Introduction to Manufacturing & Test Capabilities of Shengu Nuclear Power Division
Shengu Nuclear Power Division independently delivers the full manufacturing workflow for pump products, covering component machining, complete unit assembly, performance inspection and type testing. It is a professional R&D and manufacturing base for high-end pumps with comprehensive supporting capabilities.
I. Machining Capabilities
The division’s machining equipment falls into two categories: CNC precision equipment and conventional general-purpose machines, featuring complete specifications and wide coverage. It supports full-process machining of pump components and the production of large-scale, precision and complex parts. Equipment is centrally laid out in the North & South Nuclear Power Bays and Rotor Workshop.
(I) CNC Machining Equipment
1. CNC Lathes & Turn-Mill Centers (Core Equipment for High-Precision & Composite Machining)
Full series of vertical, horizontal and 5-axis turn-mill composite machines are available for rotary parts including discs, shafts and pump casings.
Heavy-duty vertical turn-mill: Max machining diameter 6,500 mm, table load capacity up to 150 tons, ideal for ultra-large heavy nuclear power components. Conventional models cover machining diameters from 1,600 mm to 2,800 mm with positioning accuracy up to 0.008 mm, integrating turning, milling, drilling, boring and grinding in one setup.
Horizontal turn-mill: Max swing diameter 900 mm, maximum turning length 2,000 mm with full 5-axis linkage capability, enabling multi-surface machining of complex parts in a single clamping. Standard horizontal CNC lathes process shaft & disc parts of Φ400~500 mm with machining accuracy IT6~IT7.
2. 5-Axis CNC Machining Centers
Two heavy-duty 5-axis machining centers are deployed. Maximum table dimension: 1,250×1,250 mm, single machine load up to 3 tons, maximum 3-axis travel 2,000 mm, positioning accuracy 0.008 mm. They excel at complex cavities, spatial curved surfaces and multi-hole precision box components to meet strict requirements of nuclear precision structural parts.
3. CNC Boring & Milling Centers
Mainly floor-type and horizontal CNC boring mills with spindle diameters of Φ130 / Φ160 / Φ200. Maximum table load 70 tons, maximum X-axis travel 14,000 mm for boring, milling and drilling of large boxes, pump casings and multi-hole assemblies. Equipped with abundant accessories including right-angle milling heads, facing heads and extension boring bars for versatile machining conditions.
4. CNC Grinding Equipment
Including CNC vertical grinders and 5-axis CNC tool grinders for flat surfaces, inner holes, outer circles and tool regrinding. Repeat positioning accuracy ±0.0025 mm, runout of internal/external grinding spindles ≤0.0025 mm to guarantee surface precision and roughness.
5. CNC Drilling & Milling Machines
CNC deep hole drilling machines specialize in central holes of shafts, drilling range Φ8~30 mm, maximum drilling depth 1,500 mm, hole straightness 0.3~0.5 mm per 1,000 mm.
CNC drill-milling machines offer maximum drill diameter Φ50 mm, combining drilling, milling, boring and tapping up to M30.
(II) Conventional General Equipment (Support for Rough & Semi-Finishing)
Seven categories of stable domestic standard machines: vertical lathes, horizontal lathes, boring mills, grinders, milling machines, drill presses and slotting machines for mass conventional machining processes.
Conventional vertical lathes: Single/double-column models, max machining diameter 5,000 mm, maximum workpiece weight 30 tons for rough/finish turning and simple grinding of large rotary parts.
Conventional horizontal lathes: Specifications Φ400~850 mm, maximum turning length 6,000 mm for all types of shafts and sleeves with complete thread machining functions.
Horizontal boring mills: Spindle Φ85 / Φ130 mm, max table load 8 tons for medium & small hole arrays with precise dimensional and geometric tolerance control.
Grinding machines: Full coverage of cylindrical grinders, universal cylindrical grinders and precision surface grinders, maximum grinding length 8,000 mm, workpiece roundness up to 0.0015 mm, minimum surface roughness Ra0.1 μm.
Milling, drilling & slotting machines: Complete lineup including column milling machines, special keyway mills, radial drills and slotters for planar surfaces, grooves, keyways, drilling and slotting to fulfill auxiliary machining demands.
