Know-how • Innovation • Expertise

Creusot ForgeCreusot Mécanique

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PrOducts at the heart OF the integrated strategy OF the areVa grOuP

We ManuFacture the key cOMPOnents OF the nuclear reactOr

Creusot Forge and Creusot Mécanique manufacture forgings and castings destined mainly for the nuclear market.

Our know-how, capacity for innovation and quality standards enable us to develop products which match the exact needs of our clients.

Creusot Forge and Creusot Mécanique form part of AREVA’s industrial presence, dedicated to the design and manufacture of the heavy components and mobile components used in the nuclear island.

World leader in the supply of forgings and castings

AREVA’s full scope of supply (nuclear island)

at the heart of the reactor: the primary loop

Design and EngineeringManufacture of forgings

and castings

Nuclear Power Station

Services Site Installation

Heavy and Mobile components assembly

and fabrication

1 reactor pressure vessel and vessel internals: impenetrable thick metal wall in steel enclosing the

heart of the reactor and containing the fuel assemblies.

2 steam generators (sg): provide heat transfer from the water of the primary circuit to the water of the secondary circuit.

The water is converted into steam, which drives a turbine which is linked to an alternator producing electricity.

3 reactor coolant Pumps (rcP): force the primary water through the reactor and steam generators, and ensure the safety of the system by cooling the core.

4 Pressurizer: maintains the pressure in the primary cooling circuit at a specified level (around 150 bars) to prevent the water boiling.

5 Primary piping: provides the transfer of water between the reactor pressure vessel and the steam generators.

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Manufacture of heavy and Mobile coMponents: industrial installations

From Creusot Loire to AreVA…

Creusot Forge is one of the very few forges in the world capable of making the sophisticated parts necessary for the manufacture of the primary components for the nuclear island.

The first foundry activity started in Le Creusot in 1782. Our deep-rooted skills and know-how have played a leading role both in the French nuclear power program, and later on in our expansion overseas.

1782 StartoffoundryactivitiesinLeCreusot1876 EstablishmentoftheforgingshopinLeCreusot

the biggest forging hammer in the worldisputintooperation(500tonnes)

1956 new 7,500 tonne press1960 StartofFrenchcivilnuclearprogram1979 Installationofanew 11,300 tonne press1988 first forged bottom headforasteamgenerator

(withintegratednozzles)1992 first monobloc forged primary pipesystem2003 Manufactureoffirst monobloc reactor closure head2005 ManufactureoffirstEPRTMreactorcomponents

(GenerationIII+)2006 AssimilationofCreusotForgeandCreusotMécanique

intotheareva group2008/ Completerevampofthe7,500and11,300tonnepresses2009 Forgingshopcapacityincrease

Sincethelaunchofthecivilnuclearprogram,wehavesuppliedmorethan 2 700 forged and cast parts fortheprimaryislandsofnuclearinstallationsthroughouttheworld:France,USA,China,Brazil,SouthAfrica,Switzerland,Finland,Belgium,SouthKorea…

experts for more than 200 years

Renovated 7,500 tonne press

Renovated gantry miller

Heavy components Forgings and Castings Mobile components Maintenance

AREVA NEWPORT NEWS NewportNews,VA

CHAlON/ST-MARCEl Chalon-sur-Saônecreusot forGe

creusot MÉcaniQue le creusot

JSPM Jeumont

SOMANUMaubeuge

Test Centre JSPMMaubeuge

AREVA DONGFANG (ADJV) Deyang

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To offer the best technology in regard to:•Integratednozzles•Monoblocforgings•Dimensionaloptimisation•Thelargest-possibleforgings

To be the acknowledged leading supplier for new power stations

To continue to fulfill the needs of our clients in the replacement market

To meet all demand for any type of reactor (PWR/BWR)

our markets

EPR TM: more reliable and more competitiveTheEPRTMreactorisapressurisedwaterreactor(PWR)ofthe1600MWclass.Itisthemostadvancedpressurisedwaterreactorcurrentlyavailable,offeringanincreasedlevelofreliability,considerablyreducedproductioncosts,andoptimisednuclearfueluse.

ATMEA1 TM: the advanced Generation III+ PWRTheATMEA1TMreactorisamediumpower(1,100MW)pressurisedwaterreactor(PWR)designedbyATMEA,ajointventurebetweenAREVAandMitsubishiHeavyIndustries(MHI).ItfulfilsthemarketneedforamediumsizedPWR,offeringthesafetylevelsoftheGenerationIII+andoptimisedprofitability.

