The Design Division performs system-level development of various type reactor plants and their main components, develops design documentation.
Design divisions perform:
- Development and multi-optional optimization of design solutions;
- Computational analysis and justification of design solutions, characteristics and modes of operation;
- Analysis and generalization of the running plants operating experience;
- Field supervision of manufacture, installation and operation of the developed products;
- Development and implementation of IT in the enterprise management processes.
Main departments of design division:
Development of NSSS components` layout and flow scheme
Development of reactor and reactor core mechanical designs
Development of basic equipment:
- Circulating pumps
- Heat exchangers
- Steam generators
- Control and protection system actuators
Development of fuel handling and process equipment
The Design Division is a big team of highly qualified experts: designers, mechanical engineers, physicists, heating engineers, metallurgists, electronic engineers, technologists, programmers. They widely use modern computers and efficient software including three-dimensional CAD-systems, which ensure the development of complex engineering systems and equipment with optimization of design solutions and thorough justification of operating parameters, characteristics and modes.
The Division for Design Scientific and Technical Validation (DSTV) fulfills thorough analysis and scientific and technical validation of reliability and safety of the reactor plant at all stages of its life cycle.
The tasks of the DSTV Division include:
- Analysis and validation of neutronic characteristics, design and composition of reactor cores, effectiveness of reactivity control systems, neutron monitoring tools and nuclear safety conditions, development of programs and support of reactor core tests at test facilities and operating reactors;
- Analysis of thermal physical and thermal-mechanical processes, strength and lifetime of fuel assemblies and reactor cores in normal operating conditions and in accidents, optimization and validation of design solutions aimed at intensifying of technical and economical indices;
- Analysis and validation of radiation protection performance in normal operating conditions and in accidents, analysis of dose rates during RP operation and handling of radioactive sources, analysis of radiological consequences of accidents including a postulated severe fuel meltdown accident, analysis and validation of localizing systems performance, and validation of nuclear object arrangement;
- Analysis of thermal hydraulics of reactor plant equipment and systems in static, dynamic and emergency modes, validation of design decisions on pump and heat exchange equipment, normal operation systems, safety systems, development of requirements for testing scope and methods for reactor plant systems at test facilities and objects, development of recommendation on optimization of structures from viewpoint of thermal hydraulics, thermal cycling and efficiency of heat removal channels;
- Analysis of RP dynamics in normal maneuvering modes, in case of equipment failures and outages, in design basis and beyond design basis accidents, validation of automated reactor plant control algorithms, development of requirements for automation systems, adjacent systems and an entire object, support of automation systems development and tests, development of reactor plant computer simulators and virtual power units;
- Analysis and validation of strength of all reactor plant equipment and system elements, development of recommendations on design optimizations aimed at strength assurance, development of requirements for inspection and test methods, analysis of design behavior under thermocyclic, radiation and dynamic impacts;
- Analysis and validation of lifetime characteristics of reactor plant equipment and systems, including those beyond prescribed indices, development of forecasting methods for their residual life;
- Participation in development of regulation-methodological documentation of federal norms and rules and national standards in nuclear power application area;
- Analysis of processes in a reactor and a containment in primary circuit depressurization accidents, analytical validation of reactor plant safety, design and efficiency of emergency core cooling systems.
The list of tasks that the DSTV Division resolves includes:
fine-tuning structural elements of RP systems and equipment through model testing; studying the features of heat-and-mass exchange processes using RP equipment assembly models; generating a database for verifying 3D thermal-hydraulic codes.
The above objectives are achieved using a large complex of computer codes. The majority of these codes was developed in JSC “Afrikantov OKBM”, verified by the results of extensive benchmark and full-scale tests and operational databases, and certified according to the safety rules for the relevant range of parameters of developed reactor plants.
Now, one of important factors to keep and strengthen Company’s competitiveness is a wide application of numerical experiment technologies based on complex usage of 3D thermal-hydraulic analysis (computational fluid dynamics - CFD) and temperature and strain-stress state of structures (finite-element analysis - FEA) at SuperComputer. In some cases, application of these technologies permits to replace full-scale experiments with numerical ones and provides a unique possibility to study actual structures at natural parameters of fluid and to obtain complete and representative information on all proceeding processes. It results in design quality improvement with simultaneous reduction of work terms and costs.
Industrial improved-estimation codes find expanding application in engineering practice. Best foreign codes were mastered and are widely used as alternative to analyze neutron physics, radiation protection, mechanics, thermal hydraulics and safety.
