Machine-building division of the Russain state energy firm, Rosatom – JSC “Atomenergomash” – has completed on October 14th, 2015, manufacture and shipping the nuclear reactor vessel for the first Belarusian Nuclear Power Plant. It is the first reactor vessel manufactured at “Atommash” production site after the 30-year break and the first one manufactured within the structure of the State Corporation “Rosatom”.
The ceremony of shipment was attended by “Atomenergomash” CEO Andrey Nikipelov, JSC “AEM-Tehnologii” CEO Igor Kotov, the Deputy Minister of Power Economy of the Republic of Belarus Mikhail Mikhadyuk, the Minister of Industry and Energy of the Rostov Region Mikhail Tikhonov.
“The revival of “Atommash” production complex has been one of the priorities of Rosatom. Within a short period of time the production facilities have been renewed, personnel has been trained, new manufacturing technologies have been introduced. Several Atomenergomash companies, i.e., TSNIITMASH, Hydropress, ZiO-Podolsk assisted in this process by sharing the experience and attending the complex manufacturing operations.
“Atommash” was built in the 1970-s as the largest manufacturer of equipment for nuclear power plants. During 90-s and 00-s it almost lost its competences in making equipment for NPP. In 2012 “Atommash” was incorporated in the Machine-building division of the State Corporation “Rosatom”, and there was launched a large-scale program to renovate its production facilities for manufacturing of nuclear power plants equipment.
Manufacturing of NPP reactor facility is a unique competence possessed by only a few countries in the world. “Atommash” is an exclusive plant, which produces a complete set of equipment for the nuclear island for NPP, including reactors vessels, steam generators, etc. Plant capacities allow to make up to 4 equipment sets per year. At the present time equipment for Novovoronezh, Rostov, Belarusian Nuclear Power Plants is being manufactured at “Atommash”. Production of nuclear island equipment for “Akkuyu” NPP (Turkey), “Kudankulam” NPP (India) is to be launched soon.
Weight of VVER-1200 reactor vessel exceeds 330 tons, height exceeds 13 metres, and diameter is over 4.5 metres. Transportation to Belarusian Nuclear Power Plants will be a complex logistical operation. The reactor vessel will be delivered from the manufacturer by special automotive equipment to the pier of Tsimlyansk reservoir in Volgodonsk. Then it will be transported by river to Veliky Novgorod and from that point it’s delivery to Ostrovets NPP building site will be performed by a specialized railway transporter.
The Belarusian Nuclear Power Plant is being constructed according to NPP-2006 project in 18 km from Ostrovets (Grodno region, Belarus). The project of the plant reactor facility is developed by JSC “OKB Hydropress” – part of “Atomenergomash” – which carries out field supervision and design support. The first power unit commissioning is scheduled for 2018. The construction project implementation is completed by JSC “NIAEP” – CJSC “ASE” Merger Company.
“Atommash” plant (the Volgodonsk branch of JSC “AEM-Technologii” at the present time) was established in 1976. The plant was designed to manufacture up to 8 sets of reactor island equipment. The first reactor vessel produced by “Atommash” was installed at the South-Ukrainian NPP in 1981. In total there were manufactured 13 reactor vessels and more than a hundred units of reactor island equipment. “Atommash” also acted as a supplier of fuel handling machines for nuclear power plants.
The latest reactor vessel was shipped from “Atommash” in 1986. In 90-s and 00-s “Atommash” almost lost its competences in manufacturing nuclear power plant equipment – the share of orders for nuclear power plants decreased to 10%. In 2012 “Atommash” was incorporated in the Machine-building division of the State Corporation “Rosatom”, and there was launched a large-scale program to renovate it’s production facilities for manufacturing of nuclear power plants equipment. Within the scope of the program the machine-tool fleet has been updated, new technological equipment have been purchased. In the period from 2012 to 2015 total investments amounted more about 2 billion rubles (more than 50 million USD).
