|
  
    
|
|

Daya Bay Nuclear Power Plant
China: The Story of a Partnership
To meet its growing demand for electric power, the People's Republic of
China is relying increasingly on nuclear energy. At the end of 1999,
China's total installed power generating capacity was nearly 300,000 MWe,
with a planned expansion to 450,000 MWe by the year 2010. Three
nuclear power plant units generating a total of 2,100 MWe are
currently in operation, while another eight rated at a total capacity
of 6,600 MWe are under construction.
Framatome ANP has a long history in China beginning in 1986 with the signing of the contracts to build the Daya Bay project (two 900 MWe units). Those units came on line in early 1994. Before its last refueling and maintenance outages, Unit 2 achieved 87.7% availability and Unit 1 is close to the same result. This availability factor puts the Daya Bay units among the top performers in the world.
This project was followed by the Ling Ao project, two 1000 MWe units, situated near the operating Daya Bay Nuclear Power Plant in China's Guandong province. Framatome was contracted to supply the nuclear island,and the erection and start-up through commercial operation of the power station.
The Qinshan II project was the first to take advantage of the technology transfer that is serving the Chinese goal of self-reliance in the next reactor generation called CNP 1000. Finally, the technology transfer for fuel has enabled the Yibin plant in Sichuan to supply all the reloads for the Chinese PWR units.
Furthermore, Framatome ANP is supplying a variety of electrical and I&C systems to the Tianwan project, two 1000 MWe units of Russian design.
The Ling Ao Project
The two 1000 MWe Ling Ao nuclear units situated near the operating Daya Bay Nuclear Power Plant in China's Guandong province now have entered the startup phase. Framatome ANP is supplying the nuclear island and associated services up to the commercial operation of the Ling Ao Power Station owned by the Ling Ao Nuclear Power Company (LANPC). The 23rd Corporation (C23), a Guandong province construction company cooperating with Framatome ANP, is responsible for the erection of the whole nuclear island. Framatome provided technical assistance through what is called a self-reliance program (technology transfer) with the objective of enhancing the autonomy of the Chinese company. The preliminary parts of the project, engineering and manufacturing, are nearly completed, with more than 95% of the engineering documentation issued, and more than 96% of the equipment for both units delivered on site as of the end of November 2000.
Up to now, the construction of the Ling Ao station is on schedule and meets the customer's objectives. The primary system construction of Unit 1 is complete. Commissioning of Unit 1's primary system is progressing following the successful elementary testing of the electrical systems and of the pumping station in September 2000. Cold functional testing is scheduled to begin in April 2001, along with the hydrotest of the primary system.
Unit 1 has entered the startup phase and the year 2000 will be remembered as a very good year for this project. All the main components of Unit 2 are installed, following Unit 1 by eight months. In 2002 the customer should be able to generate its first power from the new Ling Ao Nuclear Power Station.
Framatome ANP provides startup engineers who are fully integrated into the LANPC startup team. LANPC is in charge of the startup and commissioning activities.

Localized Manufacturing
One of the distinctive features of the Ling Ao project is the equipment manufacturing that was carried out
in different regions of China. After more than two years of intense manufacturing by the Chinese suppliers - with technical assistance and under
the supervision of Framatome - all the main components of Unit 2 were delivered to the site. In addition to
the component localization program, Chinese teams took responsibility for
most of the construction work.
The three steam generators and the pressurizer left the Dongfang Boiler factory in Sichuan by road. They were then shipped by barge on the Yang Tse River to be delivered
in Shanghai. From there, they were loaded by a floating crane onto a ship and arrived at Ling Ao on July 12, 2000 to be unloaded on the Daya Bay dock by another floating crane.
The reactor internals were completed in Shanghai N¡1 workshop and shipped in August 2000.
Xian 524, a manufacturing company in Shaansi Province, delivered the main fuel-handling system equipment for Unit 2. China Nuclear Energy (CNE) Erzhong completed manufacturing their last equipment (handling equipment for internals and reactor vessel head) in November 2000.
Near the Ling Ao site, the joint venture, S&T, (Spie, a construction company, and C23) completed prefabrication of the auxiliary pipes for both units in July 2000. And, CEMR, a Changzu company, completed feedwater and steam pipes prefabrication.
The goals for localized manufacturing of the Ling Ao nuclear island project were achieved on schedule and complied with the most stringent international quality specifications. Through the technology transfer and close cooperation with Framatome and other French companies, the participating Chinese companies improved their technical expertise and manufacturing capability. They are now prepared to take a larger role in manufacturing components for the next nuclear project.
