nuclear government of corporation of power india

8/14/2019 Nuclear Government of Corporation of Power India

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KUDANKULAM NUCLEAR POWERPROJECT

Nuclear Power Corporation ofIndia Ltd

(A Government of India Enterprises)

M.S.Suresh


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Indian NuclearProgram


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Energy Comparisons1 kg Coal 3 kw.h

1 kg Oil 4 kw.h

1 kg Uranium 50000 kw.h

(3,500,000 kw.h with closed fuel cycles)

Fuel Required for 1000 MWe Plant (annual)

Coal 2,600,000 t 2000 train of 1300 t each

Oil 2,000,000 t 10 super tanker

Nuclear 30t 10 m 3 of reactor core

(Uranium)

Land Required for 1000 MWe Plant

Fossil Nuclear Site 1-4 km2

Solar (thermal or Photovoltaic) 20-50 km2 (a small city)

Wind Field 50-100 km2

Bio Mass Plantation 4000-6000 km2


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BASICS OF NUCLEAR ENERGY

The source of Nuclear Energy lies in the

equivalence of mass and energy according to

Einsteins equation:

E = m c2,

where Eis the Energy,Joules

cis the velocity of light, m/s

m is the mass, kg


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HOW A NUCLEAR REACTOR WORKS ?


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Stage I: 10,000 MWe throughPHWRs and LWRs.

Stage- II: Fast Breeder Reactorswith plutonium as fuel and

thorium as blanket for breeding U-

233.

Stage-III: Breeder Reactors usingU-233 as fuel and thorium as

blanket.

Short term goal is to complementgeneration of electricity at

locations away from coal mines.

Indias long term nuclear energypolicy is based on recycling

nuclear fuel and harnessing the

available thorium resource.

Energy potential of three stageprogramme is placed more than 3

times the energy potential of coal

reserves.

LWR

INDIAN NUCLEAR POWER PROGRAMME


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PHWR- Pressurized Heavy water Reactor

Fuel-Natural Uranium

Moderator- Heavy Water D2O

Coolant Heavy water

PWR- Pressurized water Reactor

Fuel-Enriched Uranium

Moderator- Water

Coolant Water

FBR - Fast Breeder Reactor

Fuel - Plutonium

Coolant Liquid sodium

LWR

INDIAN NUCLEAR POWER PROGRAMME


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2x 220

2x 160, 1x540

1x 540

2x 220

1x 150

1x 2002x 220

2x 220

2x 2001x 500 (PFBR )

2x 2202x 220

Kudankulam

Kalpakkam

Narora

Rawatbhata

Tarapur

Kaiga

In Operation -15

Under Construction- 8

Kakrapar

2x 1000

INDIAN NUCLEAR POWER PLANTS

In Operation -3310 MWe Under Constn-3920MWe


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rief Background of KKN


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SITE SELECTION

Site cleared by DAE Site Section Committeefor setting of 4x500 MWe. - 1988.

Clearance from AERB for Site & High Power

Committee on Tamilnadu Government forenvironmental obtained.

Site investigation for 4x500 MWe including

Bore holes were started in 1987-88.

Site was subsequently allotted for 2x1000MWe VVER Plant.


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Tamilnadu State Environmental Committee

Clearance .

Clearance from Tamilnadu ForestDepartment.

Clearance from Ministry of Environment &Forest,

500m shoreline clearance from PMs office.

Clearance of committee on conservation ofseashore for location of Atomic PowerStation at Kudankulam from Tamilnadu Govt.

Clearance from AERB for Excavation.

Clearance from AERB for Construction of

CLEARANCES FOR KKNPP


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KKNPP


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Sea Water Intake pipeline

Breakwater dyke

Intake Structures

Fish protection facility

Sea Water Inlet pipeline

Bridge

Chlorination plant

Discharge channel

Forebay

Siphon walls

Main pump house

Part of essential load pipeline

Shoreline protection bundUZP

HYDROTECHNICAL STRUCTURES (INTAKE AND OUTFALL)


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Sr.No.

