JPRS ID: 8955 USSR REPORT RESOURCES

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• Content Type: REPORTS

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~8 FEBRURRY 1980 CFOUO 6r80) . 1 OF 1
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JPRS L/8955
28 February 1980 -
USSR Re ort -
p .
= RESOURCES
CFOUd 6%80)
~ -
~Fg~~ FOREIGN BROADCAST INFORMATION SERVICE
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_ JPRS L/8955
_ 28 February 1980
. USSR RE~ORT -
R~souRC~s
~
(FOUO 6/80)
~ CONTENTS PAGE
ELECTRIC POWER AI~TD POWER EQUI~?KENT
_ Technical Progress in Thermal Equipment Installation
_ (V. A. Kozhevnikov; ENERGETICHESKOYE STROITEL'STVO,
_ Nov 79) 1
' Methods of Increasing Efficiency of TES, AES Equipment
Installation
(Yu. S. Medvedev; ENERGETICHESKOYE STROITEL'STVO,
; Nov 79) . 7
.
Improving the Mett~ods of AES Equipment Installation -
(A. M. Gusinskiy, M. Ya. Khizhin; ENERGETICHESKOYE
STROITEL'STVO, Nov 79) 17
Organization of Ele~ctric-Power Supplies for GES
(I. E. Veyts; ENERGETICHESKOYE STROITEL'STVO,
Nov 79) 24 -
_ Improved Supports for Electric Power Lines
(L. I. Peterson, et al.; ENERGETICHESKO`~E STROITEL'- -
_ STVO, Nov 79) 31
FUELS ANll RELATED EQUIPMENT -
New Oil-Well Completion Method Described -
(A. U. Sharipov, et al.; BURENIYE, Dec 79) 42
- a - [III - U5SR 37 FOUO]
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EL~CTRIC POWER AND POWER EQUIPMENT ~
UDC 621.311.22.C02.5.002.72: 658.5
TECHNICAL PROGRESS IN THERMAL EQUIPMENT INSTAILATION
Moscow ENERGETICHESKOYE STROITEL'STVO in Russian No 11, Nov 79 pp 6-7
[Article by V. A. Kozhevnikov, deputy minister far Power Engineering and
Electrification of the USSR: "Basic Directions of Technical Progress in
the Area of Thermal Equipment Installation Projects"]
[Text] Fo,om the Editorial Board. The Energomontazhproyekt
Institute, i::^eated 10 years agc?, is working productively
toward perfec~ing the organization and technology used in
generating proje~~~. for the installation oi Qquipment at
TES's and AES's. Below are published articles in which '
the Institute's mosr effective developments are
illuminated.
In the 3 years of the lOth Five-Year Plan, equipment with a combined ~utput
of 23.8 million kW has been installed and put into service at TES's and -
AES's that are under canstruction. This includes four power units of one
million kW capacity each at the Kursk and Chernobyl'skaya AES's, six 800
- MW power units at the Zaporozh'ye and Uglegorskaya GRES's, as well as a
number of power units of lesser capacity. A substantial increase in the
technical-economic indicators for installation projects has been attained.
By the end of the Five-Year Plar~, 22.7 million kW of new capacity must be
put into service. This includes power units that have been delivered: the
main 1,200 MW power unit at the Kostroma GRES; 1,000 MW power units at the
C{~ernobyl'skaya, Smolensk and Novovoronezhskaya AES's; one 800 MW power
- unit at the Ryazan' GRES; and six 500 MW units at the Reftinskaya GRES and
the Ekibastuz GRES-1.
The rate at which new output capacities are comnissioned will increase
rapidly in the llth and 12tn Five-Year Plans. At the same time, the fol-
lowing qualitative changes are planned in thermal electric power
- development: -
an increase in individual unit output;
_ an increase in the AES's contribution to the over-all structure of com-
missioned capacity, especially in the European portion of the USSR;
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. an increase in the contribution of coal-fired TES's (especially those
operating on low-caloric and high-ash coals) in the structure of com-
missioning all thermal electric power stations;
--accelerated development of power production in the country's northern =
and eastern regions;
--an increase in requirements for environmental protection.
- All of this stipulates increasing the volume and complexity of installation _
projects in terms of the commissioned capacity. -
- For example, if the mass of thermomechanical equipment needed to produce
1 MW of output at an 800 MW gas/fuel oil fired power unit comprises 37
tons, then a 500 MW power�unit using Ekibastuz coal has 62 tons for each
MW, an 800 MW unit on Berezovskiy coal has 63 tons and an AEC power unit
with an RBMK reactor has 50 tons.
At the present time, the labor expenditure for the installation of one ton
of equipment an~ounts to 9-10 man-days at a TES and 15-18 man-days at an
AES.
- Possibilities for further increasing the number of installation workers
are limited. Therefore, a~equired condition for the execution of this
planned program of thermal electric power development is a reduction in
labor expenditures on equ~pment installation brought about by improvement
in the technology and organization of installation projects, and increase -
in thA level of their mechanization and also by perfecting design solutions.
The installation of equipment is the cr�owning step in rigging an electric -
power project. The time it takes to put a project into service depends
upon the duration of the installation work; besides this, the major por- -
~ tion of capital investments is usually already obtained by the time the
- equipment i~s installed. Thus, the duration of the installation, together -
with the labor and material cons~mption in the installation work, deter-
mi?~es the effectiveness of the capital investments. The efficiency o~
the operation is directly connected to its quality of execution, since the
elimination of any installation defect demands an additional expenditure _
of time as well as labor and material resources.
The work on increasing the efficiency and quality of the installation must _
not be d~rected toward carrying out isolated measures. It is necessary
for the work to be conducted smoothly and ob,iectively while the latest
- scientific-technical achievements and advanced experience are employed.
Toward this end, in 1969 a decision was adopted to organize the
Energomontazhproyekt Technological Design Institute. In the ensuing 10
years~ the I~stitute carried out a number of projects directed at increas- ~
ing the efficiency and quality of equipment insta1lation at TES's and AES's.
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;
In the area of thermal equipment installation projects, the chief tasks
connected with increasing the efficiency and quality of installation work .
are:
~ perfecting TES and AES designs;
increasing the degree to which equipment is factory-prepared;
developing and introducing new installation methods;
industrializing installation projects, transferring as much of the volume
of such projects as possible to the plants, bases and assembly areas;
- improving the technology of welding operations, including heat treatment
and quality control of the welds;
increasing the level to which the operations are mechanize~, developing and
introducing new, very productive installation mechanisms.
The designs for TES's and AES's r~ust fully insure the feasibility of adopt- .
ing efficient installation technology. In order to do this, the develop- -
ment of the design at all stages (especially at the early stages) must be -
conducted with the participation of the installation technicians, that is,
with the participation of the Energomontazhproyekt Institute. -
- The joint work of the Institute and the plants--manufacturers of the t~sic
equipment--must be accomplished in a corresponding manner. At the same
time, it is expedient to incorporate in the equipment's design solutions
~ which ensure that the equipment can be dismantled into its delivery units
with a minimum of scatter, and which ensure the feasibility of guiding a
large-scale assembly directly into its planned location using apparatus that .
does not require the piece to be set down alon~ the way. The design of the
" units should ensure that the stresses imposed during installation are -
absorbed through the units' internal rigidity.
