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Heavy nuclear componentsChalon/St-Marcel Plant
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AREVA EPR reactor is based on the most advanced Generation III+ PWR technology currently available.AREVA has used its experience to develop a reactor design that offers enhanced safety and competitiveness: extreme robustness against external hazards, specific compartment to isolate the core in the event of a
core meltdown accident, quadruple redundant safeguard system, control room HMI providing real-time data.
The EPR reactor
DiD you know? Nuclear safety refers to the measures implemented during the design, operating and decommissioning phases of nuclear power plants to prevent the dispersal of radioactive substances and thereby protect human health and the environment.
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Core products in line with the AREVA Groups integrated strategy
AREVA manufactures key nuclear reactor components
AREVA is involved in all activities specific to the nuclear sector, particularly the design and construction of nuclear power plants. The Chalon/St-Marcel plant manufactures heavy primary system components (reactor vessels, steam generators and pressurizers). The plants expertise in cutting-edge nuclear technology ensures that these components are manufactured in compliance with two major requirements: optimal reliability required by clients and nuclear safety authorities, and energy performance required by utilities.
The Chalon/St-Marcel plant is part of a network of AREVA industrial sites devoted to the design and manufacture of heavy and mobile components of the reactor coolant system.
Expertise in cutting-edge nuclear technology
AREVA integrated offer (reactor coolant system)
Reactor core and primary coolant system
1 Reactor pressure vessel (RPV) and internals: Heavy-wall steel vessel containing the reactor core: fuel assemblies.
2 Steam generators (SG): Used to transfer heat from the primary cooling system to the secondary cooling system, thus converting it into steam that drives a turbine coupled to a generator. 3 Reactor coolant pumps (RCP): Used to ensure nuclear safety by allowing the primary coolant system water to circulate through the reactor core and steam generators.4 Pressurizer: Used to maintain the primary cooling system in liquid phase by applying a pressure of 155 bar.5 Reactor coolant piping: Used to transfer primary cooling system from the reactor vessel to the steam generators.6 Control rod drive mechanisms (CRDM): Used to control the nuclear reaction inside the reactor vessel and stop it within 2 seconds, thereby ensuring nuclear safety.
Manufacturing of heavy and mobile nuclear components: Industrial footprint
Heavy components Forged and cast components Mobile components Maintenance operations
PROJET AREVA NEWPORT NEWS Newport News, VA
USINE DE ChAloN/St-MARCEl St-Marcel
CREUSOT FORGECREUSOT MCANIQUE Le Creusot
JSPM Jeumont
SOMANUMaubeuge
CENTRE DESSAI JSPMMaubeuge
AREVA DONGFANG (ADJV) Deyang
Over 50 years of experience in the nuclear industry
1958 Creation of Framatome
1964 Delivery of the reactor pressure vessel for the first PWR unit at the Chooz A NPP (Creusot-Loire)
1972 Construction of steam generator manufacturing facility (CETIC) at Chalon
1973 Construction of reactor vessel manufacturing facility at Creusot
1975 Construction of heavy nuclear component manufacturing facility at St-Marcel
1986 Centralization of heavy component workshop at Chalon/St-Marcel
2001 Creation of the AREVA Group
2005 - 2009 Extension of heavy nuclear component manufacturing facility (investment amounting
to over 50 million euros)
2009 Delivery of heavy components for the first EPR reactor at Olkiluoto (Finland)
Design and engineering
Manufacturing of forged and cast components
Services
Experience feedback
Manufacturing ofmobile components
heavy component assembly
Nuclear power plantOn-site installation
Aerial view of the Chalon/St-Marcel plant
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Our markets
n EPR: Safer and more competitive
The EPR reactor is a 1600+ MWe-class pressurized water reactor (PWR). It is based on the most advanced Generation III+ PWR technology currently available, offering enhanced safety, significantly reduced production costs and optimal use of nuclear fuel.
n AtMEA1: Advanced Generation III+ PWR
The ATMEA1 reactor is a medium-power PWR (1100 MWe) currently developed by ATMEA, a joint venture between AREVA and Mitsubishi Heavy Industries (MHI).It addresses the need for a medium-sized PWR offering Generation III+ safety features and optimal cost-effectiveness.
n KERENA: Innovative BWR
The KERENA reactor is a Generation III+ boiling water reactor (BWR) with a power output of approximately 1250 MWe, developed at the request of German utilities in cooperation with other European countries. It incorporates mostly passive safety systems while maintaining a number of active safety systems, thus providing a high level of safety and significant flexibility for operators.
