Zircoloy Package
□ Crane Package
□ Hoist Package
□ Drive Mechanism (AR, CR & SR)
□ Stand Pipe Thimble Package

12. Procurement Strategy for GHAVP-1&2
□ Bellow Package
□ Lifting Table
□ D2O Heat Exchanger Package, PDHRS-CD & ECCS
□ Pressuriser and Bleed Condenser
□ Reactor Header Assemblies
□ Steam Generator
□ Phosphor Bronze Wire-mesh supply
□ Primary Pump, Blowers & Compressors Package
□ Primary Coolant Pump Package
□ Distillation Column for D2O Upgrading Plant
□ Fuel Handling System Items

13. Procurement Strategy for GHAVP-1&2
 10 nos. of EPC Packages.
 Primary Package
 Common Services Package
□ Plant Water Package
□ Transformer Package
□ Diesel Generator Package
□ Nuclear Instrumentation Package
□ Turbine Island Package
□ Control Centre Instrumentation Package
□ Field Instrumentation Package
□ Main Plant Electrical Package

14. Procurement Strategy for GHAVP-1&2
 03 Nos Major Site Contracts.
□ Main Plant Civil Works
□ NDCT & CCW Package
□ IDCT Package

15. • Primary Piping Package (PPP)
Scope of major packages
SN. Description Unit Quantity
1 Feeder Pipes Kms. 27
2 CS Pipes Kms. 31.5
3 SS Pipes Kms. 83
4 SS Tubes Kms. 66
5 Custom bends Mtrs. 387
6 Feeder fittings Nos. 4700
7 CS/SS fittings Nos. 75000
8 Tanks/Vessels/Misc. Equipment Nos. 300
9 Lead Shielded Vessels Nos. 182
10 Strainers Nos. 170
11 Snubbers Nos. 80
12 Heat Exchangers (PHE + Shell & Tube) Nos. 76
13 Metallic Bellows Nos. 386
14 Filter vessels Nos. 74
15 Vee wire screen Nos. 207
16 Heaters Nos. 56
17 Sub-micron filters Nos. 22
18 Lead shots MT 95
19 Lead Bricks Nos. 38000
20 Instruments LG/FG/LMD Nos 150

16. • Main Plant Air Conditioning & Ventilation Package (To be part of PPP from GHAVP-
1&2 onwards)
Scope of major packages
SN Description Unit Quantity KAPP-3&4
1 Centrifugal Fans, Axial Fans & Propeller Fans Nos. 417
2 Coolers & Air Handling Unit (AHU) Nos. 204
3 Dryer Systems 12
4 Isolation Dampers Nos. 236
5 GSS Ducting Sqm. 55000
6 Grills, diffusers,dampers,louvers etc Sqm. 785
7 HDPE Filter,Felt Fabric Filter,HEPA Filter & combined HEPA and Charcoal
Filter,Filter Frames
Nos. 2000
8 Fire Dampers Nos. 917
9 Air Washer Plant Nos. 7
10 Containment pentration Bellow Nos. 64
11 Passive Catalytic Recombiner (PCRD) Nos. 180
12 Containment Filtered Venting System (CFVS) Nos. 2

17. • Common Services Package (CSP)
Scope of major packages
Sl. Description Unit Quantity
1 CS Pipes Kms. 75
2 SS Pipes Kms. 53
3 CS Pipe fittings Nos. 66000
4 SS Pipe fittings Nos. 56000
5 Structural material MT 2000
6 Hilti Bolts Nos. 5000
7 CM Chiller (210 TR) Nos. 04
8 VAL Chiller (930 TR) Nos. 03
9 Compressors (20 NM3/min at 8.5 kg/cm2) Nos. 03
10 Air Drying plants Nos. 04
11 Tanks & Vessels Nos 150
12 Heat Exchangers Nos. 30
13 Valves Nos. 8000
14 Diaphragm Valves Nos. 1400
15 Pumps Nos. 200
16 Ultrasonic flow meter Nos. 32
17 Strainers/steam traps Nos. 500
18 Decontamination equipment Nos. 06
19 Laundry equipment Nos. 16

18. SL. Description Unit Quantity
(for 2 x 700MWe)
1 285 MVA Generator Transformer (Single phase) Nos. 6
2 70 MVA Startup Transformer Nos. 4
3 70 MVA Transformer Nos. 4
4 6.6 KV Switchgear (Class-IV & III) Nos. 8 + 8
5 415 V Switchgear (Class-IV, III & II) Nos. 14 +12+4
6 415 V Motor Control Centers (Class-IV, III & II) Nos. 12+24 +4
7 4200 KW DG sets Nos. 8
8 500 KVA Uninterrupted Power Supply (UPS) Nos. 4
9 HV Power Cables Kms. 54
10 LV Power Cables Kms. 560
11 Control cables Kms. 450
12 Control Power Supplies (ACVRs) Nos. 12
13 Cable Trays and accessories Nos. 1,10,000
14 360 V DC Power batteries Bank 4
15 220 V DC Control batteries Bank 8
16 Electrical Penetration Assemblies (Power) Nos. 52
17 Electrical Penetration Assemblies (C&I) Nos. 50
18 Structural steel for Cable tray supports MT 1000
19 Main Output System Protection panels Nos. 8
Major Electrical items in 2 x 700 MWe PHWR Nuclear Power Plant (Excluding
220 KV and 400 KV Switchyard)

