Structural Integrity

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 in LWR Program
and Technical preparedness for Indian
Vendors
Workshop on Structural Integrity
Assessment on Nuclear Assets
AERB Auditorium May 09, 2018
Gautam Biswas
Executive Director (Engg.-LWR)
Nuclear Power Corporation of India Limited

3. Outline
LWR Profile in India
LWR Capacity Addition Plan and Status
Evolving Business Model for KKNPP
Localization Through Indian Scope
Some Initiatives for Localisation
Localization Challenges

4. LWR Profile in Indian Nuclear Power Programme
 Nuclear power : A very reliable sources of 24 x 7 ‘base-load’
power generation .
 LWRs : Most common type of nuclear reactor among all nuclear
power reactors in the world.
 Present total installed capacity of Nuclear Power India is 6780
MW
 LWR Installed capacity : 2320 MWe
Two Units of BWR –TAPS-1&2 (2X 160 MWe)
Two Units of LWR – KKNPP-1&2 (2&1000 MWe).

5. • Majority of the Nuclear capacity in the World is supplied by Light
Water Reactors (around 84%)
• Majority of Reactors under construction are Light Water Reactors
• In India out of 22 reactors in Operation, 18 are PHWR and 4 are
LWR.

6. NPCIL’s OPERATING NUCLEAR POWER PLANTS
KAPS (PHWR) 2x220 MWe
TAPS (BWR) 2x160 MWe
NAPS (PHWR) 2x220 MWe
RAPS (PHWR) 1x100
MWe; 1x200 MWe,;4x220
MWe
KAIGA (PHWR) 4x220 MWe
MAPS (PHWR) 2x220 MWe
KKNPP (VVER) 2x1000 MWe *TAPS (PHWR) 2x540 MWe
.
6

7. Capacity Addition Plan - LWRs
(Potential Vendors & Technologies)
ASE, Russia
VVER (1000 MWe)
EdF, France EPR
(1650 MWe)
VVER 1200, Russia
(~1200 MWe)
WEC, USA AP 1000
(~ 1200 MWe)
Others
~ 40000 MWe
6000 MWe
~ 9900 MWe
~7200 MWe
~ 7200 MWe
~9500 MWe

8. KKNPP 3&4:
COD (U-3) Mar 2023
COD (U-4) Nov 2023
KKNPP-3&4 (2x1000 MWe)
Construction in full swing with
FPC in June 2017.
KKNPP-5&6 (2x1000 MWe)
Geo-technical investigation
under progress.
LWRs (VVER) at KUDANKULAM SITE- STATUS
FPC: First Pour of Concrete COD: Commercial Operation Date
KKNPP 5&6:
COD (U-3) Mar 2025
COD (U-4) Dec 2025

9. KK Unit-3 Main Plant Buildings in May 2018

10.  In-principle approval for LWRs
• 6 units of 1650 MWe at Jaitapur, Maharashtra.
• 6 units of 1200MWe at Kovvada, Andhra Pradesh.
• 6 units of 1200 MWe at Chaya Mithivirdi, Gujarat .
(this is in addition to the six units of 1000 MWe LWRs at
Kudankulam, Tamilnadu)
 A new site is also being considered for 6 units of VVER-1200
type reactors
LWR Capacity Addition Status

11. Kudankulam, T.N. (KKNPP 3&4):
• Land available at existing site.
• Contracts signed with ASE, Russia; Construction is
under progress.
Kudankulam, T.N. (KKNPP 5&6):
• Land available at existing site.
• General Framework Agreement and Long
Manufacturing Cycle Equipment Contracts signed.
LWR Capacity Addition Status

12. Jaitapur, Maharashtra:
• Land acquired for the Project & Site office established.
Pre-project activities in progress.
• Environmental Clearance from MoEFCC : Obtained.
• Siting clearance : Under AERB review .
• Technical offer received from EdF: Under evaluation.
Kovvada, Andhra Pradesh:
• Land acquisition process in progress;
• Techno commercial discussions with foreign vendor
(Westinghouse, USA) under progress.
LWR Capacity Addition Status

13. Balance of
Plant
Field Instrn.
Equipment
ARMS
Compressors
Chillers
Switchyard
GIS
Indian Capabilities
Indian
Capabilities
Nuclear
Island
Turbine
Island
Control &
Instrumentation
Water
Systems
Construction
& Erection

14. Evolving Business Model For KKNPP
 KK Unit 1&2:
 Complete plant design and equipment supply was carried out by the
technology provider (ASE, RF).
 Licensing, construction, erection, commissioning activities by NPCIL
with the technical support and supervision of ASE
 KK Unit 3&4:
 Design (NI+ TI+ Some portions of BOP i.e CCW) and equipment supply
under the scope of the technology provider.
 Design and procurement of some BOP systems(whole facilities),
licensing, construction, commissioning of complete plant by NPCIL with
the technical support and supervision of ASE
 KK Unit 5&6:
 Similar to KK Unit 3&4 with enhanced scope of design and
procurement of certain systems and equipments in NPCIL scope with
reference to KK3&4.

