Bharatiya nabhikiya vidyut nigam limited (bhavini)

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. 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. • 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. 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. 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

7. Stringent administrative and quality
controls at every stage

8. 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

9. 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 !!!

10. Highly reactive Liquid
Sodium transfer

11. Largest and deepest excavated pit in Indian
nuclear plants immediately next to sea
(200 meters from the sea)

12. 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

13. Off Shore Submarine Tunnel

14. Under sea Tunnel 567 meters
length at 50 meters below the sea
Constructed for the first time in the country

15. Tsunami bund/Shore Protection/Outfall Channel
Tsunami bund
Shore
protection
Outfall Channel
15
15

16. Coastal plantation
Engineered sand dune
Unique method of Tsunami protection
system for the reactor site

17. INCREASE IN ELEVATION
The nuclear island finished floor level
is raised to 15.7 meters for reactor
protection from future Tsunami if any

18. Fabrication of gigantic reactor
components for PFBR

19. Fabrication of over dimensional, thin
walled reactor components at PFBR site

20. FABRICATION OF MAIN VESSEL
Great
Challenge
Made for
the first
time in the
country
Diameter achieved within 10mm tolerance for total 12900 mm

21. INNER VESSEL
Positional accuracy,
alignment and
orientation has to
be maintained
during fabrication

22. To be lifted during
erection without swing
Man standing
Safety Vessel with Thermal Insulation Panels

23. 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

25. 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

26. 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

27. Fabrication of 26 meters length
Steam Generators in shop

28. FABRICATED STEAM GENERATORS
Straightness achieved within 3mm on 26,000 mm length of SG !!!!!!

29. Challenges in header pullout to bend tubes
welding for Sodium to Air Heat Exchangers
Extremely
Difficult

30. Header Welding - Needs highly qualified and skilled welders

31. Header Welding- Extremely difficult
Challenge

32. Reactor equipment erection

33. Erection of
PFBR
equipment
without
single dent

34. ERECTION OF MAJOR COMPONENTS
Safety Vessel
Main Vessel
Thermal Baffle

35. Safety Vessel is being lowered into Reactor Vault
in a constrained space without swing

36. Erection of Thermal Baffle

37. ERECTION OF MAJOR COMPONENTS
Grid Plate
Inner Vessel
Roof Slab

38. Massive
Argon
Buffer
Tank
erection

39. 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

40. 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

41. 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

44. AWARDS - HUMAN RESOURCES
Development and inspiration of
true potential of human capital
“Best HR Practices–2012 Award” by National
Institute of Personnel Management (NIPM)

45. Award for outstanding Concrete Structure
“ICI (TNCC) - Ultratech Award”
by Indian Concrete Institute

48. 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

49. 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

50. 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

51. 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

52. 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

53. Over all Night View
PFBR the pride of
nation
53

54. Thank
You