Experience on APR1400 Construction - International … Design Optimization - Detailed Design of...

Experience on APR1400 Construction

IAEA TWG-LWRVienna, July 26-28, 2011

Jong Tae Seo

1/14

1. APR1400 Design Development

2. APR1400 Design Characteristics

3. FOAK Project – Shin Kori 3&4

4. Summary

2 APR1400

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Development Strategy

APR1400 Design Development

3 APR1400

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Uprate power to 4,000 MWth (1,450 MWe) based on OPR1000’s 2,825 MWth (1,050 MWe) technology

Incorporate Advanced Design Features to enhance safetyand operational flexibility

Meet the Utility Requirements (domestic & world-wide) Proven Technology Constructability Maintainability Regulatory Stabilization

Development Strategy


4 APR1400

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* OPR1000 : Optimized PowerReactor 1000

*APR1400 :Advanced Power Reactor 1400

1,400 MWeUnder Construction

- SKN # 3,4, SUN # 1,2

NSSS DesignPalo Verde #2 (CE,1300MWe)

Core DesignANO #2 (CE,1000MWe)

OPR10001,000 MWe

- In Operation - YGN #3,4 (’95/’96) - UCN #3,4 (’98/’99)

Improved OPR10001,000 MWe

- In Operation - YGN #5,6 (’02/’02) - UCN #5,6 (’04/’05)- Under Construction - SKN #1,2 - SWN #1,2

ADF/PDFLatest Codes & Standards

EPRI URDSystem 80+


5 APR1400

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Phase I (’92.12 – ’94.12): Conceptual Design- Reactor Type Selection- Development of Top-Tier Design Requirements- Comparative Study on Major Systems and Components

Phase I (’92.12 – ’94.12): Conceptual Design- Reactor Type Selection- Development of Top-Tier Design Requirements- Comparative Study on Major Systems and Components

Phase II (’95.3 – ’99.2): Basic Design- Development of Detailed Design Requirements- Development of Design Specifications for NSSS Major Components- Preparation of Standard Safety Analysis Report

Phase II (’95.3 – ’99.2): Basic Design- Development of Detailed Design Requirements- Development of Design Specifications for NSSS Major Components- Preparation of Standard Safety Analysis Report

Phase III (’99.3 – ’01.12): Optimization and Licensing- Design Optimization- Detailed Design of Long-Lead Items- Licensing of the Standard Design

Development Phases


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6 APR1400

Standard Design Approval by KINS in 2002

Design Review

Standard Design Approvalof APR1400

Standard Safety Analysis Report


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7 APR1400

Parameters APR1400Thermal/ Elec. Power 4,000 MWt / 1,450 MWeDesign Life 60 YearsSeismic Acceleration 0.3 g

Operating Parameters- Thot / Tcold 615 / 555 OF- Operating Pressure 2250 psia- RCS Flow Rate 1.66 x 106 lb/hr- Main Steam Pressure (@Full Power) 1000 psia- Main Steam Flow Rate 8.975 x 106 lb/hr

Safety Parameters - CDF 2.25 x 10-6 < 10-5/RY- Containment Failure Frequency 7.19 x 10-7 < 10-6/RY- Thermal Margin >10%- Emergency Core Cooling System 4-train, DVI,

Fluidic Device in SITPerformance Requirements- Plant availability More than 90 %- Unplanned trip Less than 0.8/year- Refueling cycle 18 ~ 24 months

Design Parameters


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8 APR1400

RCS Configuration

APR1400 Design Characteristics

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9 APR1400

Reactor Core

Number of assemblies : 241

Thermal margin : above 10 %

Refueling cycle : over 18 months

Batch average burn-up : 55,000 MWD/MTU

Enhanced operational flexibility

- Daily load follow operation capability

- MOX loading capability up to 1/3 core


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10 APR1400

Reactor Vessel & Internal

Reduced radiation exposureReduced radiation exposure• Reduced Cobalt contents in base material

Integrated Lower Internal AssemblyIntegrated Lower Internal Assembly

• Welded IBA to UGS upper flange - Eliminate tie rods, round nuts,

snubber flange & Block

Integrated Inner Barrel AssemblyIntegrated Inner Barrel Assembly

• Integrated core support barrel, core shroud,and lower support structure in one assembly

Enhanced RV integrityEnhanced RV integrity• No weld seam in fuel region shell• Using low Copper contents material


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11 APR1400

Integrated Head Assembly (IHA)

Integrated ComponentsIntegrated Components• Head area cable tray

system, CEDM air handling unit, cooling duct, cooling manifold and head lift rig, etc.