15. KKNPP-3&4 Contract : Provision for division of responsibility between
NPCIL and RF for SSCs based on following broad based approach:
 Design & Supply in the scope of NPCIL based on technical inputs from
RF (For example : Balance of the plant system components, Tanks etc.)
 NPCIL assigned the responsibility of procurement as per the detailed
Tender Technical Specification (TTS) from RF (For example Safety
related DG sets)
 The total value of Indian scope for KK 3&4 about Rs twelve thousand
Crores.
 A detailed evaluation/qualification of many vendors underway for
localization of Safety Tanks, PHRS heat exchanger and Feed water heat
exchangers.
LOCALIZATION Through Indian Scope

16. Nuclear
island
Turbine
Island
BOP Tech. Superv.
for guarantee
PROJECT MANAGEMENT NPCIL NPCIL NPCIL
BASIC DESIGN VENDOR VENDOR VENDOR
DETAILED DESIGN VENDOR VENDOR
VENDOR
+NPCIL
LICENSING
NPCIL +TA from
VENDOR
NPCIL +TA from
VENDOR
NPCIL +TA from
VENDOR
OVERALL SCHEDULING &
PROJECT MONITORING
VENDOR
+ NPCIL
VENDOR
+ NPCIL
VENDOR
+ NPCIL
BY
VENDOR
EQUIPMENT SUPPLY VENDOR VENDOR
VENDOR
+NPCIL
INTERFACE
MANAGEMENT
VENDOR
+ NPCIL
VENDOR
+ NPCIL
VENDOR
+ NPCIL
CONSTRUCTION &
ERECTION
NPCIL +
(VENDOR
TA+ SUP.)
NPCIL +
(VENDOR
TA+ SUP.)
NPCIL +
(VENDOR
TA+ SUP.)
TESTING &
COMMISSIONING
NPCIL with TA from
VENDOR
NPCIL with TA from
VENDOR
NPCIL with TA from
VENDOR
TYPICAL DIVISION OF RESPONSIBILITY

17. • BOP : EPC Package
• SSC : Common services/ switchyard/ ventilation/ material handling equipment
on complete facility basis. The systems includes switch yard, DM plant, Chiller
plant, desalination plant, compressor plant, gas generation plant and certain
auxiliary systems.
• Major equipments associated with Main plant
DG, switchgears, cables, CS/SS tanks/Heat Exchangers, ARMS
field instrumentation equipments etc
• Civil Construction : Complete construction of the plant including supply of
commodities.
• Complete Electro-mechanical and instrumentation equipment erection
activities.
• Complete Plant Commissioning along with the technical support of the vendor.
Major SSC under Indian Scope for KKNPP 3&4.

18. Major SSC under Indian Scope for KKNPP 3&4.
Switchyard Equipment
including Gas insulated
switchgears
Material Handling Equipment
Transformers Desalination Plant and DM Plant
Switchgears Fire Alarm and Fire Fighting Systems
Cables & Cable metal
Structures
Ventilation Systems
SS and CS tanks Automatic Radiation Monitoring
System
Plate type Heat exchangers Field Instrumentation Equipments
etc.
Diesel Generator Sets Batteries, Rectifiers & Inverters
Chillers and Compressors Pressure Doors

19. Electrical System – Major items planned to be procured
locally
400kV and 230kV Switchyard Equipment including Gas
insulated switchgear
230/6kV oil & 6/0.4kV dry type - Transformers
6kV, 0.4kV Switchgear
Cables, Cable trays and fire barrier items
Batteries, Rectifiers & Inverters
Diesel Generator Sets
Common plant SCADA
Protection relays

20. Low Pressure & high Pressure Heaters
First and second stage emergency core
cooling accumulators
~
Passive heat removal system heat exchanger ~
Generator Transformers
~~
In addition to the Equipment procured for KK3&4 the following are planned for KK5&6
Major SSC under Indian Scope for KKNPP 5&6.

