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Automated load flexibility of NPP VGB PowerTech 5 l 2016

Kurzfassung

Verbesserung der automatisierten Last­flexibilität von Kernkraftwerken mit ALFC

In verschiedenen deutschen bzw. schweizer Kernkraftwerken mit Druckwasserreaktor (DWR) wurde und wird die Regelung der Reak-torleistung verbessert, um flexibler auf die sich aus der zunehmenden volatilen Einspeisung regenerativer Energien ergebenden Anforde-rungen der Netzbetreiber reagieren zu können (Netzstabilität). Ziel ist es, insbesondere mit Blick auf die deutschen Kernkraftwerke mit rund 1.500 MW Nennleistung, folgende Fahr-weisen anbieten zu können: – Primärfrequenzstützung mit bis zu –200 MW

Lasthub (asymmetrisch herunter in 30 Se-kunden mit bis zu 15 Minuten Teillast und wieder auf Volllast in 30 Sekunden)

– vom Lastverteiler ferngesteuerte Sekundärre-gelung mit rund 600 MW Lasthub und Gradi-enten von 30 bis 40 MW/min

– „klassische“ Lastrampen mit telefonischer Absprache mit rund 1.000 MW Lasthub und Gradienten bis zu 40 MW/min

– die Primärfrequenzstützung kann mit den an-deren Fahrweisen kombiniert werden

Die neuen Möglichkeiten der digitalen Leit-technik (z.B. TELEPERM® XS) ermöglichen diesen Betrieb soweit zu automatisieren, dass keine unterstützenden Handeingriffe mehr erforderlich sind. Diese Möglichkeiten wurden und werden von AREVA im Rahmen der ALFC-Projekte (Advanced Load Following Control) umgesetzt. Vielfältige Anpassungsalgorithmen an reaktorphysikalische Variationen während des Betriebes ermöglichen eine präzise Rege-lung der axialen Leistungsdichteverteilung und des Reaktivitätsmanagements im Reaktorkern, die die Grundlage für eine hohe automatisierte Lastflexibilität innerhalb der überwachten Be-triebsgrenzen des DWR darstellt. l

Improving automated load flexibility of nuclear power plants with ALFCAndreas Kuhn and Peter Klaus

Introduction

In several German and Swiss Nuclear Pow-er Plants (NPP) with Pressurised Water Re-actor (PWR) the control of the reactor pow-er was and will be improved in order to be able to support the energy transition with increasing volatile renewable energy in the grid by flexible load operation according to the need of the load dispatcher regarding the power system stability. Especially re-garding the mentioned German NPPs with a nominal electric power of approximately 1,500 MW, the general objectives are the following automated grid-relevant opera-tion modes (F i g u r e 1):

– Primary frequency control (1) with load jumps up to –200 MW (asymmetric downwards within 30 seconds and with a duration of max. 15 minutes and back to full load within 30 seconds). In this operation mode the grid frequency is linked directly to the turbine power con-troller in order to compensate directly the energy misbalance of the grid within 30 seconds.

– Remote secondary control (2) by the load dispatcher; hereby stochastic load chang-es with gradients of 30 to 40 MW/min within a power range of ∆PG ≈ 600 MW can be required. In this case the load dispatcher directly governs the target setpoint of the turbine load within the mentioned range (which is limited in the turbine control); whereas the load gradi-ent is set by the reactor operator accord-ing to the need of the load dispatcher and the actual possibility of the NPP. The reaction time of the load dispatcher is 15 minutes and typically the NPP gets a new setpoint every 15 minutes according to the needs of the grid and the prices in the electricity stock exchange.

– “Classic” load following operation (3) via telephone contact with the load dis-

patcher with gradients up to 40 MW/min within a power range of ∆PG ≈ 1,000 MW. In this case the load dispatcher com-municates via telephone with the reac-tor operator regarding all aspects of the load ramp (gradient, target load) and often including the duration of the part load situation. The reaction time is more than one hour.

– Generally the primary frequency control can be combined with the other men-tioned grid operating modes.

