Construction management of Indian pressurized heavy water reactors

Abstract

Pandit Jawaharlal Nehru and Dr. Homi J. Bhabha, the visionary architects of Science and Technology of modern India foresaw the imperative need to establish a firm base for indigenous research and development in the field of nuclear electricity generation. The initial phase has primarily focused on the technology development in a systematic and structured manner, which has resulted in establishment of strong engineering, manufacturing and construction base. The nuclear power program started with the setting up of two units of boiling light water type reactors in 1969 for speedy establishment of nuclear technology, safety culture, and development of operation and maintenance manpower. The main aim at that stage was to demonstrate (to ourselves, and indeed to the rest of the world) that India, inspite of being a developing country, with limited industrial infrastructure and low capacity power grids, could successfully assimilate the high technology involved in the safe and economical operation of nuclear power reactors. The selection of a BWR was in contrast to the pressurized heavy water reactors (PHWR), which was identified as the flagship for the first stage of India's nuclear power program. The long-term program in three stages utilizes large reserves of thorium in the monazite sands of Kerala beaches in the third stage with first stage comprising of series of PHWR type plants with a base of 10,000 MW. India has at present 14 reactors in operation 12 of these being of PHWR type. The performance of operating units of 2720 MW has improved significantly with an overall capacity factor of about 90% in recent times. The construction work on eight reactor units with installed capacity of 3960 MW (two PHWRs of 540 MW each, four PHWRs of 220 MW each and two VVERs of 1000 MW each) is proceeding on a rapid pace with project schedules of less than 5 years from first pour of concrete. This is being achieved through advanced construction technology and management. Present efforts are focused on further reduction of gestation period. This is in contrast to construction period of 7–14 years in the earlier projects with labour intensive construction methods, learning period and indigenisation. The schedule and cost are interrelated and ultimately determine the viability and competitive edge of a project. With rich experience of over 30 years of operation and construction management it is well established that setting up of nuclear power projects in India in 4–5 years is quite feasible because of tremendous developments in construction technology; mechanization, parallel civil works and equipment erection, computerized project monitoring and accounting systems. By considering the best achieved times for the critical path activities of previous and ongoing projects, even a 4-year schedule is achievable. For nuclear power to be competitive it is essential that the gestation period is reduced and the capacity utilization enhanced. Both of these are the goals of the Indian nuclear power program. Presently the overnight cost per kW installed capacity is in the range of US$ 1100–1300 with levellised tariff of 5 c/kWh.