The number of welding operations in the area of installation must be kept
to a minimum. In order to do this it is necessary to provide for the option
of carrying out the major portion of these operations during assembly of the -
units on the construction platform.
Owing to the efficient design of the equipment, the rigid tolerances of its
- manufacture and also because of the necessary testing and checking of the
assembly that is conducted at the plant, it is ess~ntial that labor-
- consumptive fitting operations be eliminated in the installation area.
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E
The Energomontazhproyekt Institute must take an active part in the develop-
- ment of standards and technical specifications for the delivery of equip- _
ment, while striving to include in these documents requirements for impro-
ving installation technology. The Institute must also participate in
approving the technical specifications for the delivery of equipment at
concrete projects.
~ The perfecting of the design for the boilers' dust and gas flues (PGV's) `
and for non-standardized equipment at TES's and AES's is of great signif-
icance in reducing the expenditure of inetal and labor in manufa~turing and
' installation. The basic directiuns for work in this area shoul,~ be the -
- standardization of group decisions and the standardization of components
and elements; the adoption of refined accounting procedures which would
eliminate the unfounded increase in the mass of the dust and gas flues; _
and the adoption of efficient designs for cqmponents and elements (fire-
boxes of circular cross-~~ction, flexible, non-metallic expansion joints,
etc.).
In the area of installation technolagy the main attention must be directed
toward increasing the modular nature of the equipment. The design of an -
~nstallation module of optimal dimensions and mass should ensure its con-
ne~tion w.ith all the assemblies and components of the thermomechanical -
section, the thermal insulation and also elements of the measuring instru-
ments and the power unit. ~
- The complex and multistage technological processes,including the installation
of oil lines for the turbine plants and KhVO [further expansion not pro-
- vided] pipelines, adjustment of the permanent linings, etc., must be
replaced one step at a time.
- It is necessary to perfect methods of centering and aligning the turbine
equipment, the internal hull arrangement of the reactors, ~tc., and to
broade~ the area of application of optical and laser instruments in order -
to carry out these operations.
v
The unification of designs; the standardization of assemblies and components
" of the pipelines, dust and gas flues and technological metal structures; and
the madernization of the factories of Glavteploenergomontazh create the pre-
- requisites for the further industrialization of installation operations and -
the change-over from the centra1ized manufacture of semi-fin~ished installa-
tion materials to the centraljzed outfitting and assembly of equipment
modules.
This trend is part~cularly ~ffective in the continuous construction of large
scale fuel and power production complexes. It is essential to insure the
introduction of industrial production technology at the Ekibastuz Regional
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Industrial Assembly Base (RPKB), the construction of which is being com- -
pleted at the present 'cime. We must also insure the issuing of working
- drawings for the RPKB [further expansion not provided] of the Berezovskaya
GRES, planned for operation in 1982, so that the technology put into the _
pro~ect can be applied even during construction of the first unit of the
Berezovskaya GRES-1.
_ The experience o~ assimilating the installation technology at the RPKB of
the Ekibastuz GRES must be studied, and utilized during planning of RPKB's
of prospective electric pawer complexes, as well as during planning ~f the ~
- interconnected bases of installation trusts in areas ofi concentrated power
equipment constructioi~.
A most important task is the further development of the techr~ology for =
welding, heat treatment and the quality control of the welds. At present,
10-12 percent of the total labor expenditure for equipment installation
goes toward carrying out these opzrations, and the quality of their execu-
tion is one of the basic factors determining the reliability of the equip-
ment's operation.
The imp?�ovement of installation work technology is inseparably linked to
the further development of inechanization. An increase in the units' indi- -
vidual power outputs and, correspondingly, an increase in the height of the _
- main housings and the r~eight of the units require the construction of
. cranes which have a lifting capaclty~ and lifting height that considerably
exceed those adopted previously. These cranes must have an increased speed
o~f lift and must ensure the feasibility of their rapid assembly and dis-
assembly. Cranes of folding or sectional design and of low lifting capac-
~ ity are needed for operation in the closed, isolated chambers of AES's.
Despite the installation workers' desire to reduce the amount of adjust- -
ment work, the demand for equipment to carry out these operations is
growing. The technical requirements for these devices irr the areas of
productivity, accuracy and ease of installation and service are also
increasing. The time needed to produce the new devices, which at the
present time is excessively long, should be reduced owing to the creation
of the Institute's production base and the singling out of a factory in
_ the Teploenergooborudovaniye trust for the mar~ufacture of rigging
- equipment.
Along with the development of devices and apparatus for techndlogical
- purposes, we must also perfect accessory equipment intended to ensure
safe working conditions (scaffolding, cages, stock enclosures, etc.).
In many ~Nays, the efficiency of the instal~ation operations depends upon
the high-quality deliver,y of auxiliary and non-standard equipment, low-
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pressure pipelines and other items, manufactured by the
Glavteploenergomontazh plants.
In order to satisfy the growing demand for these products on the part of
builders in the power industry, it~is necessary to sharply increase the
- output of these products by the construction of new plants, as well as by
re~onstruction and expansion of existing plants. At the same time, we
- must also carry out the qualitative development of this industry in order
to guarantee a substantial ir~crease in operating efficiency. In the
designs for new and refurbished plants we must plan for the maximal mechan-
ization and automation of production and the adoption of new highly pro-
- ductive technological processes. At the same time,we must develop designs
for products on the basis of their standardization and consider the require- -
ments for progrsssive technology in their manufacture.
Toward the solution of the problems just enumerated we must direct the
labors of the Energomontazhproyekt Institute and those design and scien- _
tific research institutes of the USSR Minenergo that collaborate with it. _
_ COPYRIGHT: Izdatel'stvo "Energiya," "Energeticheskoye Stroitel'stvo."
1979. _
9512
CSO: 1822
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ELECTRIC POWER AND POWER EQUIPMENT
. UDC 621.311.22.Q02.5.002.12: 658.5
METHODS OF INCREASING EFFICIENCY OF TES, AES EQUIPMENT INSTALLATION -
- Moscow ENERGETICHESKOYE STROITEL'STVO in Russian No 11, Nov 79 pp 7-11
[Article by Engineer Yu. S. Medvedev] . =
[Text] In order to speed up technical progress in the areas of organization
- and technology needed to carry out operations for the installation of TES ~
and AES equipment, the Energomontazhproyekt Institute was created ten years
ago and the following directions for its activity were determined:
perfecting the organization of manufacturing operations, installation tech- _
nology and welding of thermomechanical equipment at TES's and AES's; _
developing designs for high-efficiency lifting machines, installation
devices and the means of small-scale mechanization;
designing factories to manufacture auxiliary boiler equipment and low- -
pressure pipelines, as well as production bases for the installation
- trusts; . -
designing dust and gas flues for boilers, developing standardized com-
ponents for auxiliary boiler equipment and low-pressure pipelines.