Pkg.No. Name of the Package Agency

1 C-1 Levelling & Grading(Completed)

M/s. SRC

2 C-2 Excavation (Completed) M/s. SRC

3 C-3 Reactor & ReactorAuxiliary Building

M/s. HCC

4 C-4 Turbine, Control &

Emergency PowerSupply Buildings

M/s.

Simplex

5 C-5 Plant Auxiliary Buildingsand Structures

M/s. L&T

6 C-6 Pump house, Sea Water M/s. HCC

CIVIL WORKS MEGA PACAKGE CONTRACTS

K


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Reactor Building-1K

K

N

P

P

Fully inside lined reactor containment for KKNPP: first

time in the country


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afety Featur


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Kudankulam Reactors are Water cooled Water moderatedEnergy Reactor (VVER-1000) of Pressurized Water Reactor(PWR) technology, which is world wide proven concept.

VVER-1000 reactors, are the most advanced reactorssimilar to the PWRs of western design

21 numbers of VVER-1000 reactors are in operation withmore than 200 reactor-years of operating experience

WER-1000 plant designs were evaluated by variousagencies such as IAEA and concluded that it is safe and

advanced design.

KKNPP: ADVANCED REACTOR


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86000 m3 / hFlow rate of coolant through reactor7

6.27 MPaPressure of the steam generated at the outlet from the SG10

2 x 1000 MWe

(1111 MV.A)

Capacity of Generator11

43000 MWd/ T of UMean burn-up of the fuel9

15.7 MPaPressure of reactor primary system coolant at outlet of the core4

40 yearsDesign Life of the Plant (Reactor Pressure Vessel)1

3012 MWtRated thermal power of the reactor Plant2

ValueParameterSr. No.

3.92 to 3.84 %Average enrichment of the fuel reloads with U235

8

321 oCPrimary coolant temperature at the outlet from the reactor6

291 oCPrimary coolant temperature at the inlet to the reactor5

4No. of Circulation loops of the reactor plant3

KKNPP: Main Technical Parameters


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Safety has the overriding priority in all stages of the project i.e.

design,procurement,construction,commissing & operation.

Kudankulam reactor has futuristic engineering features for thepostulated beyond design basis scenarios.

Additional features will make reactor simple, reduction of manmachine interference, safe and reliable.

Some of the Additional features are-

Double Containment

A passive system for residual heat removal

Containment filter and venting system to protect containment

from over-pressurization Quick born injection system to ensure diversity in shutdown.

Kudankulam design shall meet all national and internationalenvironmental norms and standards.

KKNPP: SAFE REACTOR


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Airplane Crash

Tsunami Water

flood

Shock Wave

Seismic Effect

Reactor Containment design bases

All possible safety measures taken into account

in the design of the Nuclear Power Plants


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KKNPP Site: Levels


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ACTIVEAND

PASSIVESYSTEMSOF SAFETY

IN KKNPP-VVER 1000NPP


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ReactorPressureVessel

forKKNPP


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K


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View of site Before start of worK

K

N

P

P

Aug 25, 2000

K


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KKNPP site -At the startLeveling

K

K

N

P

P

June 16, 2001

K


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KKNPP Site: After site gradingK

K

N

P

P

Aug 15, 2001

K


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KKNPP Site: ExcavationK

K

N

P

P

Nov 30, 2001

K


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KKNPP Site: Consolidation GroK

K

N

P

P

Jan25, 2002

K


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KKNPP Site: Batching plant erecK

N

P

P

Feb27, 2002

K


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KKNPP Site: 31st March2002

K

N

P

P

Mar 31, 2002

K


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KKNPP Site: May 2002K

N

P

P

May 30, 2002

K


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KKNPP Site: Sep 2002K

N

P

P

Sept 18, 2002

K


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KKNPP Reactor Building: Sep 20KNP