Technology Transfers: A Key Ingredient for Success
Technology transfer from Framatome to Chinese institutes started as early as 1992 when the first technology transfer agreement was signed between Framatome and China National Nuclear Corp. (CNNC). This royalty-free agreement, covers the technology of the whole nuclear island.
Through the following years, Framatome assisted Beijing Institute of Nuclear Engineering (BINE), Nuclear Power Institute of China (NPIC), both belonging to the CNNC, in the first implementation of this agreement. The Qinshan phase 2 design from the preliminary design to the final detail, was the first project to take advantage of the technology transfer. To date, with technical assistance from Framatome engineers and technicians, more than 100,000 pages and more than 10,000 drawings have been transferred, including the necessary computer codes. Many Chinese trainees have enhanced their knowledge as residents in Framatome offices.
Another technology transfer agreement was signed with Chinese General Nuclear Power Corp. (CGNPC) in 1995, extending the scope of technology transfer in China to the fields of construction, startup, licensing, and operation. This agreement also covers the design and fabrication of high-technology equipment, and is still in effect today. In September 1997, a third technology transfer agreement was signed to assist C23 in the construction of Ling Ao to allow C23 to reach self-sufficiency.
In 1999, a large technology transfer was initiated for the 18-month fuel cycle, allowing China to reach self-reliance in fuel management. All necessary computer codes were transferred to CGNPC and NPIC. A team of Framatome engineers spent several months in NPIC offices in Chengdu to help NPIC personnel to gain confidence in fuel management improvement methods.
These agreements are not the only ways in which Framatome transfers its technology to China. For each order given to a Chinese company to manufacture equipment, Framatome transferred documentation and provided assistance during the manufacturing process by sending the best specialized workers to transfer to their Chinese counterparts all their know-how in such fields as welding, machining, quality control etc.
The Qinshan II program technology transfer enabled Framatome to participate in the Qinshan II project designed by Chinese institutes, with Framatome technical assistance and supply of components, some of which were localized.
The Qinshan II nuclear units (2 x 600 MWe) were developed by CNNC based on the Daya Bay technology, thanks to the technology transfer initiated in 1992. This led Framatome to support CNNC institutes in the design of this product. Moreover, Framatome supplied the reactor internals, in-core instrumentation, parts of the CRDMs, hydro test pump, and other components. One set of reactor internals was produced in China.
Fuel Technology Transfer: on the Right Track
The AFA 2G fuel technology transfer (1991/1995) involved China Nuclear Energy Industry Corp. (CNEIC) as contractual interface, NPIC as designer, and Yibin Fuel Plant (YFP) as manufacturer. As a result, YFP mastered the fuel manufacturing and provided Guangdong Nuclear Power Joint Venture Company Limited (GNPJVC) with reliable products. Finally, the technology transfer for fuel has enabled the Yibin plant in Sichuan to supply all the reloads for the Chinese PWR units.
In order to reduce the kWh cost by shifting from annual to 18-month cycle operation, GNPJVC decided, at the end of 1998, to extend its cooperation with Framatome. Therefore a new fuel technology transfer covering design, licensing support and manufacturing was set up among Chinese partners and Framatome.
AFA 3G fuel assembly meets the ambitious objectives of GNPJVC: proven high performance, increased burn-up capability, thermal hydraulic operational margins, and the most economical solution.
The AFA 3G technology transfer allowed French and Chinese counterparts to visit each other's countries, and provided friendly exchanges.
The schedule included several steps:
Early 1999
-preparation and transmission of comprehensive technical documents for design, license, and manufacture of the AFA 3G fuel assemblies
1999
 -Coaching and training sessions for both design and manufacture
Nov. 2000
 -YFP engineers successfully completed qualification testing, demonstrating they were fully prepared to manufacture advanced fuel
2001
 -YFP is ready to manufacture its two first AFA 3G reloads.
CNP1000: Nuclear Islands
In 1997 Chinese authorities expressed their desire to expand their nuclear industry development program, and set the following conditions for constructing nuclear power stations:
- The technology shall be safe, reliable, proven, and advanced
- The Chinese industry shall achieve self-reliance
- The localization of engineering activities and equipment manufacturing shall progress quickly and reach a high level
- The units shall be competitive with other sources of electric power.
To meet these requirements, Framatome, together with Electricité de France (EDF) and Alsthom prepared a joint proposal to meet Chinese objectives through the construction of a series of CNP1000 nuclear islands.
The proposal relies on the experience the Chinese nuclear industry accumulated through the construction and operation of Daya Bay, design and construction of Ling Ao, and Qinshan phase 2. The construction of these three-loop, 1000 MWe units will benefit from the continuous improvement and extensive experience of the French nuclear power plants, which totals more than 1000 reactor years of operating experience and 30 years of continuous engineering and industrial progress. The Framatome proposal for the CNP1000 model meets the most stringent international requirements.