Work in these directions, which at the present time remain predominant and
determining, aids in the reduction of construction time and the lowering _
of construction costs for TES's anc~ AES's, in the conservation of material
resources and aids in the increase of operating efficiency on the part of =
installation workers and laborers at auxil~ary boiler equipment and pipe-
line plants.
The Institute constantly seeks new methods to increase the efficiency of -
equipment installation at TES's and AES's. The institute's sectians
are participating in the work of the chief designer at the very earliest
stage of TES and AES planning, including development of the general con-
struction plan, the composition of equipment in the main building and the -
selection of lifting devices. Thanks to such cooperation, a basis is being
created for the application of progressive installation technology and ~he
complex mechanization of rigging and assembly operations.
The introduction of the Institute's proposals makes it possible to reduce
the volume of work and the cost of construction, thanks to a more efficient _
- distribution of primary and auxiliary equipment. For example, according to -
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- a proposal from the Institute's Khar'kov affiliate for the standardization
of machine-room layouts, the positioing height of the crane rails and,
correspondingly, the height of ~he machine rooms were reduced by one meter ~
at the machine rooms of the Berezovskaya GRES-1 and the Perm and Chigirin
GRES's. These stations have power units of 800 MW capacity. In addition, _
the layout of the boiler works' rPar section was changed. ihis made it =
possible to introduce a standardized scheme for the mechanization of the
equipment installation. The application of this proposal for each of the =
18 boilers at the three GRES's will insure a reduction of the labor expen-
diture by 1,800 man-days and of the construction time by two months. The _
realization of a proposal from this very same affiliate for improving the _
layQUt of the TPP-312A boiler unit at the Zuyevka GRES-2 will allow us to _
save 250 tons of inetal on the boiler and to reduce labor expenditures on -
the installation by 1,400 man-days.
The work of the chief designers and installation engineers during the
designing of an AES acquires particularly great significance, since the
installation of equipment in isolation cubicles is associated with great
difficulties and requires great expenditures of labor. For example, the
development by the Institute of an efficient distribution of primary
equipment in the air-tight portion of the rea~tor room in the AES's _
- ~necial building (holding a commercial VVER-1000 reactor) makes it pos-
sible to conduct the installation of heavy equipment "right off the -
wheels (they plan to install special elevating mechanisms in the isola-
tion cubicles). It has become possible to reduce the labor expenditures
by 79,000 man-days and the cost of construction by two million rubles.
~ The Institute is taking part in work on standardizing AES design decisions, _
in particuiar, on developing a design for a corr~nercial atomic power station
- with VVER-1000 reactors, a design which will be used during construction of
the Zaporozhskaya, Volgodonsk, Khme1'nitskaya and other AES's.
In the process of work ~~n improving d~sign solutions for AES's with VVER- ~
_ 1000 reactors, reactors far which the Gidroproyekt Institute is developing
- a standardized design, the construction and layout of the emergency local- -
izing basin has been changed. This will make it possible to decrease the
construction cost by 200,000 rubles.
- The chief designers and affiliates of the Energomontazhproyekt Institute
must expand the local worlc on designing power production projects, since
while doing this they achieve not only a reduction in labor consumption
and construction costs, but also a reduction in the construction time. In -
our opinion, it is necessary at this stage of atomic power plant design to
- entrust the technological institutes with the development of a correspond- _
ing division "Organizational Planning of ~onstruction."
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The high level of installation technology and the modular nature of the
primary and auxiliary equipment when delivered has a decisive influence
_ on raising the installation workers' efficiency. Thus, it is very impor-
tant that the installation engineers assist the workers at the Design -
= Bureau's machine constructio~~ plants in creating the design of the main -
units. Work at the institute is being conducted in this direction, but
as of yet it is not extensive enough.
According to contracts with the Ordzhonikidze Plant and the Turbine and -
Boiler Plant, the basic arrangement have been worked out for increasing
the level of installation technology for types P-64-1, P-70, P-67 and 7MP-
501 main b~ilers (1000, 1650, 2650 and 1800 tons per hour, respectively)
and for the high-pressure VPG-600 st~am generator. According to a contract ~
- with the Barnaul Boiler Plant, similar developments have been carried out
on the BKZ-420-140 KS boiler with a fluidized bed and the RKZ~420-140 LPI
boi~er with vortical stoki~g.
Work on inGreasing the technological level of the TPE-214 SKhL boiler for
the Neryungrinskaya GRES has been carried out in conjunction with the
Turbine and Boiler Plant. This work has allowed us to bring the amount of
modular installation work up to 90 percent and to decrease the labor expen-
~ diture by ~000 man-days. Designs for the reactor supports were developed -
by the Institute when agreement was reached on the technical ~iesign for
_ the corr~nercial variant of the V'JER-1000 reactor's steam generating equip- -
~ ment. The standardized "dry shielding" design that had been proposed
allows us to carry out all assembly, welding and quality-control opera- -
tion~ ~nder plant conditions.
Relating to the number of basic proposals for the RBMK-1000 reactor are: -
the elimination of installation mounts on the upper and lower plates of
the biological shielding; the elimination of 16 installation man-holes on
- the upper plate of the additional, secondary shielding; and the delivery
of the reactor shell, expansion joints, the annular tank for the secondary _
shielding and the shield cylinders in consolidated modules. The intro-
duction of these proposals will permit us to reduce the labor expenditures
by 10,000 man-da,ys on one power unit alone. This testifies to th~ fact that
the Institute's work with the design bureaus and the plants tha� manufac-
ture AES equiprnent must be expanded. In particular, the Institute must
take part in approving the technical requirements for the delivery o#'
equipment.
- The Institute's specialists are working in close contact with the design
bureaus of the power equipment construction plants and are achieving reali-
zation of these proposals at the earliest stages.
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- The USSR Minenergo can render consid~rable scientific-technical advice at ~
the same time. In the section of construction and installation operations `
the Scientific-Technical Council must examine equipment designs from the
standpoint of increasing the degree to which they are ready for installa-
tion and must also solve the problem of setting a limit for the execution
- of projects with the Minenergomash. It is expedient that Minenergomash, -
together with the USSR Minenergo, develops new All-Union Standards for the
delivery of equipment. _
- The sy5tematic work of the Institute toward improving the design and stand-
ardization of auxiliary boiler equipment and low-pressure pipelines manu-
factured by plants of the Teploenergooborudivaniye trust, aids in reducing _
the metal expended on their manufacture and the labor expended on their "
- installation.
In 1979 planning was carried out for standardized mounts and suspension _
supports for dust and gas flues and low-pressure pipelines. Drawings
and Al?-Union Standards were developed for reservoirs at thermal zlectric
_ power plants. We have begun developing drawing for standardized stainless
steel reservoirs for AES's.
A new design for lenticular expansion elements for pipelines with a short- -
~ned lens allows us to significantly expand their application by raising
the pressure from 0.6 to 1.6 megapascals. The creation of partially
~ re'lieved lenticular expansion elements makes it possible to reduce thrust _
force on ~Lhe mounts by a factor of Z.
