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San’ao Nuclear Power Plant 1&2, China

 

San’ao Nuclear Power Plant 1&2, China

 
 

Dextra has successfully supplied 340,000 Griptec couplers for the anti-aircraft impact shell construction of the San’ao Nuclear Power Plant units 1 and 2, featuring the advanced HPR1000 Hualong reactors.

Griptec, recognized as the only 100% proofed splicing system, has gained the trust of over ten nuclear reactors globally, cementing its reputation for reliability and safety in high-stakes environments. The system’s stringent quality assurance processes ensure that each coupler meets the demanding standards required for nuclear applications, providing unparalleled performance and durability.

One of the standout features of Griptec is its high-productivity bar end preparation equipment. This state-of-the-art machinery boasts an impressive processing speed of 30 to 45 seconds per bar end, significantly enhancing construction efficiency. Additionally, the equipment is designed for operation by a single operator, optimizing workforce utilization.

Moreover, Dextra is the first manufacturer of products for civil works construction whose quality management system is ISO 19443 certified for nuclear safety. This certification underscores Dextra‘s commitment to the highest standards of safety and quality in the nuclear industry, reflecting the company’s dedication to excellence and reliability.

The San’ao Nuclear Power Plant project is a key component of China’s strategic initiative to expand its nuclear power capacity, which is vital for meeting the country’s growing energy needs while reducing carbon emissions. By supplying Griptec couplers, Dextra is playing a crucial role in ensuring the safety and efficiency of this project.

 

EnergyConnect – Whittens Buronga Substation

EnergyConnect – Whittens Buronga Substation

EnergyConnect project has emerged as a groundbreaking initiative that will revolutionize the sharing of electricity between New South Wales (NSW), Victoria, and South Australia. At the heart of this transformative project lies Dextra’s indispensable contribution – supplying almost 30,000 meters of Glass Fiber Reinforced Polymer (GFRP) rebar in diameters 13mm, 25mm, and 38mm. This not only marks a monumental step in the realm of construction but also propels the vision of a more sustainable and interconnected future.

The EnergyConnect Project

The EnergyConnect project is a testament to Australia’s commitment to enhancing energy infrastructure and promoting cooperation between states. This project aims to create a robust electricity transmission network that will enable efficient sharing of power resources across three states. As Australia transitions towards cleaner and more sustainable energy solutions, the EnergyConnect project plays a pivotal role in fostering a resilient and interconnected power grid.

Dextra’s Contribution

Dextra supplied a substantial quantity of GFRP rebar, showcasing its commitment to providing cutting-edge and sustainable construction materials. The use of GFRP rebar is a game-changer in the construction industry, offering a corrosion-resistant alternative to traditional steel reinforcement.

The 30,000 meters of GFRP rebar, ranging in diameters from 13mm to 38mm, were strategically incorporated to reinforce electrical transmission line and substation structures. This not only enhances the structural integrity of the infrastructure but also aligns with the broader goal of reducing the environmental impact of construction activities.

Advantages of GFRP Rebar

GFRP rebar, also known as Fiberglass Reinforced Polymer (FRP) rebar, brings several advantages to the construction table. Unlike traditional steel reinforcement, GFRP rebar is corrosion-resistant, making it an ideal choice for projects in regions with challenging environmental conditions. The EnergyConnect project, spanning multiple states with diverse climates, benefits immensely from this corrosion-resistant characteristic, ensuring the longevity and durability of the infrastructure.

Furthermore, GFRP rebar is significantly lighter than steel, simplifying transportation and handling during the construction process. This contributes to increased efficiency and reduced labor costs, making it an attractive choice for large-scale projects like EnergyConnect.

Flamanville EPR

Flamanville EPR

Flamanville is the first reactor built after the new generation EPR design (European Pressurized Reactor), after a 100% Chinese design. It will have a capacity of 1.3GWe when entering service in 2019.

Dextra has been present on site since the beginning of the construction works in 2008 and until 2015.

For this challenging project, Dextra has been supplying its Griptec rebar splicing solution through its local fabricator partners. The rebar preparation was supported by an additional machine placed at site.

Griptec is the preferred rebar splicing solution of the nuclear industry thanks to its unique performance level and an automatic testing process which systematically tests all the connections produced as part of its standard cycle: a guarantee that 100% of the connections perform above project requirement.

More than 800,000 Griptec connections have been used on the project, including 400,000 position assemblies, allowing to connect large diameter rebar without rotating them. The Griptec connections have been installed on reactor building and APC shell, as well as auxiliary buildings.