19. MAJOR SCOPE OF C&I PACKAGES
Field Instrumentation Package
SN Description Unit Quantity
1 Instruments and Accessories (Transmitters, Gauges, RTDs, Thermocouples, Sensors, Level,
Pressure, DP Switches)
Nos. 9000+
2 Cables KM 2000+
3 SS Tubing KM 100+
4Industrial System like Physical Protection System, Access Control System, Fire Alarm System,
Communication System and CCTV System
Lot Lot
5 Local Control Panels Nos. 500+
6 Junction Boxes Nos. 5000+
7 Flow Elements, Flow Meters, Gauges and PLC based systems. Lot Lot
CONTROL CENTRE INSTRUMENTATION PACKAGE
400 plus Computer based and Relay based systems, Control Room Panels and
Computer Accessories.
NUCLEAR INSTRUMENTATION PACKAGE:
40 systems related to Nuclear Instrumentation, Radiation Monitoring and SPNDs.

20. Setting up of Reactors in Fleet mode
 Sanction from Government of India for setting up of
7000MWe (PHWR)+ 4000MWe (LWR) in one go.
 Financial sanction is in place as on today for 8400 MWe
(PHWRs) + 4000 MWe (LWRs).
 It is first time in the history of power sector that financial
sanction is issued by Government of India for 16
reactors.
 Total cost involved is ₹2,00,000 Cr. (₹1,20,000 Cr. for
PHWRs and ₹80,000 Cr. for LWRs).

21. Setting up of Reactors in Fleet mode
 70% of the above cost will be for the manufacturing
sector and about 25% for the construction sector
(Leaving only IDC, salary & perks for NPCIL)
 The above job is to be completed in next 10-12 years i.e.
about ₹20,000 Cr. per year, which is more than ₹50 Cr.
per day.
 Entire nuclear industry shall take up this challenge and
get themselves organised for making it happen.

22. • End shields (2 nos. per Reactor unit): 20 Nos
• Calandria (1 No. per Reactor unit) : 10 Nos
• Reactor Header (8 Nos. per Reactor unit): 80 Nos
• Pressuriser (1 No. per Reactor Unit): 10 Nos
• Steam Generator (4 Nos. per Reactor unit): 40 Nos
• Primary Coolant Pumps (4 Nos. per Reactor Unit): 40 Nos
Tendering actions already initiated for all these components……
Requirement of Major Equipment for Fleet Mode
Reactors:

23. Fleet Mode Reactors - Schedule for First Pour of
Concrete (FPC)
• Five Years (60 Months) Construction Schedule is considered from First Pour
of Concrete (FPC) to Criticality

24. Fleet mode Challenges
• Siting and pre-project activities
• Enhanced industrial support in
manufacturing and project execution
• Planning for human resource- for
realizing the rapid growth plan
• Renewed approach in safety review and
regulatory clearance

25. For the success of this program
 Engineering input shall be frozen
 Supply chain shall be well organised
 Construction, Erection and Commissioning shall be on
time (both Civil and EPC)

26. Engineering Input
• Standardisation is the key; both detailed plant
engineering and equipment engineering shall remain
the same.
• GHAVP-1&2 layout, design & engineering will be
followed for all future 700 MWe type PHWRs except
for site specific changes.
• Keeping GHAVP-1&2 as the standard model, two
enveloping designs; one for soil strata and other for
rock strata have been envisaged for Seismic
Qualification process.

27. Supply Chain
• Nuclear Suppliers have the pivotal role to play
• We will have full transparency in ordering
• Strategy for procurement has already been
approved by NPCIL Board
• For some of the long delivery items we are
already into tendering mode

28. Challenges in supply chain….
• Quality issues in the recent past is an area of
concern. It is a challenge definitely Industry
need to address.
• We expect Industry to learn from experience of
KAPP-3&4 and RAPP-7&8.
• Industry shall build robust internal QA system
and Focus on First time correct approach.
• Quality shall be ensured by fool proof systems in
the shop floor / Construction sites by the
Industry – not by NPCIL QA

29. Challenges in supply chain….
• Simultaneous construction activities will be needed at
number of sites. Support of industry for construction
activity at such large scale is a challenge.
• Weak financials of the contractors affecting the site
progress is a major area of concern in the recent past.
Industry need to address this.
• Industry also need to address their HR issues. We
need quality manpower & expertise with the
Industries.

30. • NPCIL is already addressing HR issues. Major
recruitment is planned; thrust being given on NPCIL
QA manpower.
• We are also working on the feedback received from
Industry. Changes suggested in GCC and Contract
conditions are being addressed. Will be implemented
for future contracts.
Challenges in supply chain….

31. • Nuclear power shall be cost competitive. It is
important for all stakeholders.
• Environmentalists also identify Nuclear as a green
power today.
• If we ensure cost competitive & safe power, many
such fleet mode we can expect in near future.
Challenges in supply chain….

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Indian Structural Integrity Society (InSIS)
Website: www.instint.in
Contact us: insisblr@gmail.com