Professional Documents
Culture Documents
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
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
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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
Nuclear
Power Plant Division
Nuclear Power
Plant Planning Corporate Quality
Industrial Machinery Control
& Plant Division Dep’t
6
Nuclear Design & Production
Ulchin #3,4 PM
Ulchin #5,6 PM
Wolsong PM
KEDO PM
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.
BEIJING
North Korea Nuclear Power Plant
(N. Korea #1,2)
SEOUL
TAIPEI
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
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
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.
9
A D VA N C E D F E AT U R E S O F K S N P
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
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.
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.
Closure Head
Closure Stud
Support Pad
16
Material
Support Columns
Cladding
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.
COOLING SHROUD
MOTOR 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
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
Mass Production 3 1 2
Ranking : 1 = Best, 3 = Worst
Trunk Line
Polyesthylene Sheath
Secondary
Side Primary
After Side
Explansion
Explansion
Charge
Before
Explansion
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)
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.
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.
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.
PHWR SYSTEM
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.
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.
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.
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
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.
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.
35