Wedoany.com Report-Sept. 19, The CA01 “super module” has been successfully installed at unit 1 of the Lufeng nuclear power plant in Guangdong province, according to the Shanghai Nuclear Engineering Research and Design Institute (SNERDI). The installation took place on September 16 and marks a key milestone in the project, signifying the start of a new phase involving both structural construction and equipment installation.

The CA01 module, made of concrete and steel, has a hoisting weight of nearly 990 tonnes. Measuring more than 26 meters in length, 29 meters in width, and 23 meters in height, it consists of 47 sub-modules. Positioned inside the containment building of unit 1, the structure will house critical equipment including the reactor pressure vessel, steam generators, and associated components.

The module is part of the CAP1000 reactor design, which is the Chinese version of Westinghouse’s AP1000. This design relies on modular construction, allowing large structural components to be prefabricated in factories and then assembled at the construction site. Due to its size, the CA01 module could not be transported by conventional means and was constructed directly on-site.

SNERDI, a subsidiary of State Power Investment Corporation, described the CA01 as the largest, heaviest, and most complex structural module within the nuclear island. The project team faced four primary challenges during installation: its complicated structure, substantial weight, center of gravity deviation, and the requirement for millimeter-level precision in positioning.

SNERDI stated: "The project team achieved these breakthroughs through technological innovation and refined control." The team applied laser scanning technology to create a full-scale digital replica of the module, which allowed precise calculation of its center of gravity. Based on this data, engineers developed a dedicated multi-point hoisting system equipped with a three-stage balance beam to manage the T-shaped structure’s balance.

By combining traditional contour line layout methods with advanced 3D scanning collision checks, the team overcame difficulties associated with the confined installation space and minimal clearance from surrounding embedded structures.

The Lufeng site is designed to host six nuclear reactors. First safety-related concrete for unit 1 was poured on February 24 this year, making it the third reactor at the site to begin construction. Units 1 through 4 are planned to use the CAP1000 design. The National Development and Reform Commission approved the construction of these four reactors in September 2014. However, State Council approval for units 1 and 2 was only granted on August 19 of last year, while approval for units 3 and 4 is still pending.

Additionally, in April 2022, the State Council authorized construction of two Hualong One units at Lufeng, designated as units 5 and 6. First concrete for unit 5 was poured on September 8, 2022, followed by unit 6 on August 26, 2023.

The installation of the CA01 super module at unit 1 reflects progress in modular construction techniques and underlines the importance of technological innovation in advancing large-scale nuclear power projects in China.