Based on a well balanced, proven design, the CNP1000 includes state-of-the-art technologies that ensure a high level of safety together with high plant availability, and flexibility to provide the means to compete in the ever-demanding electricity marketplace.
Among the main features incorporated in the CNP1000 design are the latest manufacturing technologies developed to increase the longevity of the main reactor components for a 60-year lifetime, like the latest 1,300 MWe and 1,400 MWe (N4) units being commissioned in France.
The advanced AFA 3G nuclear fuel assemblies proposed for CNP 1000 benefit from the experience of the world's largest research and development program. These advanced assemblies satisfy Chinese objectives in terms of high burn-up (up to 60 GWd/t) and economical long cycles (18 - 24 months). The combination of the CNP1000 built-in margins and the AFA 3G advantages will allow operational flexibility while providing the operator with remaining margins (exceeding 15 percent) as demonstrated by analyses.
The CNP1000 design will incorporate the most advanced and proven digital I&C system, and a fully computerized control room. This technology contributes to the improvement of plant economy and safety through easier and more effective operation.
Major improvements of the CNP1000 units, compared to French and Chinese units, will allow the operator to further increase its availability factor, which is already one of the best in the world. These improvements ensure a very high level of safety as demonstrated by the probabilistic risk assessment that was performed by an EDF/Sofinel/Framatome team. The assessment identified a core damage frequency significantly lower than the Chinese requirement.
Their stringent performance requirements are supported by proven efficient components and designs that will accrue long term benefits. The technical features of the CNP1000 as well as Framatome ANP's experience in China and increased strong industrial relationships ensure that CNP1000 offers China one of the most competitive production tools in today's electricity market. China's self-reliance and localization objectives will be met, thanks to the existing and fruitful cooperation established between Framatome ANP and the Chinese companies.
The world's first large-screen display in a nuclear power plant: selected displays - clearly visualized - for the entire control room personnel (control console operators, maintenance and shift supervisors).
The Tianwan Nuclear Power Station is committed to 2 1000 MWe units with an option for 2 additional units. Phase 1, comprising the construction of two Russian-designed VVER-1000 Model "NPP 91" units, is already well underway. These two units are being built on the basis of international cooperation between the plant operator Jiangsu Nuclear Power Cooperation (JNPC), the plant designer Atom Energo Project (SPAEP) and Russian companies as well as a large number of international subcontractors. Chinese enterprises are responsible for civil construction as well as system installation and startup. Unit 1 is scheduled to go on line in December 2004, with Unit 2 following one year later.
Following receipt of a contract in 1998 to supply all of the plant's instrumentation and control systems, Siemens was awarded a second contract in 1999 to provide the emergency diesel generators. This was followed in 2000 by further orders for 24-volt DC converters, passive hydrogen recombiners and the ventilation systems.
Instrumentation and Control Systems
Tianwan is to be equipped exclusively with digital equipment for its operational and safety instrumentation and control (I&C) systems. JPNC chose Siemens I&C equipment (TELEPERM XS for all I&C systems requiring nuclear qualification and TELEPERM XP for operational I&C systems) to be supplied by a consortium made up of different groups of Siemens including the nuclear power division, now part of Framatome ANP. Russian organizations are supplying part of the reactor I&C.
Emergency Diesel Generators
Framatome ANP, as consortium leader, and MTU, a subsidiary of Daimler Chrysler, will supply a total of eight emergency diesel generator sets -four to be delivered to Unit 1 in March 2002 and the other four to Unit 2 in 2003. Framatome ANP and MTU will be supervising initial startup at the plant.
Siemens and MTU have worked together successfully on many projects in the past. For example, the majority of nuclear power plants built by Siemens are equipped with MTU diesel engines.
Hydrogen Recombiners
Tianwan 1 and 2 will be supplied with a total of 88 passive catalytic hydrogen recombiners -44 for Unit 1 in early 2003 and the remaining 44 for Unit 2 a year later. Chinese companies, contracted by the customer, will install the components in the first quarter of 2004 and 2005 respectively. A site supervisor from Framatome ANP will provide these companies with technical assistance and will supervise the work.
Ventilation Systems
Framatome ANP will be delivering the ventilation equipment between February 2002 and April 2004. This order is being executed together with 13 subcontractors from China, Switzerland, the Netherlands and Germany. Chinese companies will be responsible for installation and startup. The contract scope covers not only supplying approximately 5,200 individual components but also supervision of installation and startup, as well as training plant personnel in equipment maintenance. The technical requirements of this equipment range from "non-nuclear classified" to "safety-related." The supply scope for the air handling and refrigerating units also includes all necessary internal I&C equipment.
|