IHA ReducesIHA Reduces• Refueling Time• Occupational Radiation

Exposure• Component Storage Area• Seismic Load


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12 APR1400

Reactor Coolant Pump

Vertical pump

Motor-driven centrifugal pump

Bottom suction & horizontal discharge

Single stage impeller


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13 APR1400

Pressurizer with POSRV

Increased VolumeIncreased Volume• Total volume : 2,400 ft3

• Enhancing coping capability against plant transients

• Performing over-pressure protection and safety depressurization

• Main valve open by pilot valve actuation • Steam/Water/Two-Phase discharge• No drift of the opening set-point• Reliable valve operation without

chattering and leakage• Low susceptibility for valve stuck-open

Pilot Operated Safety Relief ValvePilot Operated Safety Relief Valve


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14 APR1400

Steam Generator

• Increasing space to install SG nozzle dam- Improving stability in mid-loop operation

Modified SG Inlet Nozzle AngleModified SG Inlet Nozzle Angle

• Increased anti-vibration bars- Reducing flow-induced tube vibration

Improved Tube Support Bars and PlateImproved Tube Support Bars and Plate

Design ParametersDesign Parameters• Integral Economizer• Number of tubes : 13,102 / SG• Plugging margin : 10 %• Tube material : Inconel 690


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15 APR1400

Safety Injection System

CONTAINMENT

SITSIT

SIT SIT

S/G RV S/G

SIP

SIP

SIP

SIP

IRWSTRCP

RCP

RCP RCP

• No safety injection water spillage in cold-leg break LOCA

• Increase the reliability of the injection during LOCA

Simplified DesignSimplified Design

Direct Vessel InjectionDirect Vessel Injection

• Mechanically independent 4 train• 1 SIP/train• 1 SIT/train• No low pressure pumps• One injection mode


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16 APR1400

Safety Injection Tank with Fluidic Device

Fluidic Device Fluidic Device

• Extend injection duration of SIT

• Playing a role of low pressure SIP

• Flow rate depends on the Stand Pipe

height and resistance of Supply Port &

Control Port

Safety Injection TankSafety Injection Tank

• Design pressure : 700 psig

• Volume : 18000 gal (1 ea)


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17 APR1400

Cylindrical Containment with IRWST

Pre-stressed concrete structurePre-stressed concrete structure

Steel-lined inner surface for leak-tightnessSteel-lined inner surface for leak-tightness

• Height: 229.5 ft, Diameter: 150 ft, Thickness: 4 ft• Design Pressure: 60 psig

• Eliminates switch-over operation during LOCA• Heat sink for feed and bleed operation• Minimizes contamination of Reactor Containment Building

In-containment Refueling Water Storage Tank (IRWST)


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18 APR1400

Containment Protection System

Containment Hydrogen Control SystemContainment Hydrogen Control System

Containment Spray SystemContainment Spray System• Design characteristics

- 2 pumps (Backed up by 2 SCPs)- Water source : IRWST

• Functions- Maintaining hydrogen concentration belowdesign criterion

• Design characteristics- 30 Passive Autocatalytic Recombiners(PAR) - 10 Glow plug type igniters


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19 APR1400

Severe Accident Mitigation System

Reactor Cavity Flooding SystemReactor Cavity Flooding System

In-Vessel Retention – ERVC strategyIn-Vessel Retention – ERVC strategy

• Flooding reactor cavity to cool molten core• Water Source : IRWST• Water driving force : Gravity• Designed in accordance with SECY-93-087

- Cavity floor area > 0.02 ㎡/MWt

• Submerging reactor vessel lower head to cool and to retain molten core in reactor vessel

• Water source : IRWST• Water driving force : SCP, BAMP

M M

M

ExistingNew

Cavity

Reactor Coolant System

Containment Building

HVT

IRWST IRWSTM M

External Reactor Vessel Cooling System for In-Vessel Retension (Active Feature)

Gravity Driven Cavity Flooding System for Ex-Vessel Coooling (Passive Feature)

Aux. Building

SCP (5000 gpm)

BAMP (200 gpm)

CVCS

RCS

M

M MMM


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20 APR1400

MMIS Overview


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21 APR1400

APR1400 Design CharacteristicsAdvanced Control Room

• Major components

- Redundant compact workstation

with soft control

- Large display panel

- Advanced alarm system

- Safety console

· Backup for common mode failure

- Computerized procedure system

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22 APR1400

Layout : Slide-along Arrangement (2 units)

• Auxiliary Building (AB)- Quadrant arrangement to enhance safety- Accommodating MCR, Emergency D/G,Fuel handling facilities

• Reactor Containment Building (RCB)- Pre-stressed cylindrical wall and hemi-spherical dome concrete structure

- Wrapped around by auxiliary building

• Compound Building (CB)- Accessible from both units- Housing common facilities of Access control, Radwaste treatment, Hot machine shop, etc

