R2.03/03 S (1) Assistance to Diagnostic & Maintenance Operation for VVER Primary Loop - Part B: Maintenance Tools for Primary Loop (Lot 1 and Lot 4)

The present contract was based on a comprehensive project (R2.02/97 – see 30302) programmed in 1997. The purpose of the R2.02/97 project was to provide assistance in diagnostics and maintenance of VVER reactor coolant system (primary circuit loops). A part of the project was procurement and supply of maintenance tools aimed at improving quality of reactor coolant system (RCS) maintenance resulting in:

reduction of number and severity of observed RCS integrity problems
reduction of radiation doses received by maintenance personnel during RCS maintenance
a possible increase of rated power of the VVER-1000 reactor.
The equipment supply was divided in four lots. Equipment Technical Specifications for all the lots were developed within the R2.02/97 project. However, the equipment delivery could not be contracted within the original project, therefore a new equipment supply project R2.03/03 was established in 2003 including all four lots. The tenders for all the lots were opened to public in November 2005 and offers were made for each lot. Three separate contracts were finally concluded for the lots 1+4 (contract 114514), 2 (contract 76777) and 3 (contract 115574).

The general aim of the R2.03/03 project was to deliver to Rosenergoatom a set of modern tools for maintenance and repairs of RCS equipment of the VVER-1000/V320 reactors. This particular contract (114514) was concluded for delivery of the Lot 1 and Lot 4 including

(for the Lot 1) One complete set of cutting and bevelling machines, with associated tools and accessories, suitable for cutting and bevelling pipes in one simultaneous operation, to be delivered to Kalinin NPP as the End User of Lot 1.
(for the Lot 4) one complete, portable machine with associated tools and accessories for machining of steam generator header flanges, and one complete, portable machine with associated tools and accessories for machining reactor coolant pump flange for Volgodonsk NPP as the End User of Lot 4.
Although each piece of equipment was to be delivered to a specific NPP, the equipment was supposed to be available also for the other Rosenergoatom NPPs to take advantage of it. During the warranty period, however, the equipment was to be used solely by the End User.

The contract for the equipment procurement and supply was signed with Gemco International B.V., Netherlands on 15 May 2006. Initially, the contract was concluded for 4 months, but later on, it was extended by 35 months to the total of 39 months expiring on 16 August 2009. Finally, the contract was closed on 4 May 2010. The reason for the substantial contract extension were problems in communication between the involved Russian parties (including the Russian Humanitarian Aid Committee), which delayed the overall customs clearance procedure and hampered delivery of the equipment to the End Users.

According to the TS for the Lot 1, the pipe cutting and bevelling equipment had to be pneumatically operated, portable and fit for two operators, capable to reach the pipe compartment/location and applicable to the required dimensions of the pipes. Remote control operation and possibility of re-surfacing bevels were required. The main function of the equipment has been to cut and bevel pipes of three different dimensions in one simultaneous operation with the face milling for all wall thicknesses. Ability to produce bevel angles up to 45�and perform counter boring were required. The maximum roughness had to be between Ra 3.2 and Ra 6.3. The movement of the cutting tools had to be automatic and adjustable.

The certificate of final acceptance of the set of maintenance tools for cutting and bevelling pipes for Kalinin NPP, including accessories, maintenance toolkit and spare parts in accordance with TS was signed by the supplier, Gemco International B.V., and the recipient, the Concern Rosenergoatom + Kalinin NPP, on 13 July 2009.

According to the TS for the Lot 4, the SG header flange equipment had to be pneumatically operated, portable and fit for two operators, capable to reach the SG compartment/ flange location and applicable to the required dimensions of the flanges. The main function of the SG flange maintenance tool had to be surfacing and groove machining at the SG header flanges while being installed inside the header or on a SG nozzle. The main function of the RCP maintenance tool had to be cutting of the RCP flange sealing surface while being installed inside the RCP casing. The required roughness of the finished surface was between Ra 0.8 and Ra 3.2.

The certificate of final acceptance of the two sets of maintenance tools for machining the SG and RCP flanges for Volgodonsk NPP, including accessories, maintenance toolkit and spare parts in accordance with TS was signed by the supplier, Gemco International B.V., and the recipient, the Concern Rosenergoatom + Volgodonsk NPP, on 7 August 2009.

Conclusions

The contract, however delayed in its implementation, has been successfully completed and has fully met its objectives.