KERENA ™: the innovative BWRTheKERENA™reactorisa1,250MWboilingwaterreactor(BWR),developedfortheneedsofGermanelectricitycompanies,incooperationwithotherEuropeancountries.Themostlypassivesafetysystemsarecombinedwithacertainnumberofactivesystemstoensureahighlevelofsafetyandgreatoperatorflexibility.

our commitments reactor supply record

our products are incorporated into More than 100 nuclear reactors throuGhout the world

More than 60 reactors in Europe More than 30 reactors in the USAMore than 10 reactors in China

Themarketfornuclearplanthastwosegments:thereplacementmarket(heads,pressurizersandsteamgenerators)andthemarketfornewpowerstations.Thislattermarketiscurrentlyexperiencingsignificantgrowth,atatimewhenourclientsarebecomingevermoredemandingintermsofsafety,technicalrequirements,competitivenessandrespectfortheenvironment.

location of our products since 2005

New installations Replacement market

USAComanche PeakSte-lucieMillstoneAno II+ UNISTAR EPR TM

BRAzIlAngra

SWEDENRinghals

FINlANDOl3 EPR TM

CHINAling Ao III & IVQinshan III & IVCPR 1000Taishan I & II EPR TMFRANCE

FA3 EPR TM

RSG EDF

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our productsour larGe stainless steel coMponents

our larGe carbon steel coMponents

our product portfolio

Primarypiping,reactorvesselinternals,primarypumpcasing.Stainlesssteelisanalloycontainingchromiumandnickel,whichisusedforitscorrosionresistantproperties.

Reactorvessels,steamgenerators,pressurizers.Thelowcarbonsteels20MND5(RCC-M)orSA508,Gr.3,Cl.1(ASME)arecarefullyprocessedsteelgrades,idealforcladdingandwithoptimalweldability.

reactor pressure vessel

Pressurizer Primary Pumps

steam generators

Primary piping

Monoblocclosurehead

Uppershell Conicalshell

s.G.

Ellipticaldome

StainlesssteelHeavyreflector(Coreinternals)

Stainlesssteelcoreshellwithbuilt-in

nozzles Primaryhead

Tubesheet

Heads Pumpcasing

Creusot Forge is the only forge in the world which is qualified and which is globally acknowledged to have the capacity to supply all of these large components.

�These components have beenuniversally renowned since the start ofour activities.

Hotlegswithbuilt-innozzles

Elbow Coldlegswithbuilt-innozzles

rcp

rpv

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our manufacturing processes: an unrivalled know-how

forGed coMponents

Principals of shell production starting from a hollow ingot

A shell is a forged cylinder, which can exceed 5m in diameter and 250mm in wall thickness. This cylinder is the main constituent of many larger components; steam generator, pressurizer, reactor pressure vessel …

Digital simulation

Steel melting in an electric

furnace (recycled automobile scrap)

ladle refining

Ingot pouring

Re-heating of ingot prior to forging (1200°C)

Drawing on a mandrel

Heat treatment

Shaping

Non-destructive inspection

Finished part ready for delivery Machining

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castinGs

MachininG

Wemanufacturethelargeststainlesssteelcastingcomponentforthenuclearisland:thecasingforthePrimaryPump.

Acastingisprocessedinasandmouldwhichprovidesthedesiredshape.Thecastingthenundergoesaseriesofoperationsstartingwitharc-airgouging(wheremetalismeltedbyanelectricarcandblastedawayinajetofair),grinding,weldingandmachining,beforebeingsubjecttonon-destructiveinspections(withlinearaccelerator)andahydraulictestunderpressure.

IntheCreusotMécaniquemachineshop,AREVAcarriesoutprecisionfinishmachiningonlargecomponents.Thankstoarangeofmachinetoolsofexceptionallylargesizeandaccuracyandtothetechnicalskillsoftheoperators,CreusotMécaniqueisabletocarryouttheprecisionmachiningofthestainlesssteelpartsoftheheavyreflectorfortheEPRTM

reactorpressurevesselinternals.

Primary pump casings

Machining of RPV closure head

Heavy duty milling machine

Machining of heavy reflector for EPR TM

Machining shop at “Creusot Mécanique”

Our key operations

our added value a state-of-the-art production facility

• 2 hydraulic presses completely revamped in 2008 and 2009

-11300tonnes -7500tonnes

• Gas re-heating furnacescapableofbringingpartsuptoforgingtemperature(>1200°C)withinhours(thesefurnacesareamongstthemostpowerfulintheworld).

• numerous automatic gas heat-treatment furnacescapableoffollowingdetailedtemperaturecurvesinordertoyieldthedesiredmechanicalpropertiesofparticulargradesofsteel.

• MachiningMorethan50machinetoolsequippedwiththelatestgenerationofNCcontrols(verticallathes,horizontallathes,millingandboringmachines)allowingprecisionmachiningtoveryclosetolerances.

production and forging of hollow ingotsforlargeshells(>toØ5m)

forging of monobloc headsforreactorpressurevessels

Machining of stainlesssteelcore internalsandheavyreflector

punching operationofthenozzlesonsteamgeneratorprimaryheads

forging of stainless steel primary pipingwithbuilt-innozzles

digital simulationoftheforgingprocess

forging of conical shellswithstraightsidesonsteamgenerators

forging of stainless steel ingotswithaweightgreaterthan150tonnes

8 Competitiveness

Project

certificates and Qualifications

•RCC-M•ASME since 1980•NNSA•ISO 9001 (2008)•ISO 14001 in progress• OHSAS 18001 in

progress

inspections

Ourinspectionproceduresareunderpinnedbyanexhaustiverangeoftechniqueswhichareindependentfromproduction:-Non-destructive:ultrasonics,eddycurrent,magneticparticuleexamination,lasertelemetry

-Destructive:tensiletesting,toughnesstesting,hardness,Pellinitests.