• Turbine Building (TB)- Steel structure with reinforced concrete

turbine pedestal- Common tunnel for all underground facilities


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23 APR1400

Quadrant Arrangement of Safety Components

Quadrant C Quadrant A

Quadrant D Quadrant B

CCWP 3

CCWP 4 CCWP 2

CCWP1

SCP 1

SCP 2

SIP 3

SIP 2

SIP 1

SIP 4CSP 2

CSP 1

SIP ( Safety Injection Pump) SCP (Shutdown Cooling Pump) CSP (Containment Spray Pump) CCWP (Component Cooling Water Pump)


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24 APR1400

FOAK Project – Shin Kori 3&4

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25 APR1400

Brief History


Feb. 2001 : Set up basic construction plan for SKN 3&4

May 2002 : Received Standard Design Certification for APR1400

Aug. 2006 : Contract signing for A/E, NSSS, TG

Nov. 2006 : Contract signing for ICD/Fuel

Mar. 2007 : Contract signing for Construction

Sep. 2007 : Started site grading

Apr. 2008 : Received Construction Permit / Started excavation

May 2011 : Operating License Application

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26 APR1400

Milestone Schedule (Unit 3)


Site Grading : Sep. 13, 2007

Excavation(CP) : Apr. 15, 2008

First Concrete Pouring : Oct. 16, 2008

Set Reactor Vessel : Jul. 15, 2010

First Energization : Jun. 1, 2011

Cold Hydro Test : May 2012

Fuel Loading(OL) : Jan. 2013

Commercial Operation : Sep. 2013

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27 APR1400

Project Progress


2007 2008 2009 2010 2011 2012 2013 2014

Unit3

Unit4

10/169/13 4/15

9/13 4/15

SiteGrading(9/13)

Excava-tion(4/15)

RVSet(8/1)

1st

Energ-ization(7/1)

FirstConcrete(11/1)

7/1 5/1 9/1 1/1 9/308/19 7/18

HFT(9/1)

FuelLoading(1/1)

CHT(5/1)

Commercial Operation(9/30)

7/15 6/1

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28 APR1400

Project Progress


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2001년 2002년 2003년 2004년 2005년 2006년 2007년 2008년 2009년 2010년 2011년 2012년 2013년 2014년

As of June 30, 2011

○ Plan : 74.26%

○ Actual : 74.85%

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29 APR1400

Project Structure


Equipment Start-upConstruction

T/G

DOOSAN

BOP

KHNP

A/E

KEPCO E&C KHNP

KEPCO E&C WEC

LocalConstructors

Project Management

KHNP

FUEL

KEPCO NF

NSSS

DOOSAN

GE Vendors

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30 APR1400

Construction Activities


Reinforcing Bar of Basemat

RCB Exterior Wall 3-tiered CLP ModuleMSIV Room Piping & Valve

MCR Ceiling Structural Steel, etc

Installation of Single or 2 Pieces-Dome Liner Plate

Structural Steel

Pre-fabrication & ModularizationPre-fabrication & Modularization

Improvement of TBN Sole Plate ChippingShortened Post-Tensioning Period

Automatic Welding of Reactor Coolant LoopConcurrent Installation of RC Loop Pipe & RV Internals

Shortened Installation Period of TBN LP Hood & IHA

Other Advanced & Optimized

Process

Other Advanced & Optimized

Process

Steel Deck Plate Method

3D CAD Models for Construction4D Simulation, etc

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31 APR1400

4D Simulation


Integration of 3D CAD and schedule for providing optimized construction schedule, visualization, and information management Improves constructability Shortens the construction period

4D System

3D CAD

Schedule

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32 APR1400

Site Views


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33 APR1400

Manufacturing


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34 APR1400

Construction Pictures


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35 APR1400



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36 APR1400



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37 APR1400

Major Contributing Factors


Infrastructure Design, Manufacturing, Procurement, Construction, and

Operation Supply Chain

Well established through continued construction projects Human Resource

Engineers and Workers with ample experience Project Management

Owner (KHNP) leadership and experience National Policy

Strong support from government with long-term plan

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38 APR1400

Summary

• Increased thermal margin• Physically separated quadrant arrangement of safety systems• Adoption of new design features confirmed through design

validation program• Reinforced seismic design basis

Enhanced Safety

• Increased capacity factor and reduced unplanned trips• Reduced construction time by advanced technologies• Extended plant design life

Improved Cost Effectiveness

• Full digitalized I&C system and operator-friendly man-machine interface• Increased operator action time• Reduced occupational radiation exposure

Convenient Operation & Maintenance

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Experience on APR1400 Construction - International … Design Optimization - Detailed Design of...

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