Power supply for Spain’s most important Nuclear Power Plants

LOCATION: NUCLEAR POWER PLANTS, SPAIN (COFRENTES, ALMARAZ and TRILLO) 

INSTALLED POWER: Prime power 630kVA; Standby power 700kVA; 400/230V 50Hz with output factor of 0.8.

Special Configuration: Gensets, control panels, changeover control and power panel, connection panels, fuel transfer pump, specially built to withstand earthquakes as per seismic definitions and norms stated in “IEEE 344 Standard for Seismic Qualification of Equipment for Nuclear Power Generating Stations”

65755_7image154naom_571f3ea77453a

PROJECT AIMS

The goal of this project was the successful installation andl start-up for 3 gensets with their respective control panels to provide power for the ALTERNATIVE EMERGENCY CONTROL CENTRE (AECC) in the three distinctive Nuclear Power Plants. The focus was on a fully integrated star to finish project and included the; design, documentation, manufacturing, testing, seismic certification, supply, and logistics.

In the after math of the Fukushima-Daiichi Nuclear Power Plant incident in Japan during the tsunami of 2011, the Western European Nuclear Regulators Association (WENRA) defined amongst other factors, the stress tests to be carried out in European Nuclear Power Plants.

As a result of these evaluations the Spanish Nuclear Safety Council (CSN) requested that each nuclear power plant should create an alternative centre to implement and continue emergency operational management should a situation arise forcing the evacuation or abandonment of the Centre for Operational Support and the Technical Support Centre, and as determined by the assessment of the power plants director. The CSN determined that the implementation of the ALTERNATIVE EMERGENCY CONTROL CENTRE (AECC) should be carried out in all the Spanish nuclear power plants.

PROJECT DETAILS

dsc_4048

This particular project was developed in the first half of 2015. The initial study of the technical specifications and the preliminary designs were undertaken during the last quarter of 2014. GENESAL was finally awarded the contract by the client in early 2015. On the date the contract was formally agreed a meeting was held to launch the project in the clients offices during which the project timing and delivery, stages, documentation and the steps necessary to reach a successful conclusion, were established.

As we were dealing with a “critical” project, classed as a last resort energy powered solution in the event of the requirement to shut down the nuclear reactor due to an emergency or natural disaster, we focused the first stage of the project on the development of prototypes of each individual generator. This then led on to seismic resistance testing for the gensets based on the estimated seismic activity levels which could occur in their operational location. The results determined that the Genesal prototypes were able to withstand this potential seismic activity and continue functioning correctly after a potentially serious incident.

dsc_4074-copia

During the design phase of the prototypes, we undertook a serious of diverse seismic studies with the collaboration of the Mechanical Engineering department of the University of La Coruna in North West Spain. Simulations were carried out to study the behaviour of the different control panels, floor fixings, and the genset support frame with a 700 litre fully enclosed fuel tank. Upon completion of the testing and simulation, and with the design approved by the client, we constructed the pro-types. These were subsequently sent to a laboratory specialising in vibration where seismic testing was done and validated satisfactorily allowing for production of the final product in series.

SOLUTION

Upon completion of the gensets and their validation by the CSN (Spanish Nuclear Safety Council), they were installed in the ACEM (Alternative Centre for Emergency Management) in a specially designed room for the genset and associated control features. The genset and control elements then went through the start-up procedure and were incorporated into the management systems of the power-plant.

1-img_9488-copia

SEISMIC TESTING

As determined by the “IEEE 344 Standard for Seismic Qualification of Equipment for Nuclear Power Generating Stations, and the seismic response spectra as provided by our client (which reached 3g, we carried out the seismic validation testing procedures of all the equipment involved for each individual nuclear power plant using two different methods:

• A computer simulation was carried out with the University of La Coruna in North West Spain. The following – components were tested:

– control panels,

– changeover control and power panel,

– connection panels,

– secure floor fixings

– fuel transfer pump

Once manufactured, all the parts were sent to a laboratory specialising in vibrations to seismically validate and certify them in accordance with the requirements of IEEE 344. We should highlight that upon successful completion of the testing all the parts used were disposed of as they are now not considered apt for end user facilities, and new identical parts are built.

• In the case of the Genset as a whole, due to the elevated investment required, the validation of each unit was carried out through simulations, calculations and reports on finite materials. Testing requirements were in line with those as determined by the standards incorporated in IE344 as well as the Eurocodes standards for structural design in order to calculate the legs and the secure floor fittings.

More information here

Combined Cycle Plant GEN750TC

CASE STUDY

Emergency diésel power generator to be installed in a Combined Cycle Plant in Chilca, Lima province, Peru. The plant has a General Electric gas turbine and a Siemens steam turbine , capable of generating a net 110 MWe.

OVIDIO ALDEGUNDE

REQUIREMENTS

  • Space limitations.
  • Internal division between 3 rooms: generator room, control room and tank room. The control room must be climate-controlled.
  • 6 hours of independent operation at 100% load.
  • Corrosive atmosphere with high content of suspended dust.
  • Maximum noise level 85 dBA at a distance of 1 metre.
  • Fire detection and extinguishing system.

OVIDIO ALDEGUNDE       OVIDIO ALDEGUNDE       OVIDIO ALDEGUNDE

UNIT DESIGN

Based on a study of the loads to be supplied, the selected power unit had a rating of  680/750 kVA, 60 Hz, 480 V. To meet the requested specifications, GENESAL ENERGY chose the following solutions:

  • To overcome the space limitations, the unit was assembled in a 30’HC container designed especially for the project.
  • The unit as required was divided in to 3 rooms:
  1. Generator room: Containing the power generator along with the batteries.
  2. Control room: The control panel and generator power panel are installed in this room. The wiring connections are located at the bottom of the generator.
  3. Tank room: A custom-made, approved, 1500 litre double-walled parallel piped-shaped tank was installed, guaranteeing 6 hours of independent operation at full load.
  • Because the atmosphere where the generator would be operating is highly corrosive (marine atmosphere), it was painted in accordance with ISO 12944, following a C5M diagram, which consists of type SA 2 ½ shot blasting in accordance with ISO 8501, one initial 80 µm coat of zinc-rich paint, two 100 µm coats of epoxy paint and a final, 100 µm coat of polyurethane paint (RAL 7032), giving a total dry film thickness of 380 µm.
  • The atmosphere where the generator is located has a high content of suspended dust. Therefore, powered grilles were installed on the generator’s air intake and outlet. The slats open when the generator is operating and close automatically when the generator shuts down.
  • To meet the noise requirements, the generator was attenuated with acoustic panels consisting of rock wool and perforated plates, and was equipped with noise reducing filters on the air intake and outlet. The exhaust soundproofing was installed inside the container to avoid complications during the on-site installation.
  • The fire extinguishing system includes a detection component consisting of a smoke detector system in all 3 rooms aswell as an extinguishing system that uses water mist in the engine room and tank room, and CO2 in the control room.
  • The control panel was designed to meet the specific requirements of the project engineering team.
  • Redundant programmable automaton.
  • Fibre optic communication with the redundant DCS by modbus TCP/IP
  • 4” touchscreen
  • Protection relay meeting the following ANSI-based electrical protection requirements: 50, 51, 51N, 59N, 59, 27, 81m, 81M, 46, 49, 25, 78, 32, 40
  • Protection relay meeting the following ANSI-based electrical protection requirements: 87G, 24
  • Synchronizer between generator and networks

OVIDIO ALDEGUNDE Combined Cycle Plant GEN750TC