Currently, such key equipment for nuclear power industry like reactor facilities, steam generators, core catchers, main circulation pump housings, handling and process equipment for Novovoronezh, Leningrad, Rostov, and Belarusian Nuclear Power Plants is present at various manufacturing stages in “Atommash”. Furthermore, manufacturing of reactor facility equipment for the “Akkuyu” NPP in Turkey, “Kudankulam” NPP in India will be started in the nearest future.
The plant possesses unique logistical facilities enabling shipment of finished products by any types of transport without dimensional restrictions.
Socio-economic indices of “Atommash”
|
Index |
2012 |
2015 (strategic vision) |
|
Operating revenue |
2.6 bln rubles (2013) |
6.3 bln rubles |
|
Taxes paid in regional and local budget |
5 mln rubles |
138 mln rubles |
|
Insurance benefits paid non-budgetary funds (RF PF, etc.) |
12.1 mln rubles |
295.8 mln rubles |
|
Number of employees |
Close to 1,500 persons |
Over 2,500 persons |
|
Average wages |
About 19 thousand rubles (semi-annual outstanding wages unpaid was observed) |
Over 36.5 thousand rubles (26.8 thousand rubles in Volgodonsk) |
Belarusian Nuclear Power Plant will consist of two power units with total capacity up to 2400 (2х1200) mW. All equipment for the nuclear island of Belarusian Nuclear Power Plant is manufactured by JSC “Atomenergomash” enterprises.
Key point in developing equipment for new generation nuclear power plant is represented by security ensured for all working regimes within the plant. Safety increase will be ensured by maximum use of experience gained in production and exploitation of power units with VVER-440 and VVER-1000 reactors.
It takes 840 days to manufacture a VVER-1200 reactor vessel. The issues of quality and safety are highly prioritized at every production stage. General plan of inspection comprises 315 quality checkpoints. 74 kinds of inspection operation are attended by the customer’s representatives and specialized authority organization. The following types of inspections are employed in the course of production:
- visual;
- dimensional;
- ultrasound;
- eddy current;
- crack detection;
- radiographic (X-ray control).
Prior to shipment to the customer VVER-1200 reactor vessel passes the hydrostatic tests. For this purpose 24.5 MPa pressure is generated inside the reactor vessel. In such a manner the integrity of parent metal and welding joints is inspected.
Totally, all works for designing, manufacturing, testing and control over equipment are being carried out in full compliance with normative documents of the Russian Federation and IAEA requirements, and national demands of countries, where the equipment manufactured is to be shipped.
At “Atommash” the quality management system is used, which is relevant to the requirements of ISO 9001:2008 international standard. The compliance of the quality management system with international standards is proved by IQNet, ASME, Lloyd’s Register Quality Assurance and other certificates. “Atommash” is also equipped with its own certified laboratory.
JSC “Atomenergomash”
JSC “Atomenergomash” (AEM) is a machine-building division of the State Corporation “Rosatom”, a manufacturer of key equipment for nuclear and heat power generation, shipbuilding, gas and petrochemical industries.
The company comprises about 30 major manufacturing, R&D, engineering enterprises in the territory of Russia and abroad. These companies are developers and manufacturers of equipment, which is installed at every NPP of Russian design.
Nowadays, Atomenergomash holding offers to its customers the complex solutions inclusive of design engineering, manufacture of work pieces and equipment, assembly works and maintenance services. In the scope of atomic power engineering “AEM” represents itself as a single-source supplier of the entire nuclear reactor and turbine equipment for NPP. “AEM” also provides naval nuclear reactors for the new-generation icebreakers. In the scope of thermal power industry “AEM” is a single-source manufacturer of equipment for HPP boiler island.
Equipment manufactured by “AEM” companies has been installed in more than 20 countries; 13% of the nuclear power plants in operation worldwide and 40% of the thermal power plants in the Russian Federation and FSU countries use the company’s equipment. Number of company’s employees amounts to over 22,000.