A great economic impact is provided by work done b,y the Institute on per-
fecting and standardizi~g the grouping of auxiliary equipment and the , _
boilers' dust and gas flues.
Proposals to improve the grouping and the design of the gaslines for the
_ TGP1P-1202 boiler at the 1200 MW power unit of the Kostroma GRES have guar-
_ anteed an 800 ton savings in metal expended.
The introduction of standardized groupings of the auxiliary boiler equip~
ment of the type TGME-464, TGME-454, TPE-208, BKZ-420-140 PT-2 main
- boilers and the KUGM-1 00 water-heating boiler provides a savings of labor
and metal expenditures. For example, the standardized grouping of tf~e -
TPE-208 boilers (for the Shaturskaya, Cherepovetskaya, Smolensk and~~ _
- Pechora GRES's) and the TGM-96/B's (far the Severnaya, Riga, Kishinev,
Nizhnekamsk and Saransk TET's) a7lows us to reduce meta1 consumption in the
gas flues by 55 and 82 tons per boiler, respective~y.
7hanks to the development of a single set ;,r v~orking drawings for 75 to 80
percent of the gas flues at the Penza, Saransk, Severodvinskaya and Orlov _
TETS's, the savings in metal for each boiler, on the average, amounts to 60
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tons. These drawings will also be used ~uring the construction of
several other TETS's. ~
The adoption of seven ~tandardized auxiliary boiler arrangements for 93 -
boilers at 43 electric power statio~s put into service during the current
- Five-Year Plan will permit us to save 4,300 tons of inetal and reduce labor
expenditures by 15,300 man-days.
= Working drawings for dust and gas flues that were done for the TETS's ZIGP1 =
[further expansion not provided] have been adopted at eight electric power
- stations. _
Instead of right-angle gas flues of large cross-section, round rolled flues
are now universally employed, which make it possible to reduce ~he metal
expended by 20 to 40 percent and the labor expenditure by 35.
_ Research work is being conducted on replacing the lenticular metal expan-
sion elements with flexible expansi~n elements made from fireproof fabric.
Calculations during planning of the auxiliary boiler equipment are carried
_ out on a computer. -
The greatest reserves f~~� ;ncreasing the efficiency with which the instal-
lation operations are perfo,rmed are revealed during development of POS's
~ and PPR's [further expansiori not provided].
During development of installation technology for the TGMP-1202 boiler of
the Kostroma GRES's 1200 MW power unit, the following progressive solutions
were accepted: the assembly and installation of bracing beams were done in
stacks along the entire wall of the furnace or convection shaft; the placing
of the maximum number of modules in their design locations without the use
_ of temporary suspension devices; the construction of through-ways in the
covers of tfie deaQrating stacks in order to deliver equipment and conduits -
to all designated spots with the aid of a lifting crane. The introduction -
of these solutions will allow us to reduce the labor expenditure by 200,000
man-days and reduce the metal expended in the manufacture of installation
devices by 600 tons.
Besides this, we have worked out the technical documentati~~ for assembly
of the K-1200-240, K-1030-65/1500, T-175/210-i30 and K-500-130 turbines
using an optical method. Technology has been developed for checking the
axial and vertical alignment of the 'JVER-1000's rea~tor channels by the
- optical method, as well as technology for the construction of instruments
and devices used to carry out :hese operations.
A significant economic impact is achieved during organizational planning
of the thermal equipment installation operations at AES's. In only the -
last few years ~vork expenditures have been reduced by 190,000 man-days and
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~
~ -
� the cost of construction by 726,000 �~ubles as a result of improving organ- .
izational work at the Kursk, Chernobyl'skaya, Smolensk and Southern Ukraine
= AES's.
- Thanks to the introduction of the more refined technology suggested by the -
- Institute, thc: periods of installation of equipment in the reactor sections ,
of the Chernobyl'skaya and Southern Ukraine AES's were reduced by 90 and 25
~ days, respectively; the labor expenditures at both AES's were decreased by
more than 20,000 man-days; and the cost of construction was lowered by
70,000 rubles.
_ Particu~arly indicative are the results from the development of installa-
tion technology at the No. 2 power unit of the Chernobyl'skaya AES. Thanks
to the introduction of new technology (a considerable portion of the opera-
tions dnne in the reactor shaft is transferred to a shop where further
assembly is performed) the installation of equipment in the reactor section
- was carried out in seven months, as opposed to the twelve required when .
using the old technology, and tt~e power unit was put inta operation within
the established period of time. Labor expenditures on the installation of
equipment at the No. 2 power unit of the Chernobyl'skaya AES have been con-
siderably reduced in comparison with similar indicators attained during
;,onstruct'on at the No. 1 power unit. On the basis of the experience
~ acquired, we expect to reduce labor expenditures on the installation of _
t"e No. 3 power unit of the Kursk AES by 104,000 man-days in comparison
with the installation of the first unit.
= Although the Institute pays sufficient attention to the development of
equipment installation techn~logy for the reactor and the reactor compart-
ment, questions about the organization and execution of installation work -
on the auxiliary boiler equipment and pipelines, as well as about the
- execution of installation operations in the auxiliary shops, for the time
being are ~ncompassed only to an inadequate degree. This, in particular,
can explain why iabor expenditures for mounting the equipment at an AES
equipped with the RBMK-1000 reactor are three times higher than at a TES
and one and a half to two times higher when equipped with the VVER-440
and UVER-1000 reactors.
A series of authors' reviews and working designs, created by the Institute
for large-scale power plant construction projects, renders ope~~ational
assistance in solving questions that arise in the course of installation
work.
4Jork is being done on standardizing the devices used in the assembly and
installation of thermomechanical equipment, with the goal of organizing
i:heir manufacture at tne plants, their repeated use and a decrease in the _
metal expended in their production.
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~
= Great attention is being paid to improving the technology of welding and
heat treating. We have introduced the technology for automatic welding,
- done under a layer of flux with a metal cover, for consolidating the
- upper and lower slabs of the biological shielding of the RBMK-1000 reactor
of the Smolensk AES. Technology has been devploped for the mechanized
plasma-arc welding of thin-gauge stainless steel structures, as well as a -
design for the plasmatron and a follow-up system along the depth of the
weld. On the basis of investigations carried out by thp Institute, a
decision has been adopted to eliminate the heat-treating of weld joints
on pipes made from 12Kh1MF steel with diameters of up to 219 mn and wall
thicknesses of up to 18 tt~;~, This provides a savings of about 100,000
rubles per yPar. _
New brands of electrodes have been developed for welding austenitic steel. -
We have developed a heat-treat process for welds on tubing made from
_ 12Kh1MF steel that allows us to reduce the duration of the process by a -
factor of 2 or 3 times. We have also devised a method of heat-treating
weld joints in the stainless steel pipes in operation in BN-600 liquid-
metal heat-transfer reactors. The introduction of this method makes it
possible to obtain a practically non-oxidized inner pipe surface, decrease~
the expenditure of shielding gas and reduce the time needed to accomplish
heat-treating.