The production facilities of JSC "Afrikantov OKBM" are provided with modern manufacturing equipment to ensure production of prototypes of the equipment under development, test facilities, individual types of equipmentfor the Russian fleet, nuclear power industry and non-nuclear general-purpose equipment.
The total area of production facilities equals 24764 m2, the manpower is over 900 workers. There are more than 530 units of technological equipment including 270 metal cutting machines, 20 press-forging plants, over 40 welding plants, over 30 units of heating and molding equipment.
- plasma-arc and gas-plasma cutting of sheet blanks of stainless steel (thickness under 150 mm) and carbon steel (thickness under 200 mm):
- bending of sheets up to 50 mm thick;
- molding of blanks and intricate shapes of
stainless-steel, heat-resistant steel, special alloys and bronze;
- cutting of blanks from rolled stock and forgings up to 800 mm in diameter on the belt-cutting machines.
- machining of articles up to 6.3 m in diameter and 10m long on multi-purpose metal-working machines;
- high-performance machining on lathes, vertical mills, turning/milling centers and NC machines;
- fabrication of high-precision shapes on the spark-erosion wire-cutting and laser equipment;
- fabrication of electric motor stators with a complex of electric engineering activities;
- fabrication of electronic and electric equipment for industrial purposes;
- long-hole drilling and boring of holes up to 250 mm in diameter and 4000 mm long;
- fabrication of industrial rubber articles;
- fabrication of gear wheels, gear shafts, and worm couples
- hermal treatment of parts and blanks in vacuum and protective gas atmosphere;
- thermochemical treatment of parts: cementation, nitriding, aluminizing and chromizing with subsequent nitridation;
- deposition of chemical coatings on metallic articles: phosphatizing, oxydation, galvanization, anodic treatment, silver plating, chemical
passivization, chromium-wurtzite coating.
- manual arc welding with coated electrodes;
- automatic and manual arc welding;
- semiautomatic and automatic submerged-arc welding;
- electron beam welding;
- contact welding;
- manual electric-arc deposition of sealing surfaces on valves;
- vacuum soldering with silver-containing solders, soldering of Kovar to ceramics in a hydrogen environment.
- assembly of heavy-weight equipment (up to 100 t) at special sections, on beds and building berths, providing high cleanliness of inner cavities.
- non-destructive testing of welded joints and metal by physical methods (ultrasonic, radiation, capillary);
- analysis of chemical composition and mechanical properties of materials, including intercrystalline corrosion tests;
- hydraulic strength tests under pressure as high as 60 MPa;
- vacuum tests for leak-tightness.
The ongoing production complex restructuring and modernization program stipulates mastering
of new modern technologies, procurement of high-precision high-performance process equipment, introduction of modern inspection tools, and establishment of new production sectors.
The Scientific Research and Testing Complex (SRTC) is equipped with state-or-the-art experimental facilities and research installations and provides experimental investigations of neutronic, thermohydraulic, mechanical and lifetime characteristics, as well as representative tests, of the equipment under development.
Experimental facilities in the SRTC can be used for testing nuclear reactor core elements, high-pressure vessels, wide range of heat exchanging equipment including steam generators with steam parameters of up to 550 ºC and 16 MPa, pumps with the capacity of up to 20000 m3/h, gas circulators, all kinds of pipe valves, precise electromechanical equipment, actuators, manipulators and other mechanisms for nuclear power and other branches of industry.
- control rod drives and fuel handling complexes;
- valves and safety devices;
- circulating pumps, related friction units and shaft seals;
- heat exchangers and steam generators.
- neutronic characteristics;
- reactor core and steam generators thermal physics;
- physical and chemical processes in NPP circuits;
- static and dynamic strength of constructions;
- diagnostics of machinery and structures.
The RTC also incorporates:
A Test Center accredited with the Certification Center GOST R (accreditation certificate No. ROSS.RU.0001.22.AC01 dated March 03, 1998) and with the Certification System for equipment, products and technologies used in nuclear plants, radiation sources and storage facilities (accreditation certificate No. RU.0001.01.AE 00.52.22.0002 dated November 15, 1999). The Test Center conducts certification tests.
A Certification Expert Center accredited with the Certification System for equipment, products and technologies used in nuclear plants, radiation sources and storage facilities (accreditation certificate No. ROSS RU.0001.01.AE 00.52.31.0003 dated November 15, 1999). The Certification Expert Center prepares experts' reports on the possibility of issuing a certificate of conformity.