| Solution |
Ruppur APP with two VVER-1200 reactors with a total power of 2400 MW is being built according to the Russian project, 160 km from the capital of Bangladesh, the city of Dhaka, under the general contract dated December 25, 2015. For the first nuclear power plant in Bangladesh, a Russian design with VVER-1200 reactors, previously implemented at two power units of the Novovoronezhskaya NPP, was selected. This is a generation III+ project that meets international safety requirements. The general contractor for the construction is Atomstroyexport JSC (ASE JSC) - the Engineering Division of Rosatom State Corporation.
The supplied alternative diesel gensets are designed to provide electricity to consumers involved in the management of a beyond-design basis accident associated with the complete loss of AC sources at the Ruppur NPP facility of power units 1, 2 for more than 24 hours.
Beyond-design basis accident management (BDBA):
1. NPP return to a controlled state when the self-sustained chain reaction stops, constant cooling of the fuel is ensured and radioactive substances are retained within the established limits;
2. Prevention of the development of beyond-design basis accidents and mitigation of their consequences including the use of special technical means for managing beyond-design basis accidents, as well as any systems (elements), including normal operation systems (elements) and safety systems (elements) capable of performing the required functions under current conditions;
3. Protection of the hermetic enclosure of the reactor plant from destruction during beyond-design basis accidents and maintenance of its operability.
Federal regulations and rules in the field of the use of atomic energy "General provisions for ensuring the safety of nuclear power plants".
TE.2000S-T400-3RN gensets meet the rules in the area of atomic energy use.
- The diesel genset meets the equipment strength requirements according to the nuclear power plant design standards (PNAE G-7-002-86, NP-031-01). The power plants are designed based on the strength calculation under seismic loads at the Ruppur NPP site. This estimation was prepared by the Certification Center SeismEnergoProekt specifically for TE.2000С-T400-3RN diesel genset.
- The diesel genset has safety class 4 according to the Federal Norms and Rules in the field of atomic energy use NP-001-15, which includes elements used to control beyond design basis accidents.
• NP-001-15 - Federal regulations and rules in the field of the use of atomic energy "General provisions for ensuring the safety of nuclear power plants
DG equipment is manufactured in climatic version "T" - (for operation in areas with a tropical climate) according to GOST 15150, placement category "1" - with outdoor placement. The value of the air temperature during operation is from - 10°С to + 50°С. Relative air humidity up to 100% at a temperature of 35 °C, altitude up to 2000 m above sea level.
-
Diesel engine - MTU-20V4000G23, V-shaped, 20-cylinder, four-stroke, fluid cooling with ignition due to compression, supercharged internal combustion engine (diesel)
-
Alternator – Leroy Somer LSA 52.3 single bearing, brushless, synchronous, with self-excitation system and automatic voltage regulation, IP44 degree of protection
-
Starting system: 24V battery electric starter, low voltage charging alternator, battery with connection cables
-
The genset has the protection of the electric circuits of the power generator, automation circuits, and devices from short circuit currents and overloads above the allowable ones.
-
The genset is equipped with an alarm and protection system of the 3rd degree of automation
-
Built-in 200-liter oil tank.
-
Built-in service 5000-liter fuel tank.
-
UPS
-
Coolant pre-heater
-
Battery charger
-
Lighting system
-
Security alarm system
-
Fire safety system
-
Heating system
-
Cooling system
-
Air intake system
-
Exhaust system: exhaust manifold, bellows compensator, mufflers on the roof of the container (3 pcs.)
-
Automation genset and load distribution control system
-
3rd degree of automation
-
DSE7320 digital control panel
The delivery package of every diesel genset includes:
- Mobile motor pump diesel CAFFINI Libellula LIB/1-3 P43/AL-NB for pumping diesel fuel
- 2200 kW load module encased НМ-2200-Т400-К2 for periodic testing of the genset under load
- A kit of cable products for external connections.
- Spares and tool kit (oil filters, coarse and fine fuel filters, tool kit)
- Set of maintenance documents
The diesel genset design
Two gensets are containerized and each one is mounted on a separate wheeled car semi-trailer. The design of the container and trailer ensures their secure mounting.
The car semi-trailer is manufactured on the basis of the CAB 93183 chassis individually for TE.2000S-T400-3RN. There are no production models of chassis of the required dimensions.
Genset dimensions without chassis: 13000х3200х3300 mm. (LxWxH)
Genset dimensions on a chassis: 14000х3200х4700 mm. (LxWxH)
The own-produced Techexpo LLC genset container is manufactured according to all-welded technology and serves to protect the genset and equipment from weather impact.