The accelerated development of atomic power demands an improvement in
= engineering training, the organization of the operations, the installation
technology and the AES welding equipment.
- The standard time frames for submitting dPSign-estimate documentation and
providing metal and pipes to the Teplenergooborudivaniye trust's factories
_ for the manufacture of pipelines and non-standard equipment (NSO) have
become obsolete. Besides this, they were designed to be applied at TES's.
The Institute has determined the optimal time frames for the construction
- of VVER- and RBMK-equipped AES's and the delivery of equipment to them.
- This should contribute to the development of the optimal sequence for
de2ivery of equipment, pipelines and non-standard equipment, as well as
the sequence of execution for construction and installat2on operations. -
Because of this, it will be feasible to carry out a gradual sequence of
equipment installation. This is particularly important during the instal-
_ lation of equipment within isolation chambers.
A great impact is had by the combination of construction and installation '
operations. This makes it possible to use the construction organization's
, hoisting mechanisms for the set-up of large-scale equipment.
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- It is expedient to develop a plan for standardized AES production bases and
to determine a schedule of temporary structures, their dimensions and
_ designs.
- Since the number of installation workers reaches more than 2,000 men during
the one to one and a half years needed to ~onstruct a large-scale AES an~
~ put it into service, it is necessary to crea~e a clear-cut administrative
structure for the thermal equipment installatic;n workers. i
It is necessary to direct great attention to the training of the personnel
who will install the first units. The installation ~~rganizations are
obligated to develop corresponding measures, utilizing experience derived
from installing similar equipment at other electric power stations. The
engineering and technical personnel should study in advance the design
documentation and the guide-line and instruct~onal materials. -
Immediately after approving the technical design of an AES, it is necessary
= to develop a master network schedule, including times for submitting tech- ~
nical documentation, the construction section's readiness for installation,
_ the delivery of equipment and materials, the meeting of requirements for
ho~isting and installation mechanisms, etc. -
The most important tasks for the Institute and the installation organiza-
- tions in the area of improving the technology of TES installation equip-
ment in the period up to 1985 are: _
1. The introduction of a high-speed continuous production method af instal- _
lation with the execution of the pre-insta1lation operations on the RPKB
at the Ekibastuz GRES complex. The technology for pre-installation prepar-
ation of the RPKB's 500 MW power unit equipment with the f'-57 boilers, as =
we~1 as the technology for the continuous production of this equipment, was
developed by the Institute's eastern affiliate in 1977-1978. They took
into account the installation experience acquired frpm setting up similar
- equipment at the Troitskaya and Reftinskaya GRES's. However, du~ to a lag
in RPKB construc~ion, the pre-installation preparation and the installation
of the equipment for the first power units are being conducted by tradi-
tional methods. The main task consists of intraducing new methods of per-
forming operations on the third and fourth power units and of making a -
- complete changeover to industrial methods of performir~!~ the operations at
the RPKB, as well as a changeover to a rhythmic installation.
By the beginning of the equipment installation at the GRES-2 it will be
necessary to develop designs for transport methods, as well as the technol-
ogy for delivering and conveying large-scale units to the installation
zone by means of specialized mo~or transports. Since a significant portion -
of the equipment and rigging at the Ekibastuz RPKB was planned firs~, the
construction and arrangement of this equipment will demand finishing.
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2. The development and introduction of technology for continuous produc-
tion operations upon installation of equipment at the Berezovskaya GRES-1
and consequent GRES's of the Kansko-Achinskiy Thermal and Electric Power
Complex with pre-installation preparation at an RPKB. At the~e GRES's, ~
new-type (P-67) ~oilers will be mounted. These suspended, dense-gas boilers
with a 2650 ton per hour steam-generating capacity, in connection with the
properties of the fuel used, differ in dimensions and mass from the TGMP-
- 204 boilers. For example, the mass of the P-67 boiler is more than twice
that of the TGMP-204 boiler. Correspondingly, the volume and complexity
of the operations increase.
3. The development and introduction of technology for the installation of _
= equipment at GRES's with 500-800 MW power units (Pribalkhashskaya, Perm, -
Chigirin, Surgut-II and others). During work on these projects we will use
_ installation experience derived from similar equi{ment at the Zaporozh'ye, -
Uglegorskaya and Ekibastuz GRES's. Most of the design solutions will be -
_ standardized, based upon the Perm and Chigirin GRES's, both of which were
supplied with the same type of equipment, while others will be standardized
after taking into account design solutions at the Berezovskaya GRES.
It is necessary to note that the Institute is insufficiently occupied with
questions of perfecting the organization and technology of the installation
_ of equipment in the subsidiary shops and the organization of subsidiary
operations (such as transportation, equipment servicing and the management
of the tool shops), although the consumption of labor there is comparable
to that in the primary operations.
In order for the Institute to devote greater attention to the development
of production planning operations for large-scale projects, it is necessary -
- to free it completely from the development of production planning operations -
on actuating and water-heating boiler projects and on boilers of the DKUR
[further expansion not provided~, having obiliged the installation workers
- to follow the frequently employed plans that had been developed by the
Institute for similar projects.
It is impossible to solve the problem of increasing efficiency without the
development of high-output methods for mechanizing the installation and
welding operations. The Institute has done little in this direction. Plans _
have been cr~ated for more than 100 mechanisms and devices. However, only
20 have been put into commercial production, which can be explained basi-
_ cally by the absence of an experimental production base for the Institute -
_ and of manufacturing plants for commercial equipment, and by a deficient
_ supply of component items. Working drawings have been produced for a bank
of machines used in the complex mechanization of the process in which pipe-
lines are installed within the turbine condensors; for standard~zed, auto-
- matic welding machines, type ATM, for austenitic steel pipes of 57-108 mm
diameters ~nd automatic machines, type APC, ror welding the bellows into _
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the circuit of the RBMK-1000 reactor channel; for the ASTN-1000 and F,STU-1
aut~matic machines which weld non-rotating joints on pipes with a 850 mm
diameter main cross-section, made of plated steel; for 3 machine tool to
work the ends of 159-273 mm diameter stainless steel pipes, etG. -
- Considerable work is being done on designing lifting cranes for the instal-
lation of equipment. Unqiue cranes have been built: a E4~-ton capacity
gantry crane for the installation of inetal structures for AES's, a 2 x 100
ton capacity overhead crane with a 110-meter lift for the installation of
sus~~nded boilers, etc. They have standardized gantry and semi-gantry ,
- cranes, set up within the main TES building, and they are planning for the -
replacement of the 70 type sizes for cranes with 4 type sizes in 8 con-
figurations. Plans have been developed for freight slings which make it
possible for overhead cranes to lift equipment possessing masses consid-
erably (up to 50 percent) exceeding the lifting capacity of the cranes.