P

Sept 18, 2002

K


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KKNPP Site: Feb 2003K

N

P

P

Feb 24, 2003

K


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KKNPP Site: Aug 2003K

N

P

P

Aug 21, 2003

K


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K

N

P

P

KKNPP Reactor Building: Oct 20

OCT 21, 2003

K


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N

P

P

Feb 02, 2004

K

ildi b


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K

N

P

P

KKNPP Reactor Building: Feb 20

Feb 02, 2004

K

ildi b


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K

N

P

P

KKNPP Reactor Building: Feb 20

Feb 02, 2004

K


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KKNPP -RB containment linerK

N

P

P

Aug 18, 2004

K

K


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KKNPP -RB containment linerK

N

P

P

Aug 18, 2004

K

K


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KKNPP -RB internal

structure

K

N

P

P

Aug 2004

Aug 18, 2004

K

K


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KKNPP Site: Sep 2004K

N

P

P

Sept 16, 2004

iK

K


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KKNPP Site: Dec 2004K

N

P

P

Dec 20, 2004

Si b 200K

K


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N

P

P

Feb 10, 2004

KKNPP RB d 1K

K


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KKNPP RB dome part-1K

N

P

P

Containment Dome First part being lifted in TAPP

China, a similar design of KKNPP

challe

ngeahead

KKNPP RB d 2K

K


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KKNPP RB dome part-2K

N

P

P

challenge

ahead

Containment Dome Second part being lifted in TAPP

China, a similar design of KKNPP

K

K


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K

N

P

P

Major equipment erecti

K

K

C C h i i


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K

N

P

P

Core Catcher Erection inRB-1

Latest safety feature in Nuclear Reactors- Core melt

catcher at KKNPP: first of its kind in the world

K

K

T C il


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K

N

P

P

Truss CantileverErection in RB-1

K

K

E ti f L Pl t


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K

N

P

P

Erection of Lower Platein RB-1

K

K

E ti f S t


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K

N

P

P

Erection of SupportTruss in RB-1

K

K

E ti f Th t T


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K

N

P

P

Erection of Thrust Trussin RB-1

K

K


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K

N

P

P

Equipment Transportation

RPV being rolled off from barge at Mini port at KKNPP


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Sea Water Intake pipeline

Breakwater dyke

Intake Structures

Fish protection facility

Sea Water Inlet pipeline

Bridge

Chlorination plant

Discharge channel

Forebay

Siphon walls

Main pump house

Part of essential load pipeline

Shoreline protection bundUZP

HYDROTECHNICAL STRUCTURES (INTAKE AND OUTFALL)


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Off h t tK

K


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Offshore structuresNP

P

~5 lakh cu.m . was dewatered from the temporary dyke

to facilitate construction of offshore structures in the sea

KK

C i i i S h d l


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N

P

P

Commissioning Schedule

As per sanction from Government:

Unit-1 : Dec 2007

Unit-2 : Dec 2008

As per Internal Target:

Unit-1: : Mar 2007

Unit-2 : Sep 2007

KKNPP: HONOURS & ACHIEVMENTS


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Excellent rating for Memorandum Of Understanding

(MOU) targets for the year 2002-03 and 2003-04.

All milestones of Ministry Of Statistics & Program

Implementation (MOSPI), for the year 2002 and 2003,

completed within schedule.

NPCIL Safety award for the year 2002 among the

construction projects

Greentech Silver award for Industrial Safety for year

2003 AERB Safety Award for year 2004 among the

construction projects

Highest accident free period among construction

projects (>30,000,000 man-hours)

KKNPP: HONOURS & ACHIEVMENTS

KKNPP Civil Engineering


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KKNPP- Civil EngineeringFeatures


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KKNPP Ci il E i i F t


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KKNPP- Civil Engineering Features

PCC B20

B20 SCREED CONCRETE 20 MM THICK

TWO LAYERS SBS WATER PROOFING MEMBRANE

B20 SCREED CONCRETE 30MM THICK

Membrane water proofing



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SBS WATERPROOFING MEBARANE LAYING BELOW FOUNDATION


KKNPP Civil Engineering Features


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Screed Concrete over Membrane