The frame of the container floor features a reinforced structure, and the floor is made from a corrugated metal sheet at least 3 mm thick. Heat insulation of the body including floor, ceiling and walls is implemented with basalt wool at least 50 mm.
Thanks to the reinforced upper frame of the container module, one can rise it for transportation. The container is provided with fastenings for extension ropes, fittings for attaching to a trailer (marine ones), a ladder for climbing onto the roof of the container, mounting hatches, doors, ventilation openings, cable connection niches. The outer casing of the container is made of corrugated steel sheets at least 1.5 mm thick.
The genset design, the arrangement of doors, openings and passages provide the possibility of dismantling and replacing individual units and equipment housed inside the container, as well as repairing and maintaining the equipment.
All container doors are 0,9×1,9 m and are equipped with dead latches, open from the inside without a key.
All external cable connections are made based on quick-detachable connectors. The connectors are mounted in special niches with opening hatches. The hatches have elastic seals for sealing when closed.
The container module is divided into the next compartments:
- fuel compartment;
- assembly compartment;
- electric compartment.
A fuel consumed tank is housed in the fuel compartment.
The generator unit, battery box, manual fuel pump are housed in the assembly compartment.
In the electrical compartment, switchboard equipment for automatic control and load distribution systems and security alarm devices are installed.
The compartments are separated by a soundproof partition. The partition of the fuel compartment and the door to the adjacent compartment have a 2nd degree of fire resistance. Each compartment has at least two emergency exits. A viewing window made of heat-resistant glass is provided in the door leaf between the compartments.
A - assembly compartment
Б - electric compartment
В - fuel compartment
- consumable fuel tank with a filler port and a visual device for monitoring the fuel level
- system of emergency drain and overflow of fuel with a quick-opening valve
- system equalizing pressure with the atmosphere
- fire isolation valve
- electric fuel pump
- manual backup fuel pump
- coarse-mesh filter and solenoid valve of the replenishment system
- coarse fuel filter with moisture disengagement function
- system of fuel lines and valves
The fuel system of the prime engine of the diesel genset is equipped with a high-pressure fuel pump, fine mesh filters designed to control the purity of fuel and the removal of foreign substances from it.
A 5000-liter fuel tank is housed in the fuel compartment. This capacity is enough to ensure the uninterrupted operation of the genset within 8 hours. The consumed fuel tank has a visual device for monitoring the fuel level, a filler port, a device equalizing pressure with the atmosphere with a fire isolation valve, an analog fuel gauge, a discreet sensor of the emergency upper fuel level, a system of the emergency drain into the off-site tank.
The consumed fuel tank of the genset from the off-site tank is replenished automatically. To pump diesel fuel from the off-site tank a mobile diesel power pump with a 100 m flexible pipe is used, which is supplied together with the genset. A coarse mesh filter, which prevents the possible entry of mechanical parts into the fuel system equipment of the diesel genset is installed at the pipeline inlet.
- oil consumed tank with a filler port and a visual device for monitoring the oil level
- manual oil tank filling pump
- pressure equalization system with atmosphere and fire isolation valve
- automatic replenishment device
- system of fuel lines and valves
- system equalizing pressure with the atmosphere and fire isolation valve
- automatic replenishment device
- system of fuel lines and valves
The oil system of the genset provides the feeding of filtered and cooled oil from the crankcase housing to all diesel engine friction units. The oil system is made based on a mechanical device that automatically maintains the required oil level in the diesel crankcase with replenishment from the consumable oil tank.
The capacity of the supply oil tank - 200 liters. A hand oil pump is provided for its replenishment.
The cooling and ventilation system of the genset was designed specifically for operation in hot and humid climates typical for the equatorial monsoons taking into account the power of the equipment.
The cooling system of the genset consists of the cooling system of the prime engine, equipment mounted on the engine, and equipment of heaters/water-to-air heat exchangers.
The cooling system of the prime engine is implemented using two closed coolant flow circuits, a high-temperature (HT) circuit, and a low-temperature (LT) circuit. Coolant is cooled in an external cooler. The HT circuit is mainly designed to cool the cylinders and cylinder heads. LT circuit is designed to cool the coolant of charge air, fuel cooler, and lube oil cooler.
The heater consists of a water-to-air heater of the HT circuit and a water-to-air heater of the LT circuit of the coolant system. Heat is removed by a fan.
The coolant temperature is maintained automatically by the thermostats of the prime engine cooling system. Depending on the coolant temperature, the cooling unit fan motor is switched on and off by the automatic control system.