our reactor designs
FinlandEPR Olkiluoto
USA22 reactors
Brazil1 reactor
Sweden2 reactors
South Corea 2 reactors
United Kingdom1 reactor
Belgium5 reactors
Switzerland2 reactors
France58 reactors+ EPR Flamanville
South Africa2 reactors
China6 reactors+ 2 EPR Taishan
Construction in progress
our objectives
n Anticipating and meeting requirements defined by different nuclear safety authorities
n Becoming the reference supplier of new NPP equipment:
Steam generators Pressurizers Reactor vessels Reactor vessel heads and internals Equipment support components
n Offering our clients the best replacement component technology currently available:
Steam generators Pressurizers
Reactor vessel heads
Our components are installed in more than 100 nuclear reactors in 11 different countries
The nuclear equipment market is composed of two segments: new NPP components and replacement components. Reactor vessel, pressurizer and steam generator replacement operations are carried out within the scope of programs to improve the safety and energy performance of nuclear facilities throughout the world.
Installation of a steam generator inside the reactor building of the Olkiluoto 3 nuclear power plant (Finland)6 7
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Plant operators reading work instructions
Steam generator channel head
Calculations engineer viewing a model of a steam generator channel head
a Manufacturing drawing
b CAD model c Finite element meshing
d View of loads exerted on the component
DiD you know?
Analysis results are given in stress analysis reports (approximately 5000 pages).these reports provide a detailed description of each component and are subject to validation by the client and nuclear safety authority.they are kept by the utilities and updated after eachten-year inspection.
Technical expertise for customer satisfaction
Based on the clients specifications, our engineering teams define the design specifications for the components to be manufactured (i.e. reactor vessels, vessel heads, vessel internals, steam generators and pressurizers).
The Chalon/St-Marcel plants industrial methods department adapts the engineering data to ensure compliance with production and quality control requirements. This department also prepares work instructions and manufacturing drawings.
In-plant manufacturing, inspection and testing operations are performed by highly qualified operators under the supervision of metallurgical or Non-Destructive-Examination (NDE) experts.
The structural design and calculations department prepares stress analysis reports as assembly work progresses.
Based on manufacturing drawings a , experts from the structural design
and calculations department develop a CAD model b used to generate a finite element mesh c of the component to be manufactured.
They also calculate the loads exerted onto the components under normal or emergency operating conditions d .
The results obtained are then classified and compared with the applicable construction code (RCC-M or ASME) to demonstrate component compliance.
Calculations department
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Manufacturing processes
140 Total length of EPR steam generator tubes if placed end to end
Use of over 80 different welding techniques
Fully automated welding jigs and gantries
Weld thicknesses of up to 250 mm
Stainless steel or Inconel cladding with a thickness of 7 to 10 mm for corrosion prevention
Welding
Above-standard machining toolsDrilling accuracy of .01 mm for components weighing several tens of tons.
Assembling steam generator internalsLaser technology is used to align tube support plates over 3 meters in diameter with .1 mm accuracy.
Laser-guided positioning of steam generator tube support plates
Insertion of U-tubes into a steam generator
Two-wire welding gantry
Numerical vertical lathe
DiD you know?
tubing is a key step in the steam generator manufacturing cycle. this long and demanding process ensures the safety and service life of the steam generator. In the EPR reactor, a total of 5980 Inconel tubes are inserted through the tube support plates and welded to the tubesheet. this work takes approximately 3 months to complete. tubing operations are performed in clean overpressurized rooms with regulated and controlled access.
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Safety begins with employees commitment
Our personnel are constantly striving to achieve excellence in all aspects of nuclear safety, product quality control, industrial performance, occupational safety and environmental protection.
Work-specific personal protective equipment
Qualification training, internships and apprenticeships
Skill development is achieved through continuous training. The Chalon/St-Marcel plant offers qualification training, internship and apprenticeship programs for young workers.
Employee skill management: A competitive advantageAn occupational analysis system is used to track demographic, technological and strategic changes within the AREVA Group. Human resource recruitment, professionalization and skill management strategies are adapted accordingly.
Our priority: Occupational health and safetyEnsuring the health and safety of all Group employees and subcontractors is an absolute priority. Risk reduction is achieved through the continuous implementation of a strict and effective safety management system (visual safety management, safety inspections, risk assessments, training programs, etc.).
