Russia’s AEM-Spetsstal (part of Rosatom’s Mechanical Engineering Division), has begun manufacturing the VVER-TOI reactor for the unit 3 of the Kursk-II NPP. Work is underway at one of the largest automated forging complexes in Europe, where metallurgists are forging a 235-tonne ingot from special steel, from which the reactor vessel shell will be made.
In total, several ingots with a total weight of more than 2,150 tonnes will be cast for the manufacture of VVER-TOI body blanks. The largest ingot will be used to make a metallurgical blank for the shell of the reactor vessel core. This part of the reactor plant in the VVER-TOI design completely eliminates welded joints, unlike other VVER series projects.
“In the VVER-TOI design there are four welds instead of six, so metallurgical blanks have their own characteristics – some of them are larger in size than those that we traditionally make for reactors of the VVER family,” explained AEM-Spetsstal Director Sergei Kuznetsov. “This VVER-TOI is already the third, which means that our competencies and rich experience made it possible to quickly move from manufacturing a lead sample to mass production.”
The VVER-TOI body is made of steel, which retains its properties under prolonged exposure to radiation and high temperatures, making it possible to increase the service life of the main equipment. The VVER-TOI will be able to operate for up to 100 years – after 60 years of operation, it will be possible to extend the service life of the reactor for another 40 years.
“In the VVER-TOI project, we took into account the operating experience of nuclear reactors of previous generations and in some areas received a real technological breakthrough,” said Vladimir Rogov, Head of the Department of Technology, Modes & Circuit Solutions at OKB Gidropress (part of Rosatom). “Reducing the number of welds made it possible to speed up the reactor manufacturing process and facilitate its operation, and, coupled with the use of advanced materials and complex engineering solutions, increase its design service life. A great contribution has also been made to improving the safety of the power unit, including by changing the design of the main circulation pump, a combination of active and passive safety systems.”
Kursk NPP, Alexander Uvakin said construction unit 3 is proceeding according to schedule. “The first concrete has been poured for the base of the reactor building of unit 3. This involved 15,000 cubic metres of concrete and the process is entering the final stage. This year, we will have to install the first tier of the internal containment shell. This is a key construction operation, which the entire team approaches with a high degree of responsibility – everything must be synchronised without wasting working time.”
Kursk-II will replace the currently operating Kursk NPP, which comprises four ageing RBMK reactors (two of which are now closed) with four new units comprising Generation 3+ VVER-TOI reactors. Unit 2 is expected to begin operation in 2027, and the construction and commissioning of units 3&4 are planned for 2042. Unit 1 was connected to the grid in January.