Objective:toguaranteezerodefect

the teaMs at the heart of our success

ThemenandwomenofCreusotForgeandCreusotMécaniqueputtheirenergyandtechnicalskillsattheserviceoftheircustomersonadailybasis.Theyworktothemostdemandingstandardsintermsofquality,safetyandeconomicperformance.Morethantwentyskillgroupsarerepresentedonthesite:fitters,furnacemen,projectleaders,inspectors,qualitycoordinators,forgemasters,millingmachineoperators,R&Dengineers,pressoperators,machinists....

Throughourdynamicpolicyofrecruitmentandtraining,wemakeeveryefforttoensurethattheseskillsaredevelopedandkeptup-to-date.

Objective:topassonandtodevelopourknowledgeandknow-how

Quality and reliabilityThroughouttheentirefabricationprocess,wecarryoutinspectionseitheronthecomponentsthemselvesoronsamplesinthelaboratory.Finishedproductsalwayscarrywiththemappropriatedocumentationasproofoftheirqualityandtheircompliancewithcustomerspecifications.

Objective:toguaranteethehighestlevelofquality

safetyItisanabsolutepriorityforustoensurethehealthandsafetyofourownstaffandoftheworkersofourpartnercompanies.Wehaveestablishedademandingandefficientsystemofsafetymanagementwhichhasasitsaimthepermanentreductionofrisks:managementobservationofsafety,safetyvisits,riskassessment,training…

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From top to bottom, ASME, NNSA and ISO certificates

frequency rate

2006: 4,62008: 3,16 (nationalaverage>25)

- 31%

Objective:zeroaccident

management

Attention to deadlines

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Growing industrial capacities

increase of our production capacity

strateGic new developMents

increase its capacities and capabilities: ingotweight>250tonnesandanannualincreaseintonnageto50,000tonnes.

extension of the heavy forging bay.

revamp of the presses withincreasesintheircapacityandreliability.

Additionalreheatingand heat treatment capacities (650tonnefurnaceswithregenerativeburners)andimprovementintheirperformances.

More than 150 M€ have been invested since 2006 in order to optimize our industrial capacity.

automation of dimensional measurement of hot forgings (laser) Inordertoimproveefficiency,CreusotForgehasrecentlydevelopedin-houseathreedimensionalmeasuringsystemdedicatedtoitsforgingpresses.Thisnon-contactmeasuringsystembasedonlasertechnologyismoreaccurate,morerapidandmorereliablethantraditionalsystems.

hollow ingots for the production of pressure vessel shells or steam generators shellsCreusotForgeistheonlycompanyintheworldtousethehollowingotfortheproductionofshells,whichisattheheartofthemanufactureofournuclearshellforgings.Theseingotsallowaconsiderablereductioninthemanufacturingtimeofashellandprovidebettergifttocladdingoperation.

our strategic r&d partnershipsCreusotForge,togetherwiththeLeCreusotCentreforMetallurgicalResearch(CRMC)andotherlaboratoriesanduniversities,isleadingresearchprogramsaimedatthedevelopmentofnewprocessesforthemanufactureofgradesofsteel,atimprovingourforgingprocessesanddevelopingnewproducts.

Establishmentofanewtesting laboratory.

increase in machining capacity: acquisitionof6verticallathesandupgradingofallmachinestonumericcommandcontrol.

The signing of an agreement between Creusot Forge and ArcelorMittal in the presence of Nicolas Sarkozy, President of the French Republic, Anne Lauvergeon, Chief Executive Officer of AREVA and A. Mittal, Finance Director of ArcelorMittal.

Our next challenges

Continuing investment to increase our production capacity in order to respond better to the needs of our customers

Development of new leading-edge technologies

Recruitment and training: transmission and development of knowledge

Intensification of our efforts to continuously improve: • economic growth• socially responsible enterprise• respect for the environment

the environment of le creusot is also our environment

Creusot Forge and Creusot Mécanique are committed to the ongoing process improvements of the AREVA group.

As shown by our self imposed efforts in the reduction of discharges and waste,

we undertake to ensure that the effects of our activities on the surrounding

populations are negligible.

All over the world, AREVA provides its customers with solutions for carbon-free power generation and electricity transmission. With its knowledge and expertise in these fields, the group has a leading role to play in meeting the world’s energy needs.

Ranked first in the global nuclear power industry, AREVA’s unique integrated offering covers every stage of the fuel cycle, reactor design and construction, and related services.In addition, the group is developing a portfolio of operations in renewable energies. AREVA is also a world leader in electricity transmission and distribution and offers its customers a complete range of solutions for greater grid stability and energy efficiency.

Sustainable development is a core component of the group’s industrial strategy. Its 75,000 employees work every day to make AREVA a responsible industrial player that is helping to supply

ever cleaner, safer and more economical energy to the greatest number of people.

www.areva.com

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Cer

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ISO

140

01

groupe areVa

creusot Forge

56, boulevard Clémenceau71200 Le Creusot – France

Phone: + 33.(0).3.85.80.73.00contactforge@areva.com