The French Association for Industry Professionals provides welding training programs for young workers. The Chalon/St-Marcel plant has set up a welding training center for this purpose. Under professional supervision, trainees receive on-site training on industrial welding machines using noble filler materials (e.g. stainless steel and Inconel) specific to nuclear-grade manufacturing processes.
Our objective: Zero occupational accidents
Welding training center
Factory alignment of steam generators12 13
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Nuclear safety and quality assurance
Inspections are performed throughout the manufacturing process (direct inspection of components or laboratory analysis of test specimens). Each manufactured component (steam generator, reactor vessel, pressurizer) is delivered with a certificate of compliance with client specifications.
Certifications and qualifications
An integrated product quality, occupational health and safety and environmental monitoring system is implemented to ensure product compliance with applicable codes and standards.
n ASME Pressure Vessel Code Pressure vessel design and construction rules defined by the American Society of Mechanical Engineers.
n ASME N Certification Certificate authorizing the design and manufacture of pressure vessel components as per ASME code requirements.
n ASME NPt Certification Certificate authorizing the manufacture of pressure vessel components as per ASME code requirements.
n ISo 9001 (Quality Management)
n ISo 14001 (Environmental Management)
n ohSAS 18001 (Safety Management)
n RCC-M Design and construction rules for mechanical components of nuclear installations, defined by the French Association for NPP component design and construction rules (AFCEN).
n French regulations concerning pressurized water reactors Compliance with these regulations is ensured by the Nuclear Safety Authority, represented by the Pressurized Nuclear Equipment Directorate (DEP).
External monitoringManufacturing operations are overseen by the nuclear safety authority as well as by the client. As the operator, the client is responsible for ensuring nuclear reactor safety throughout the manufacturing process, starting with steel-making operations. This is achieved through audits, document reviews and on-site inspections.
The client provides on-site assistance during manufacturing or inspection processes and verifies their compliance with safety requirements for heavy nuclear components.
Certifications meeting the requirements of nuclear safety authorities throughout the world
Quality controlOur quality control methods are based on exhaustive techniques independent of production processes: Non-Destructive Examination (NDE): ultrasonic testing,
eddy current testing, magnetic particle testing, liquid penetrant testing, radiographic testing, laser telemetry, etc.
Mechanical testing: hardness testing, drop weight testing, impact testing, bend testing, etc.
1 h of inspection every
3 h of manufacture
Helium leak testing of the tube-to-tubesheet welds
Lower part of a steam generator in the radiographic enclosure
Final dimensional inspection of an EPR steam generator via digital photogrammetry
Ultrasonic weld testing
Employee undergoing COFREND certification
Dimensional inspection of tube support plates
our priority: Compliance with nuclear safety authority requirements
DiD you know?
Nuclear regulations limit the validity of welder qualification certificates to 2 years. In order to maintain his certification, a welder must have completed at least two compliant welds (i.e. that have successfully undergone radiographic and ultrasonic testing) over the past six months.
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Heavy components of the nucle ar steam supply system
82 ft
44 ft
EPR pressurizer EPR reactor vessel EPR steam generator
525 metric tons
Weight of an EPR steam generator
Reactor vessels, stea m generators and pressurizers are heavy and comp lex components requiring highly accurate machining operations ( 0.4 mils) on forgings weighing tens or hun dreds of tons.
EPR primary coolant loop
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Four EPR reactors currently under construction
Solutions for power generation with less carbon
Flamanville (France)
olkiluoto(Finland)
taishan 1 (China)
taishan 2(China)
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AREVA Chalon/Saint-MarcelB.P. 40 001 Saint-Marcel - 71 328 Chalon-sur-Sane Cedex
Energy is our future, dont waste it!
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AREVA supplies solutions for power generation with less carbon. Its expertise and unwavering insistence on safety, security, transparency and ethics are setting the standard, and its responsible development is anchored in a process of continuous improvement.
Ranked first in the global nuclear power industry, AREVAs unique integrated offering to utilities covers every stage of the fuel cycle, nuclear reactor design and construction, and related services. The group is also expanding its operations to renewable energies wind, solar, bioenergies, hydrogen and storage to be one of the leaders in this sector worldwide.
With these two major offers, AREVAs 48,000 employees are helping to supply ever safer, cleaner
and more economical energy to the greatest number of people.
www.areva.com
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