The electrical heaters of coolant maintain the working temperature of the coolant and allow the generator unit to be ready to quickly receive 100% load in automatic mode. Moreover, the DG is equipped with a diesel-fueled coolant heater with an autonomous operation of at least 48 hours in automatic mode.
The cooling air exchange system of the genset is designed to cool the equipment, ventilate premises and provide the unit with the required amount of air for its operation and cooling.
• Fuel compartment ventilation is provided by louvered supply and exhaust valves with automatically closing leaves (inertial) with a check valve function. The location of the supply valve relative to the exhaust valve provides a natural induction of airflow.
• Assembly and electrical compartment ventilation is implemented automatically with supply and exhaust valves with exhaust fans. Intake valves are completed with dust-collecting air filters and automatically closing leaves (inertial). The operation of the exhaust fans of the assembly compartment is automated by the control system depending on the air temperature in the compartment with the possibility of the manual startup from the front panel of the auxiliaries board. Exhaust valves are also equipped with automatically closing leaves (inertial).
The automation of the ventilation system control helps to maintain the air temperature in the compartments not higher than +50 °С.
-
The heating system is designed to maintain the temperature inside the assembly and fuel compartments in the cold season in the range from + 8 ° C to + 10 ° C, in the electrical compartment - from + 18 ° C to + 25 ° C.
Heating is implemented using heat convectors, the power supply and control of which are automated by the control system depending on the air temperature in the compartments. The heating of the fuel compartment is implemented using an explosion-proof electrical convector.
Electrical equipment
- The genset control panel of the genset (GCP) with the DSE7320 control panel controls the control automation of the generator unit. GCP provides a parameters control of the prime engine, power generator, the fuel level in the consumed tank with the fuel system control function, the DG distance and manual launch system, the coolant heating system, controls the position of the power generator switches, and ensures its automatic and manual switching-on and disconnection.
- The auxiliaries board provides switching, controlling and protecting the equipment circuits of the genset auxiliaries. It additionally provides:
- • control over the temperature inside the compartments of the genset;
- • control of the exhaust and supply valve of air exchange and ventilation;
- • control of exhaust ventilation systems;
- • control of the heating compartments of the genset;
- • switching of the lighting system and outlet groups;
- • the distribution of electricity (for recharging batteries, for the engine coolant heater, for power supply to the DG controller)
- Distribution device (RU-0,4): The distribution device is mounted in the floor cabinets. It is intended for the distribution of power to various types of load and consists of:
- • automatic three-phase load switches 800А (4 pcs.);
- • automatic three-phase load switches 400А (4 pcs.);
- • automatic auxiliary power supply switch;
- • bus systems
20 built-in power sockets with a rated current by 320A
To connect external power cables, quick-detachable power connectors ProConect of at least IP65 installed in special niches of the genset container walls are provided on containers:
A delivery package of external power cables:
- Power cables from the DG to the connection location 11 pcs. with 5-contact connectors installed on them, PROCONECT 3rx5 (cable plug) with a rated current of 320A. The length of the cables connected to the connectors is at least 70 m.
- Connective system for power cables (3РХ5 power connectors - 11 pcs. mounted on cables from the connection to the genset distribution device).
- Additionally, 9 pcs. of 5 contact connectors 3RH5 (cable plug) with a rated current of 320A) are supplied.
- Coiler (cable reels).
Before shipping the quality of the manufactured products was evaluated. To this end, Techexpo QC department acceptance tests were carried out in the presence of the client’s representatives. TE.2000С-Т400-3RN diesel genset. The work and reliability of the modules, the working elements of the genset, the operation of the heating, ventilation, air exchange systems, the DG was launched, and the operation of the genset in the nominal load mode for automatic and manual control was tested. The tests were successful.
Package and transportation
А diesel genset is transported to the destination separately from the wheeled trailer. Until the transportation the next equipment is partially dismantled: canopies for doors, air exchange openings, exhaust fans, and noise silencers.
The doors of the container are locked and sealed, the openings of air exchange valves and exhaust fans are closed with transport shutters, all flange connections of pipelines, cable gland outlets, power busbar outlets are closed with plugs or cases. Spare parts and accessories are packed in boxes. The boxes are installed and secured for transport inside the container of the genset.
The containers are packed in a heat-shrink film to protect the equipment from external influences.
The delivery package includes:
- А diesel genset – 2 pcs.
- Wheeled semi-trailer – 2 pcs. For transportation, the wheeled trailers were securely connected.
- Load resistor – 2 pcs.
- Set of cable products– 2 pcs.
- Power pump with pipeline – 2 pcs.
- Spares and tool kit – 2 pcs.
The supplied equipment was delivered to the port of St. Petersburg for further transportation to Bangladesh.
|