21. • Design and Engineering support for BOP EPC Package
drawing and document review.
• Design and Engineering & construction of of Away from
Reactor Facility
• Design Engineering and Construction of OESC Facility
• Seismic Margin Analysis
• Design, Engineering and Construction of NSDF
Other Scope for Local Vendors for KKNPP

22. Increase in Scope of Localization in Kudankulam-
Unit 1&2 to Unit 5&6
Sr.
No.
Description KK 1&2 KK 3&4 KK 5&6
1 Reactor Pressure Vessel RUSSIA RUSSIA RUSSIA
2 Core melt catching facility RUSSIA RUSSIA RUSSIA
3 Reactor coolant pumps RUSSIA RUSSIA RUSSIA
4 Steam Generators RUSSIA RUSSIA RUSSIA
5 Refuelling Machine RUSSIA RUSSIA RUSSIA
6 Main and Emergency air locks RUSSIA RUSSIA RUSSIA
7 Control and Protection system drives RUSSIA RUSSIA RUSSIA
8 Polar crane RUSSIA RUSSIA RUSSIA
9 Trestle crane RUSSIA RUSSIA RUSSIA
10 Generator RUSSIA RUSSIA RUSSIA
11 Pressuriser RUSSIA RUSSIA RUSSIA
12 Condenser RUSSIA RUSSIA RUSSIA
13 Turbine and auxiliary equipment RUSSIA RUSSIA RUSSIA
14 Moisture separator and re-heaters RUSSIA RUSSIA RUSSIA
15 Turbine and auxiliaries for turbine driven feed water pump RUSSIA RUSSIA RUSSIA

23. Increase in Scope of Localization in Kudankulam-
Unit 1&2 to Unit 5&6
Sr.
No.
Description KK 1&2 KK 3&4 KK 5&6
16 Pump to transfer heating steam condensate with hydraulic drive RUSSIA RUSSIA RUSSIA
17 Emergency cool down heat exchanger RUSSIA RUSSIA RUSSIA
18 Regenerative heat exchanger RUSSIA RUSSIA RUSSIA
19 Electricity pump set for primary coolant storage system RUSSIA RUSSIA RUSSIA
20 Plate type heat exchanger for emergency and scheduled cool down of
primary circuit and cool down of fuel storage pond
RUSSIA RUSSIA RUSSIA
21 Reactor building sealing, shielding and fire doors RUSSIA RUSSIA RUSSIA
22 Ion exchange and mechanical filters for purification systems RUSSIA RUSSIA RUSSIA
23 Turbine building main crane RUSSIA RUSSIA INDIA
24 Low and High pressure heaters * RUSSIA RUSSIA INDIA*
25 First and second stage emergency core cooling accumulators * RUSSIA RUSSIA INDIA*
26 Passive heat removal system heat exchanger * RUSSIA RUSSIA INDIA*
27 De-aerator * RUSSIA RUSSIA INDIA*
28 Quick Boron Injection tank * RUSSIA RUSSIA INDIA*
29 Generator Transformer * RUSSIA RUSSIA INDIA*
30 Stainless steel and Carbon steel liners of fuel pool, Reactor cavity and
Reactor auxiliary building
RUSSIA RUSSIA INDIA
* Under discussion for localisation

24. Increase in Scope of Localization in Kudankulam-
Unit 1&2 to Unit 5&6
Sr.
No.
Description KK 1&2 KK 3&4 KK 5&6
31 Unit Transformer. RUSSIA RUSSIA INDIA
32 Distribution services of Air,Water in Russian design buildings RUSSIA RUSSIA INDIA
33 Corrosion protection facility RUSSIA RUSSIA INDIA
34 Automated Radiation Monitoring System (ARMS): RUSSIA RUSSIA INDIA
35 Ventilation equipment (balance full scope: All fans, Motorised Dampers,
grills, Air Handling equipment)
RUSSIA RUSSIA INDIA
36 Carbon and stainless steel Tanks (Others) RUSSIA RUSSIA INDIA
37 Cranes and Material Handling Equipments (All others, except polar and
trestle cranes)
RUSSIA RUSSIA INDIA
38 Safety Chillers RUSSIA INDIA INDIA
39 Emergency and Reliable Diesel Generators RUSSIA INDIA INDIA
40 Plate type HX for component cooling water system RUSSIA INDIA INDIA
41 Sea water system equipment for sea water intake and outfall structures like
trash racks, stop log gates and travelling screens.
RUSSIA INDIA INDIA
42 Debris Filter RUSSIA INDIA INDIA
43 6kV Switchgear RUSSIA INDIA INDIA
44 0.4kV Switchgear (including MCC & ACDB) RUSSIA INDIA INDIA
45 Auxiliary Transformers RUSSIA INDIA INDIA
46 Rectifier RUSSIA INDIA INDIA