(III) Overall Advantages of Machining Workshop
Wide specification coverage: Processes ranging from tiny precision cutters and medium-small sleeves to ultra-heavy components of 6.5 m diameter with 150-ton load capacity.
Full-process technology: Integrated turning, milling, boring, drilling, grinding, slotting, tapping and composite machining to realize one-stop component processing.
Ultra-high precision: Precision machines reach micron-level positioning accuracy; standard equipment stably achieves IT6~IT9 tolerance, complying with stringent nuclear power equipment quality standards.
Centralized equipment layout: Core machines arranged in Nuclear South Bay 2, North Bay 1 & 2 and Rotor Workshop with optimized production logistics.
II. Product Test Capabilities
The division operates 12 professional pump test benches categorized into four types: nuclear reactor coolant pumps (RCP), nuclear Class 2 pumps, general industrial pumps and special test rigs. Nine benches are located in the Nuclear Pump Workshop, and three in Workshop No.8. All facilities comply with national standards and ASME codes, supporting factory acceptance tests, R&D trials and special-condition testing for full-series nuclear and civilian pumps. Test capacity, parameter ranges and precision standards reach advanced industry levels.
(I) Core Test Benches & Performance Parameters
1. Test Benches for Gen-III Nuclear Reactor Coolant Pumps (CAP1400 / AP1000)
Leading domestic high-temperature, high-pressure, high-flow closed-loop vertical test facilities. Design pressure: 17.2 MPa, design temperature: 350 ℃.
CAP1400 bench: Max flow rate 30,000 m³/h, motor power 10,000 kW
AP1000 bench: Max flow rate 20,000 m³/h
Supports over 20 test items for canned motor RCPs and shaft-seal RCPs including cold & hot hydraulic performance, thrust measurement, cavitation, circulation characteristics and pressure pulsation, compatible with mainstream Gen-III nuclear reactor coolant pumps.
2. Nuclear Class 2 Pump Test Benches
Two semi-open-loop benches (horizontal & vertical) with demineralized water as medium, max temperature 80 ℃, maximum flow 3,000 m³/h, peak power 1,800 kW. Covers full API OH/BB/VS nuclear Class 2 pumps for hydraulic performance, cavitation, vibration, noise, endurance and reduced-voltage startup tests with Class 1 measurement accuracy per Chinese national standard.
3. Special Nuclear Pump Test Benches
SEC Pump Test Bench: Max flow 5,000 m³/h for Essential Service Cooling Water pumps, water tank volume 2,000 m³ to complete full-range testing for 1,000 MW unit SEC pumps.
Condensate Pump Test Bench: Custom-designed for condensate pumps, max flow 5,000 m³/h, head 500 m.
4. General Industrial Pump Test Benches
Main feedwater pump / high-pressure boiler feedwater pump / booster pump benches in Workshop No.8: Max design pressure 42 MPa, temperature 180 ℃, peak power 10,000 kW. Covers BB1~BB5 feed pumps for thermal power and nuclear conventional island applications.
Hydraulic Model Test Bench: Dedicated for hydraulic model R&D of new pumps, pipeline DN50~DN300 to ensure accurate R&D test data.
5. Special-Condition Test Bench
Thermal Shock Test Bench: Max test temperature 200 ℃, simulating alternating high-temperature working conditions to verify structural reliability of pump casings.
(II) Core Advantages of Test Facilities
Full product coverage: Tests nuclear reactor coolant pumps, nuclear safety-class pumps, conventional island pumps, civilian feedwater pumps, condensate pumps, booster pumps and hydraulic models.
Wide operating condition range: Flow up to 30,000 m³/h, pressure up to 42 MPa, temperature ranging from ambient to 350 ℃, covering normal, high-temperature, high-pressure and ultra-large-flow extreme conditions.
Complete test items: Full factory and R&D trials including hydraulic performance, cavitation, vibration, noise, endurance, thermal shock, thrust and variable-load tests.
High-standard compliance: All benches meet Class 1 precision of GB/T 3216-2016; reactor coolant pump test rigs follow ASME certification standards, with test data valid for product certification and commercial delivery.
High automation: Main test benches are equipped with fully automatic measurement & control systems for automatic regulation of pressure, temperature and flow, with real-time data collection, storage and analysis.