In particular, Griptec have been used for the connections of large prefabricated panels.

 

Four sided panels with Griptec female sleeves and bridging studs

Four sided panels with Griptec female sleeves and bridging studs

 

Thanks to its Bridging Assemblies, square panels could be reconnected on four sides while coping for possible misalignment that occur when lifting the cage.

Akkuyu Nuclear Power Plant

Akkuyu Nuclear Power Plant

Akkuyu Nuclear Power Plant is a nuclear power plant under construction at Akkuyu, in Büyükeceli, Mersin Province, Turkey. It will be the country’s first nuclear power plant.

The four 1,200 MW VVER +3 units, with a total capacity of 4800 MW, is the world’s first nuclear power plant project implemented on BOO (build-own-operate) principles by a subsidiary of Rosatom – Akkuyu NGS Elektrik Uretim AS (Akkuyu Project Company).

Major construction of the first unit started in March 2018, and it is expected to become operational in 2023.

Construction of the second unit started 2 years later and is anticipated to be completed by 2024, with Unit 3, and 4 to follow in 2025 and 2026, respectively.

Dextra provided more than 700,000 Fortec+ couplers and lock nuts to date, along with bar end preparation equipment, for the use at all 4 reactors and ancillary areas.

Fortec+ is a parallel threaded mechanical splicing system designed especially for nuclear projects for the connection of concrete reinforcing bars from Ø12 to 50 mm (ASTM #4 to #18), in compliance with Eurocode 2, ASME Sec III Div 2.

With the addition of a lock nut, it was fully engaged onto the extended thread of the connecting bar and help eliminate the residual deformation of the splice.

10 sets of bar end preparation system machines were also delivered at the site. The bar end preparation can be achieved in 3 steps: cutting the end of the rebar, cold forging to enlarge the sawn end of the rebar, and threading.

Fortec+ system adds a fourth step, consisting in a quality testing at the end of the rebar preparation process. The threaded bar end is tensile tested at 90% of the rebar yield strength to guarantee its performance.

Photo credit: https://www.dailysabah.com/business/energy/construction-starts-on-2nd-unit-of-turkeys-1st-nuclear-power-plant-akkuyu?gallery_image=undefined# big (by Energya and Natural Resources Ministry)

Hinkley Point C Nuclear Power Plant

Hinkley Point C Nuclear Power Plant


The Hinkley Point C (HPC) nuclear power station is one of the biggest and most technologically complex projects in Europe.

HPC is the first nuclear power station to be built in the UK in a generation, and its construction requires a highly skilled workforce and the very best construction and engineering solutions.

The HPC Project is located in Somerset, South West England, and will consist of two nuclear reactors capable of generating 3.2GW of low-carbon electricity.

The new power station is being constructed in the same area as the existing Hinkley Point A and B stations. The former has ceased operation for quite some time, while the latter is decommissioning in 2022.

Dextra was entrusted with the supply of mechanical splices of concrete reinforcement for parts of HPC, particularly the reactor’s aircraft impact protect shell.

More than 2.5 million Griptec couplers are supplied for the construction of HPC.

Griptec is designed to comply with the most stringent project specifications, and has proven to be a popular system of choice for EPR nuclear power stations, having been used for the construction of the Flamanville 3, Taishan 1, and Taishan 2 power stations.

The Griptec mechanical splice consists of two steel sleeves which are swaged onto the end of the reinforcing bars by a specific machine that was designed and patented by Dextra.

This swaging machine incorporates a systematic non-destructive pull test. Griptec is the only coupler system that provides an automatic quality control of each processed bar.

Besides Griptec couplers, Dextra is also supplying 3 million headed bars to the project. These are reinforcing bars that are bent on one side and fitted with an anchorage head on the other side and are used for the transverse reinforcement of concrete slabs, rafts, and walls. They allow a much faster and safer site installation than conventional double-bend bars.

When complete, HPC will provide low-carbon electricity for around six million homes.


Fuqing reactors 5 & 6

Fuqing reactors 5 & 6

Fuqing Reactor 5 & 6 are the first reactors of type Hualong One, based on a 100% Chinese design. Reactors have a capacity of 1,000 MW capacity, with start of operation scheduled for 2019 and 2022.

Dextra has been present on site since the beginning of the construction of the reactor 5 in 2015, and is now involved on the 6th reactor.

For this challenging project, Dextra has been supplying its Griptec rebar splicing solution, which are used for rebar splicing into the APC shell.