25. Increase in Scope of Localization in Kudankulam-
Unit 1&2 to Unit 5&6
Sr.
No.
Description KK 1&2 KK 3&4 KK 5&6
47 Batteries RUSSIA INDIA INDIA
48 Inverter RUSSIA INDIA INDIA
49 Cables RUSSIA INDIA INDIA
50 Fire Barriers RUSSIA INDIA INDIA
51 Carbon and stainless steel Tanks (Large) RUSSIA INDIA INDIA
52 Cranes and Material Handling Equipments (Safety Class 3, 4) RUSSIA INDIA INDIA
53 Ventilation equipment (Ducts, Manual Dampers, Filters) RUSSIA INDIA INDIA
54 400 kV and 220 kV switchyards and associated systems RUSSIA INDIA INDIA
55 Power output system including control and instrumentations, except
Generator Transformer and Unit Transformer
RUSSIA INDIA INDIA
56 Diesel receiving, storage and pumping facilities RUSSIA INDIA INDIA
57 Buried Piping RUSSIA INDIA INDIA
58 Demineralization plant RUSSIA INDIA INDIA
59 Gas generation and distribution facilities RUSSIA INDIA INDIA
60 Fire detection and protection system RUSSIA INDIA INDIA
61 Oil treatment plant RUSSIA INDIA INDIA

26. Increase in Scope of Localization in Kudankulam-
Unit 1&2 to Unit 5&6
Sr.
No.
Description KK 1&2 KK 3&4 KK 5&6
62 Dewatering system RUSSIA INDIA INDIA
63 Sewage treatment plant RUSSIA INDIA INDIA
64 Chlorination plant RUSSIA INDIA INDIA
65 Compressor plant RUSSIA INDIA INDIA
66 Non safety chiller plant RUSSIA INDIA INDIA
67 Workshop RUSSIA INDIA INDIA
68 Health Physics facility RUSSIA INDIA INDIA
69 Physical Protection system RUSSIA INDIA INDIA
70 Desalination plant INDIA INDIA INDIA
71 Infrastructure facilities INDIA INDIA INDIA
72 Civil Construction INDIA INDIA INDIA
73 Electrical Erection INDIA INDIA INDIA
74 Mechanical Erection INDIA INDIA INDIA
75 I&C Erection INDIA INDIA INDIA
76 Commissioning INDIA INDIA INDIA

27. Increase in Scope of Localization in Kudankulam-
Unit 1&2 to Unit 5&6
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
KK1&2 KK3&4 KK5&6
Additional localisationunder discussion with Russia
Localisation of equipment manufacturing in India
Infrastructure work, construction, erection and commissioning
In crores

28. Some Initiatives taken for increasing the localization content.
 Formation of the technical evaluation committees (Joint
working groups) with the participation of technology
providers to evaluate the Indian industry to take up
additional manufacturing activities.
 Evaluating the suppliers manufacturing capabilities for
their suitability and qualification.
 Increase interaction with Industry to understand the
concerns and technological limitations

29. Typical Mode of Selection of Indian Vendors
 Public Tendering for wide participation.
 Whole facility based scopes like Switchyard, Balance of Plant facilities
etc. as EPC packages.
 Procurement other equipment and items thru tendering.
 Construction & erection scope – through mega package contracts for:
 Main Plant civil construction
 Sea water intake and outfall structure construction
 Mechanical erection
 Electrical erection
 Instrumentation & Control erection etc.
 Consultancy works for specialized areas
 Contracts for commissioning works

30. Localization Challenges
 Updating of design, engineering & manufacturing process to the other
international code requirements/ manufacturing standards such as Russian &
French,.
 Quality certification requirements from foreign technology provider.
 Process of Inclusion in the Foreign Vendor’s Supply Chain.
 Funding Issue : A technical tie-up between foreign Vendor and Indian vendor
may be necessary in the initial phase.
 Techno-commercial assessment for developing and qualifying spares to foreign
technology provider specification considering their initial low quantity
requirement which may, however grow over a period of time as the capacity
continues to be added.

31. Localization Challenges
Example: Electrical System
 Availability of test facilities/laboratories, for example short circuit testing
of large transformers
 Need to start a new range of products, for e.g MV switchgear of short
circuit rating of 50kA are generally not available in the Indian market as
a standard product
 New qualification requirements like internal arc compliance to the full
short circuit level for switchgear, etc.
 Meeting the overall dimensional limitations arising from the requirement
to maintain the same building footprint as in KKNPP 1,2 where the
equipment were sourced from RF – it has been seen that a majority of
the equipment manufactured from RF are more compact when
compared to what we have seen in India

32.  Back up of full fledged design institutes – either in house or centralized for
supporting design, analysis and qualification for the manufacturers
 Adaptability/conversance of the industry to other national/international codes
like IEEE, GOST, etc.
 Support of the multinational parent organization to the Indian set up even
complying with national legal requirements like CLnD.
 Verification and validation of software based safety systems complying with the
requirements of the Indian regulator/internal requirements
 Managing rapid obsolescence especially in computer based systems &
making available spares for continued operation of the existing equipment
Localization Challenges
Example: Electrical System

33. Kudankulam Nuclear Power Project

34. Kudankulam Nuclear Power Project
ProSIM R and D Pvt Ltd
Website : www.pro-sim.com
Contact us: enquiry@pro-sim.com
Indian Structural Integrity Society (InSIS)
Website: www.instint.in
Contact us: insisblr@gmail.com