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Membrane Water proofing at Foundation sides




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SCREW COUPLERS



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Fabrication UnitUniversally accepted Process of extensionof Rebar

Rebar congestion due to lap can be avoided

and effective concrete placement

Available in dia of rebar 16mm & above

Reduces the construction time

Very much handy at temporary openings

which are to be closed later

Screw couplers



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Type of Screw Coupler

Connecting Bar is RotatedType- A

Screw couplers



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Coupler is rotatedType- B

Additional Threading

Screw couplers



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Coupler is rotated & locked with Lock nutType- C

Additional Threading

Lock Nut

Screw couplers



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Coupler welded To structural element & Bar is

rotatedType- W

Welding

Screw couplers



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Cutting Metric Threads

Screw couplers



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Screw splicing with Coupler

Screw couplers



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Temp. Opening with Coupler

Screw couplers



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HEAVY CONCRETE



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Concrete prepared with Hematite aggregate

% of Iron- more than 60%

Specific Gravity- above 4.65

Chemical composition Fe2O3

Properties of Heavy aggregate

Hematite is raw iron ore

Heavy concrete

% of Iron Oxide - more than 90%


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Heavy Concrete

Heavy Concrete



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Properties of Serpentine concrete

Concrete density not less than 3650Kg / Cum

Less thickness of structural element than of normal concrete

Heavy Concrete

Radiation Shielding (Gamma)



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SERPENTINE CONCRETE



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Concrete prepared with Serpentine aggregate

% of Chemically bound water-13%

Compressive strength- 300Mpa

Specific Gravity-2.5 to 2.8

Chemical composition - 3MgO.2SiO2.2H20

Properties of Serpentine aggregate

Metamorphic mineral occurring as small pockets in

Magnesium Dolomite

Heat conductivity coefficient- 0.895 W/(m.K)

Specific Heat- 84 KJ/(Kg.K)

Serpentine Concrete



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Serpentine Aggregate

Serpentine Concrete



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Properties of Serpentine concrete

Radiation Attenuation

Thermal Insulation

Cooling effect to the surrounding

Serpentine Concrete



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GREEN CUTTING



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Preparation of Construction Joint (side)

Top laitance to be removed

after final setting of Concrete

for effective bonding

Surface roughness +/- 5mm

Surface retarder Application

Just after final setting time

wash with Air Water jet

Green cutting



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Preparation of Construction Joint (Top)

Green cutting



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PRE-STRESSING



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What is pre-stressing ?

Concrete is weak in Tension but can withstand more compression

Relatively high compressive strength concrete is used

Pre- compression induced by pre-stressing with HT steel wire

Net effect after the loading is only compression



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Principle of Pre-stressing

W

PP

+

P/A+M/Z

=

- M/Z

P/A +M/Z

P/A - M/Z



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g g

Why pre-stressing is need for the Containment?

.Containment is the Cylindrical house for Reactor

.It is the Ultimate barrier to contain accident releases

In case of hypothetical accident the pressure inside containment may

raise to 0. 4MPa

.To with stand the pressure during accident (no part of the containmentshould be in tension)

Pre-stressing

.To contain the radiation release with in the containment



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g g

Pre-stressing system For KKNPP- Freyssinet 55C15

Technical Parameter of Pre-stressing system

Greased cable un-bonded post tension Pre-stressing system

Net pre-stressing per Tendon -11.5MN

Friction coefficient -0.05 per Rad.

Pre-stressing Jack 3C1500F (15MN)

Wobble coefficient - 0.001 per M

Number of strands in one tendon - 55 Nos

Number of tendons U - 60Nos (every 3 degree)

H - 68 Nos (34 pairs at every 1.4m)

This system is adopted first time in the World for NPP

Pre-stressing



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g gPre-stressing



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g g


Technical Parameter of HDP Coated Pre-stressing Strand

Breaking load-279KN

Cross sectional area -150 Sqmm

Ultimate strength -1860MPa.