- This makes it possible to reduce the mass of the metal structures in the .
main TES bui~ding. _
As a conseqiie~ce of specializing the designs of AES equipment, a consider-
able portion of the installation mechanisms, devices and mechanized tools
- used at TES's can not be employed at atomic power plants. Thus, the
Institute has specially developed equipment for welding and installation -
operations at AES's. They have put into production machines for adjusting _
The metal structures of the RBMK-1000 reactor; for dressing weld seams on
= the channels and for cutting the edges of the facing plates; mechanisms
for finishing weld seams and for the removal of defective seam sections;
mechanisms for welding the channels to the networks and the metal struc-
tures; and installation for austentizing cold bends in the pipes, etc. The
economic impact from the introduction of these mechanisms comprises about
300,000 rubles.
- In order to reduce the time needed for designing, manufacturing and putting -
- into production examples of new installation and welding equipment, it is
necessary to create at the Institute an experimental production base and
improve the supply of its component items, as well as to set aside a -
specialized plant at Glavtep~oenergomontazh for the production of these �
installation devices only and to solve the problem of manufacturing control
_ equipment.
'The further expansion and deepening of projects by the Energomontazhproyekt
Institute in the directions mentioned will contribute to a significant
increasQ in the ef-ficiency ofi TES and AES equipment installation. _
COPYRIGHT: Izdatel'stvo "Energiya," "Energeticheskoye Stroitel'stvo," 1979.
- 9512
CSO: 1822
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ELECTRIC POWER AND POWER EQUIPMENT
UDC 621.311.25:621.039
' IMPP.OVING THE METHODS OF AES EQUIPMENT INSTALLATION
Moscow ENERGETICHESKOYE STROITEL'STVO in Russian No 11, Nov 79 pp 11-13 ~
(Article by Engine~rs A. M. Gusinskiy and M. Ya. Khizhin] -
- [Text] The rapid development of nuclear power engineering is a most impor-
tant condition for raising the technical and economic level of the country's
entire power production economy. _
At the present time, the consumption of labor and time required t~ put power
- units into service at AES's are inferior to similar indicators achieved
_ during construction of TES's. For example, the unit labor expenditure on
equipment installation at AES's using RBh1K-1000 reactors c~mprises, on the
average, 0.8 to 0.9 man-days per 1 kW of designed power, and the duration
of the AES's power unit installation with assembly of the RBMK-1000 reac-
tor's metal components is equal to 2 to 2.5 years, while the installation
of an 800 MW power unit at a TES is carried out in the course of 9 ta 10
months.
- The most important task governing the improvement of AES construction in the -
near future is reducing by a factor of two the unit labor expenditures for
- thermal equipment installation operations in comF~:irison with labor expen-
- ditures for the ir~.stallatian of the No. 2 power unit at the Chernobyl'skaya
AES, where they comprised 6 man-hrs/kW.
In order to achieve this goal, the following basic methods have been
projected:
_ 1. A reduction in metal consumption for equipment, metal components and _
pipes. The Energomontazhproyekt Institute, along with electric power
- station chief designers, is conducting work on improving equipment layout
decisions and designs for separate assemblies. The in~roduction of the
Institute's proposal for changing the design of the steam distribution
pipeline assembly,of the RBMK-100Q reactor's system for breakdown contain-
ment made it possi;le to reduce metal consumption in the assembly (by 114
tons per po~er unit) and labor consumption during installation. A new -
solution for lining'the pipe runs at the Smolensk~ Chernobyl'skaya and
Kursk AES's made it possible to considerably reduce metal consumption in
the pipes and to decrease the amount of work on adjusting and cutting pipes _
- and then facing them,
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2. Providing for the dplivery of large-size component modu~les ~rom the _
plants. During development of the working documentation, s~ecialists from
_ the Institute disassemb7e the equipment into delivery and installation _
modules. This is done in order to insure component module delivery of
equipment within the limits of railroad dimens~ons and takes into account
the fact that the equipment will be insta?led by industrial methods. Such
work was conducted, in part, during planning of the metal components for
the service platforms and the pipelines.
a 3. Improving the methods of inst~llation for primary and auxiliary :.,quip- ~
ment. Equipment developers, as a rule, when designing equipment and study-
ing the basic solutions to questions of maintenance and repair, do not
devote enough attention to the methods of installation. Experience shows
~that the participation of installation technicians in the design of equip-
ment provides positive results. The development of the boilers and pipe-
lines for thermal electric power stations and the design of equipment for
AES's can serve as examples of this. For example, altering the sling =
as~embly of the biological shielding's upper tank according to the ~
_ Energomontazhproyekt Institute's proposal made it possible to raise con-
siderably the level of installation modularity in the RBMK-1000 reactor's
metal components and to carry out test fitting. Because of this, instal-
lation time was reduced by more than two months. Proposals were also -
uevelo~ecl for improving the ir~stallation methods for all uf' the reactor's -
_ equ~ipment. All of this testifies to the necessity of legitimizing the
participation of a specialized institute in the development of electric
power station and equipment designs.
4. The organization of efficient schemes to deliver equipment to the
_ installation zone and the organization of inechanized methods of opera-
tion. This task must be solved jointly with the Atomenergostroyproyekt
Insi:itute, since construction operations and the installation of equip- _
ment at AES's are conducted concurt^ently. One must devote attention to
_ the sequence in which the operations are carried out, taking into account
the organization of the ordered irstallation and mounting of large-scale
equipment in the design locations, and using the builders' lifting machin-
_ ery while the construction operations are being conducted.
- 5. Carrying out installation and welding operations with high-efficiency
_ equipment. During constructi0n of the Chernobyl'skaya AES the Institute ~
developed and introduced devices for assembly of the reactor's metal com-
ponents, for dressing seams on the welded channels and for removing defec-
tive metal, etc., from them. The reduction in labor expenditures due to
the introduction of these mechanisms amounts to tens of thousands of man-
days. However, there are stsll many other processes amenable to mechaniza- -
tion. It is also necessary to solve the problem of a production base for
the manufacture of experimental models of this equipment and their limited
production.
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Specifications for the instailation of equipment at atomic electric power
- stations are dependent upon the increased demands for cleanliness and
quality in carrying out the operations. The presence of isolation chambers
in closed areas in which equipment, including large-scale equipment, is
arranged creates additional d~fficulties during the organization and
execution of operations at AES's.
In order to increase the efficiency of installation operations the Institute
has devel~ped:
flow charts for the installation of the basic equipment and pipelines in the
- forced recirculation, live steam and feed-water circuits;
equipment delivery routes and hoist layouts;
schemes for the location of throughways and their dimensions, as well as
schemes for the location of mounting components for the installation of
equipment in isolation chamber and in closed areas;
_ a scheme for organizing the unloading of heavy equipment for pre-
installation preparation and its subsequent delivery to the installation
zone.
Energomontazhproyekt, in conjunction with the Gidroproyekt Institute, used
common standard pipeline components and utilized sharply bent and curved
elbows, made with the help of high-frequency currents, during development
~ of the working drawings for pipelines at the Kursk, Smolensk and
Chernobyl'skaya AES's. This made it possible to reduce considerably the
amount of welding and quality-control work. A reduction in component
nomenclature made it possible to insure the industrialization of their
manufacture.