Griptec is the preferred rebar splicing solution of the nuclear industry thanks to its unique performance level and an automatic testing process which systematically tests all the connections produced as part of its standard cycle: a guarantee that 100% of the connections perform above project requirement.

More than a million Griptec connections will be used over the years for those two projects, supported by two Griptec equipment installed at site.

Dextra is also supporting the contractor teams at site with two Dextra engineers rotating to ensure operator training, setting and preventive maintenance services, this in order to ensure optimal production day and night thorough production peak times.

Taishan EPRs 1&2

Taishan EPRs 1&2

Taishan EPRs are two nuclear reaclors of EPR type of 1750 MW capacity built by Areva and located near Taishan, in the Guangdong province of China.

Dextra has been present on site since the beginning of the construction in 2009 and until 2016. The reactor operations are planned to start in 2017.

For this challenging project, Dextra has been supplying its Griptec rebar splicing solution, used in the concrete structure of the reactor.

Bartec rebar coupler solution as well as Headed Bars were also used on other building of the project.

Kudankulam Nuclear Power Plant (KKNPP) 3&4

Kudankulam Nuclear Power Plant (KKNPP) 3&4

Kudankulam Nuclear Power Plant (or KKNPP) is the largest nuclear power station in India, situated in Kudankulam in the Tirunelveli district of the southern Indian state of Tamil Nadu.

Two reactors (KKNPP-1 and 2) have been operating since 2013 and 2016, respectively, while two more (KKNPP-3 and 4) are currently under construction after the ground-breaking ceremony held on February 2016.

KKNPP-3 and 4 are pressurized water reactors of Russian design (model VVER-1000/V-412). These reactors are repeated designs of KKNPP-1 and 2, with further improvements based on commissioning and feedback from operational experience.

For the construction of these two units, Dextra supplied 350,000 Bartec couplers for the connection of rebars in the reactor building, auxiliary building and spent fuel storage structures.

Bartec is a trusted splicing system, well-known for its high performance in tension, compression, and fatigue. It is widely used in the construction of buildings, bridges, metros, nuclear reactors and more.

Unit 3 is scheduled to be completed in March 2023, and unit 4 in the subsequent year.

Upon its completion, these two reactors will add 2000 MW of electricity to the existing units, resulting in a total site production of 4000 MW per year.

Sources of images: https://twitter.com/daeindia/status/881395402171404288, https://www.deccanherald.com/content/619873/building-units-3-4-kudankulam.html

Fangchenggang Nuclear Power Plant 3&4

Fangchenggang Nuclear Power Plant 3&4

China is one of the world’s largest producers of nuclear power, and it’s consistently expanding its nuclear power production capacity with new reactors.

The Unit 1 and 2 of the Fangchenggang Nuclear Power Plant have been operational since 2016, and Unit 3 and 4 are currently under construction.

A total of six reactors are anticipated to be operational at the Fangchenggang site. Units 1 and 2 are both CPR-1000 reactors, while units 3–4 are Hualong One reactors, with projected units 5-6 planned to be Hualong One reactors as well.

Unit 3 began construction in December 2015, with unit 4 following a year later. Dextra has supplied more than 500,000 sleeves of Griptec coupler for the reinforcement of the APC structure.

Griptec is well-known for its reliability and performance in tension, compression, and fatigue, thanks to the unique design of the product that complies with the world’s most stringent projects specifications, especially for nuclear reactor building construction.

Rajasthan Atomic Power Project (RAPP) 7&8

Rajasthan Atomic Power Project (RAPP) 7&8

The Rajasthan Atomic Power Project (RAPP) is a nuclear power plant in Rawatbhata, Rajasthan, India, with 6 pressurized heavy water reactor (PHWR) units and a total installed capacity of 1,180 MW.

The plant’s owner and operator, the Nuclear Power Corporation of India (NPCIL), is expanding the plant’s capacity by building 2 additional reactors, Units 7 and 8.

In July 2011, the first pour of concrete (FPC) for the 7th reactor, with a capacity of 700MW, was completed. The unit’s start-up transformer (SUT) was also commissioned.

The 8th reactor, which will similarly have a capacity of 700MW, is scheduled to be finished in December 2021.

Dextra has supplied almost 500,000 Bartec couplers for the reinforcement of reactor buildings, auxiliary buildings, and spent fuel storages.

The 2 PHWR reactors will boost the plant’s existing capacity by 1,400MW, 700MW of which will be allotted to the state of Rajasthan.

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