Modulus of Elasticity 1.95MPa

Yield strength 1600Mpa

Relaxation loss 1000hrs 2.5% at 200C

3.5% at 400C

Weight per M -1.17Kg

Pre-stressing



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HDP coated Pre-stressing strands

Pre-stressing



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g g


Technical Parameter of Trumplate

Weight - 140 Kg

Overall dimensions - 420 mm X 510 mm X 516 mm

Brinnel HBW hardness - 170 to 230

Pre-stressing

KKNPP- Civil Engineering FeaturesPre-stressing


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Trumplate Erection for U Cable

Pre stressing



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Technical Parameter of Cable Duct

Spiral sheath (formed from steel strip of 78mm)

Dia-200mm (206 for Coupler)

Steel Tube

Dia-219mm (OD)

Thickness -0.6mm

Weight -17.04Kg/m

Weight -3.66Kg/m

Thickness -3.2mm

Pre-stressing

KKNPP- Civil Engineering FeaturesPre-stressing


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Bell mouthing Steel pipes

Pre stressing



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Technical Parameter of Anchor Block

Overall dimensions -300mm (dia) X 160mm(thick)

Weight - 65 Kg

Nominal tensile strength - 650 MPa

Roughness 12.5 m

Pre-stressing



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Technical Parameter of Wedges

Segments (parts) - 3

Steel grade - 16 Mu Cr5

Overall dimensions- 26.5 mm X 45 mm

Pre-stressing

KKNPP- Civil Engineering FeaturesP t i


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Mock up for Threading & Grouting (H Cable)

Pre-stressing



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Cross section of the grouted Cable

Pre-stressing



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Advantage of Pre-stressing system

Low friction coefficient hence less friction loss & less tendons

Since grouting is done before stressing, the influence of one stand over

other during stressing is avoided.

Single strand replacement if necessary is possible

Re-stressing in future if necessary is possibleCable is coated with grease & more resistant to corrosion

(Un bonded -0.05 per Rad as against 0.24 Per rad for bonded )

Pre-stressing



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Modulus of Elasticity - 39000MPa

Density - 2200 to 2500Kg/Cum

Water impermeability - W6 or W8

Design Requirement for B30 grade concrete

Concrete



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The concrete for KKNPP is designed for Water

impermeability of W6 or W8 as per GOST12730.05-84

Specimen specification

Dia -150mm

Height-150mm ( 40mm)

Dia -100mm (20mm)

Age -28days

Top laitance to be removed

Number of sample - 6

Concrete



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Mold with Air tight

gas- cut

Concrete

KKNPP- Civil Engineering FeaturesC


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Specimen is placed

inside the mold.

Gap between the mold

& specimen is sealedwith resin

Concrete

KKNPP- Civil Engineering FeaturesC t


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The mold with specimen

closed with rubber gas-cut and connected to

the testing M/c

Concrete

KKNPP- Civil Engineering FeaturesC


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Pressurized to 0.2MPa

Retention period

16Hrs for 40mm

Pressure increment-0.2MPa

12Hrs for 20mm

Final pressure

0.6MPa for W6

0.8MPa for W8

Concrete

Criteria Nowater should leak

KKNPP- Civil Engineering FeaturesC t i t C t


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Lift Height -2.8m

Grade of concrte-B50 Steel liner

Placement Temp- 190

C

Containment Concrete

Doka Self climbing

form

Fluid pressure on liner

Less than 0.015MPa

Layer-1

Layer-2

Layer-3

CIVIL WORKS: CONCRETING PROGRESS


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0

5000

10000

15000

20000

25000

30000

35000

40000

45000

Jan-04

Feb-04

Mar-04

Apr-04

May-04

Jun-04

Jul-04

Aug-04

Sep-04

Oct-04

Nov-04

Dec-04

Total concreting done as of Mar 16, 2005 :7.01 lakh cu.m.

Concreting done in Year 2004 : 4.01


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