The development of a plan for the ins~allation of large-scale modular equip-
ment in the RBP1K-1000 unit's emergency containment system merits attention.
The system's equipment contains a great many modules for the steam distri-
bution pipes (BPT's). The method of installing the steam distribution pipes
in the slabs with subsequent concreting through a hole in the casing did not
allow for conducting the installation in the modular method. Changing the
mounting assembly of the steam distribution pipe on the suggestion of the
Institute made it possible to accomplish the assembly of the pipes and the
_ covering plates in consolidated modules on the assembly platform. Con-
- creting of the inter-plate gap is accomplished when it is tilted through
_ 180 degress in the consolidation process. A special tilting mechanism was
specially developed to turn the module over.
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_ The introduction of a new method for installing the emergency containment
system equipment at the Chernobyl'skaya AES made it possible to reduce the
number of hoisting operations from 680 to 150, save 114 tons of inetal,
eliminate manual labor in the delivery of 450 cubic meters of concrete and
decrease considerably the amount of work in welding end caps.
In order to organize the large-scale modular installation of equipment in
the emergency containment shaft of the No. 1 power unit at the Rovenskaya
AES, the Energomontazhproyekt In~titute changed the design of the tower's
diffuser assembly. In the preventative maintenance schedule that was
developed, the Institute provided for the following installation method
for this equipment: assembly of the mounted and supported tanks, cover
plates, bottom pla tes, dome sections, service platforms and other com-
ponents in modular form up to 27 tons is done on special stands; these
modules are then delivered to the shaft; and they are completely assembled
- on an installation truss in sections of up to 70 tons mass, hoisted and
installed in sections in their operational position. The introduction of
- this method insures a 4000 man-day reduction in the labor expenditure.
The arganization of AES equipment installation op.erations requires one to
con~uct engineering training, including the participation of the
Energamontazhproy ekt Institute in the development of the following
schedule: the delivery of technical documentation by the chief designer;
a concurrent execution of construction and installation operations that
takes into account the utilization of construction cranes for the instal-
- lation of thermomechanical equipment in isolation chambers and closed com-
partments; the manufacture and delivery of equipment and pipeline; and a
master schedule for the installation of thermomechanical equipment that
= is linked to the time of delivery of such equipment and material support.
The work of the institute with the manufacturing plants makes it possible
- to improve the feasibility of installation and the modular delivery of the
equipment. At the present time, the equipment that arrives at the project
_ site often makes it necessary for the installation organizations to do the
finishing work in place. It is necessary to make it legal to draw the
- Institute into pa rticipation in the development of new AES equipment at
the technical design stage, and also into thQ approval of the technical
specifications for its delivery, as was done with the TES's.
During the last few years, the Energomontazhproyekt Institute has made a
great contribution to the development of installation methods at AES's
equipped with RBMK-1000 reactors.
At the Kursk AES they carried out the assembly and installation of the
reac~tor's metal components with the help of a three-flight scaffold mounted
at the end of the reactor compartment. The scaffold had built-in temporary
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work enclosures and two 320-ton capacity cranes mc~unted on it. Such a lay-
out had shortcomings right along with its merits--it was necessary to dis-
assemble and again set up the scaffold with the temporary work enclosures
and the cranes at the next unit. In connection with this, the Institute
proposed carrying out the installation of the reactor's metal components
in a three-section shop for consolidated assembly (the temporary work
encloses), erected in zone of the No. 2 power unit outside of the main
building. For the assembly, manipulation, transportation and installation
of the metal structure the Institute developed the special KP-640 gantry
crane with a 640 ton lifting capacity. The chief virtue of the new arrange-
ment is the fact that the assembly of the reactor's metal components is not
dependent upon the state of readiness of the reactor compartment's construc-
tion section. Besides this, it has become possible, owing to the presence -
of a crane, to unload heavyweight equipment and mount the separators and
the collectors. The introduction of this scheme during the installation of
the two units in the I line of the Chernobyl'skaya AES had an economic
impact to the sum of more than 800,000 rubles.
Particular attention was devoted to improvement of inethods of assembly,
welding and installation of the equipment for the reactor compartment. In
the flow charts prepared by the Institute, they provided for the execution
_ of the maximum number of operations in the combined-assembly and
_ pre-installation work shop, and also on the assembly and consolidation
_ platforms through the use of automated welding and the appiication of a
- sufficient number of devices. This made it possible to consolidate the
reactor's metal components into six installation modules and to conduct a
test assembly before their installation at the No. 2 power unit of the
Chernobyl'skaya AES. As a result, the reactor's metal components were -
mounted in 15 days (whereas three mont!;s were spent in carrying out this
work using the old method). Besides this, the accamplishment of final _
consolidation and test fitting in the temporary work shelters made it
possible ta erect the reactor's metal components before the installation
of the graphite masonry in 57 days (instead of 128 with the old method).
~ For the No. 2 power unit at the Chernobyl'skaya AES, the Institute has also
developed a method for installing the graphite masonry that provides for
the max:mal mechanization of the work. All operations are done with the
- help oi` special equipment and devices. As a result labor expenditures for
the installation of the masonry have been reduced by 1,150 man-days and
the duration of the work by 10 days.
At the same power unit they introduced a more refined method for the instal-
lation of st~am communications and for group installation of the technol-
ogical channels. Pipelines for the steam communications were collected and
_ installed in half rows. Technological channels were installed in twos and
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fours with the application of a special cross piece, which mad~ it pas-
- sible to reduce the time needed to carry out the operations along the
eritical route.
Due to the introduction of progressive methods, a considerable reduction in
the duration of the installation work, an increase in its quality and a _
- reduction in labor consumption has been guaranteed. Far example, the unit -
labor expenditures during installation of the second power units at the
Kursk and Chernobyl'skaya AES's were 27 percent lower than similar indi-
cator's attained during construction of the first units.
For the Novovoronezhskaya AES's power unit with the VVER-1000 reactor, the
Institute developed progressive design solutions for the organization of
the operations and a method for installing the units primary equipment.
These were directed at reducing labar expenditures and the time needed to
~ perform the operations. For example, in order to avoid delays w"en carry-
ing out operations in the reactor shaft, they provided for the assemb3y of
the reactor's upper unit in the inspection shaft with preliminary consol-
- idation of the assemblies on the assembly platform. This was done in the
fl~~w chart for the installation of the upper unit. In the flow chart for
the installation of the PGV-1000 steam generators they provided a scheme
- for the installation which allowed them to essentially reduce the instal-
lation gaps. Because of this, the time needed to carry out the construc-
tion and installation work is significantly reduced.
The Institute has also created highly efficient means for small-scale mech-
- aniza tion of assembly and installation operations: machines for adjustment
of the reactor's metal components, for dressing weld seams and for cutting
the facing plates; a device for removing defective welds; an assembly for -
- austenizing pipe bends, etc. '
The majority of progressive design solutions developed by the Institute for
- AES's have been carried out on a new level of engineering. The economic
impact from the introduction of only these operations comes to more than
a million rubles per year.
~ At the present time work is continuing on improving the organization of _
- installation operations and the methods of installing AES equipr~ent.
- When drawing up flow charts for the installation of auxiliary reactor _
equipment, pipelines, metal components, machine hall equipment and the _
- deaerator stages, particular attention is devoted to the development of _
flow charts for the combined installation of equipment and pipelines in _
isola tion chambers and sealed compartments. These charts are to contain
the formulation of the assembly records and the establishment of an instal-
~ lation sequence. This will make it possible to group the equipment, pipe-
lines and metal components for each isolation chamber and install them
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together. Such an organization of operations eliminate the necessity of
returni~g to mount the equipnient in the same isolation chamber. -
For the second lines at the Kursk and Chernobyl'skaya AES's, measures have
been drawn up which are directed at insuring that the units are put into
service within the times established by the directives. These measures
provide for the careful development ef engineering preparation in produc- _
tion; for the development of both operational organization and methods of
assembly, installation, welding and quality control of equipment; for the '
improvement of design and structural solutions; and for the creation and
- introduction of new machinery. The introduction of these measures will
allow us to reduce labor expenditures on the installation of mounted power
units by 25 percent in comparison with the ~~abor expenditures on the first =
power units.
This accumulated experience and the standardization of design solutions for
_ one type of power station create the prerequisites for the creation of .
- technical documentation for a repeat application (particularly the flow -
' charts).
During development of the technical documentation for equipment at com-
~ mercial AES's with reactors of 1000 P1W, 1500 MW and greater capacities,
- it is necessary, when taking into account the growing requirements for
qu~~ity installation, that one uses the experience accumula~ed an~+ seeks _
- out new methods for improving the orga~ization of ~the installation opera-
tions and the methods of installing the equipment and th~ pipelines.
COPYRIGHT: Izdatel'stvo "Energiya," "Energeticheskoye stroitel'stvo,"
_ 1979.
9512
CS0:1822
- 2; =
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- F.LCCTRTC POWER AND POWER EQ UIPMENT
- UDC 621.31.002.2
~RGANIZATION OF ELECTRIC-POWER SUPPLIES FOR GES
Moscaw ENERGETICHESKOYE STROITEL'STVO in Russian No 11, Nov 79 pp 41-43
[Article by Engineer I. E. Veyts: "Efficient Organization of Electric-
Power Supplies to GES Construction Platforms"] -
[Text;] During the erection of laxge-scale hydraulic
developments, manSr modern construction methods and means
of inechanization are used, including such power-consumptive ~
construction mechanisms as powerful excavators, dredges~ etc.
= A considerable portion of the electric energy is consumed by -
construction bases alongside the project, by the builders' -
- set~tlemen ~s and during the development of the excavations . -
The maximum power load during the construction of large- -
= scale hydraulic developmerts sometimes amounts to 20-30,000
kW. At the same time, the electric power consumption of the
construction base in the period of its full development
reaches 25-28 percent of the total electric load, and in the
case of utilizing the dredges for erecting the main struc-
tures, the loads can increase by a factor of 1.5 to 2.
' .During construction of the Volzhskaya GES's imeni V. I. Lenin
and imeni CPSU 22nd Congress, the electric load of only the - -
- dredges r,omprised 38,000 and 20,000 kW, respectively.
The estimated electric power of the hydraulic mechanization
facilities for the type of alluvium in the Boguchanskaya -
= GES's earthen dam would come to 50,000 kW.
During the construction of isolated projects in areas having -
severe climatic conditions, electric heating for the produc-
tion and the housing areas, as well as electric heating for
carrying out particular types of work, are brought about by
special authorization. In this case, the loads from ~he -
- electric heating alone can reach tens of thousands of kilo-
- watts. For example, the maximum power consumption at the
construction sites of the Ust'-Ilimskaya and Boguchanskaya
GES's, where electric heating is used, reac:hes 250,000 kW.
In determining the electric loads, we isolate those -
~ responsible consumers for whom a disruption in the electric
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power supply is not permitted (water drainage and boiler
systems and illumination of the foundation pits) and corisum-
- ers that are seasonal in nature (hydraulic mechanization =
� facilities, electric heating).
Particular attention is devoted by desig~ers and builders to
the preparatory period, at which time the pioneer production
base is built and the primary electric lines are run in.
At this time, construction loads are comparatively light.
It should be noted that the necessary attention is not always -
devoted to questions of the elec~ric supply in the preparato-
ry period. In these cases, the running in of the electric
. lines, particularly during construction of projects removed
- from the power system, lags behind the pace of construction
operations. This leads to an increase in the normal period
of construction. For example, the first link of a 220 kV
high-tznsion power line-- a 250 km section to supply electric ~
power to the construction site of the Boguchanskaya GES--
has been under construction for four yeaxs. At the Zagorsk
hydro-accumulation elelctric power station, located in the -
- cen ter of the Mosenergo system, the erection of short
approach lines from the 110 kV high-tension electric power
_ line to the construction site's primary step-down substation
- (GPP) required three years.
Millions of rubles
zzo - -
- 100 O romnDHaCmo BA c~nru 6
180 - c sneptocurmenod
!60 ~ ' p /Iyca nepBo~s -
140 f azpe2Qinaa 7 =
120
f0~
80 ~ 2 � 3 , -
60
4p I 4
?0 ~
� ~ 5
1950 S? 54 56 5B 60 6? 64 6b 6B 70 72 74 76 78 BO B?
Years of construction
Fig. 1 ~
_ Utilization of the means of caxrying out construction and
instal~ation work as dependent upon the supply of electric
- power to various projects. 1-Volzhskaya GES imeni 22nd CPSU
- Congress; 2-Bratsk GES; 3-Ust'Ilimskaya GES; 4-Zagorskaya -
GAES; 5- Kayshyadorskaya GAES; 6-Readine.ss of high-tension _
line connections with electric s;,rstem; 7- Commissioning of -
- the first power units. -
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In addition to this, even moie time went inta installation
- of the primary step-down substation, as a result of. which
the transition period from the preparatory to the basic .
stages was prolonged. The extent of the facilities used in
executing the construction and installation operations
depends, to a significaxit degree, upon the feasibility of
supplying electric power to the construction site (fig. 1). . ~
Upon selecting an electric power supply scheme for a project~
- one must take into account the sequential nature of the
- construction's development. -
In the preparatory period, as a rule, on-site sources of _
elPctric power (diesel or gas-turbine electric power plants
of various outputs) are utilized: 4~00 kW/~OOV type-DGU
automated diesel-electric power plant units; type ASD9 power
units of 1000, 1600 and 2000 kW and 6.3 and 10.5 kV capaci-
ties; type ESDA portable diesel electric power plants of 200 -
and ~00 kW/4~OOV capacities; type GTE 1600 and 2500 kU~/6.3 kV
electric power plants on rail cars.
J~~-y'~ : -
= _ - - _ ~ -
~ ~ ~ : \1l. I ` ~ ~ 0 ~ ~ ~ ~ J ~ .I..� � - ~ .
~ - !IIIII~~~.� ~ ' r .J~~:[' r
~ ~ ~ c~