In all these operating modes, the reac-tor of a PWR follows via the control of the Average Coolant Temperature (ACT) of the primary side. The ACT is an indicator of the energy balance of the PWR; similar to the frequency in the grid, as mentioned be-fore. This ACT is controlled by Control Rods (CR), which mainly compensate the power-relevant so-called “Doppler” reactivity (reactivity describes the relation between production and loss of neutrons), whereas subsidiary controls are mainly responsible for the axial power density distribution in the reactor core and the entire reactivity management (including ensuring sufficient shut down reactivity; controlled with boric acid and demineralised water = BODE).

The new possibilities of digital automa-tion (as TELEPERM® XS) enable the com-plex automation of these operating modes on the reactor side – and, if needed, also on the turbine side, provided that manu-al support is nearly no longer necessary. These possibilities were and will be imple-mented by AREVA with its ALFC-product (ALFC: Advanced Load Following Con-trol). Its main feature is a new adaptive re-actor control and gave the related German projects the name ALV (ALV: adaptive Leis-tungsverteilung- und Bank-Stellungsrege-lung/adaptive power density control). Manifold adaption algorithms to the reac-

AuthorsAndreas KuhnSenior Expert Plant Control and Section Manager TrainingAREVA GmbHKarlstein, GermanyPeter KlausDeputy of the Head of Plant Operation and Head of Production Engineering E.ON NPP Isar 2 Essenbach, Germany

Gen. power PG

(1) (2) (3)

Time

30 s 15 min > 60 min

Fig. 1. Grid relevant operation modes for ALFC.

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VGB PowerTech 5 l 2016 Automated load flexibility of NPP

tor physical variations during the nuclear load cycle enable mainly a precise control of the axial power density distribution in the reactor core and of the reactivity bal-ance. Finally, this is the basis for highly automated load flexibility with the parallel respect and surveillance of the operational limits of a PWR.

This technical paper shows the impressive operational results after the implementa-tion of ALFC in four German NPPs. It also gives perspectives for the approach to ALFC projects for PWR other than those of AREVA/SIEMENS-KWU.

Additionally, an implementation of ALFC in other NPPs can have further benefits, such as the following:

– The variation of low-leakage core load-ings to minimise fuel costs and/or

– nominal integral reactor power uprates can be possible.

These increased challenges led to several projects in PWRs to implement the ALFC:

– KKP 2 (Philipsburg NPP unit 2); utility EnBW; implementation in 2008

– KKI 2 (Isar NPP unit 2); utility E.ON; im-plementation in 2014 (August)

– KBR (Brokdorf); utility E.ON; imple-mentation in 2015 (May)

– KWG (Grohnde); utility E.ON; imple-mentation in 2015 (October)

– KKG (Gösgen-Däniken in Switzerland); utility ALPIQ; project started in October 2015; implementation will be in 2017.

Regarding the three E.ON-projects and the project in Gösgen there was/is only an ALFC software upgrade necessary; the needed digital I&C platform was imple-mented in forerunner projects.

Before the implementation of the ALFC in the mentioned NPPs itself, the ALFC soft-ware was tested at the plant-specific train-ing simulators together with the shift per-sonnel (reactor operator, shift leader), the responsible engineers of the NPP and the AREVA design engineers.

Basics regarding the new adaptive reactor control concept

The possibilities of digital TELEPERM® XS technology have been fully employed with these ALFC projects and the possibility of physical parameterisation – adaptation to the reactor core – is being used. The reactor power control receives a new set of reactiv-ity coefficients by the Service Unit (SU) with every new core loading. These coef-ficients and their changes are determined for each fuel cycle as a function of the ref-erence boric acid concentration which de-creases during the fuel cycle.

Knowing these coefficients, in conjunction with more precise calculation methods in the form of physical balances, allows a more accurate control

– with the power distribution fine control mode at full load operation and

– at part load during load cycles.

Near full load the relevant dead bands of the control rod bank position control can be reduced. This assures high control qual-ity near the full load point which is impor-tant if the driving margins regarding power density peak limitation (F i g u r e 2) are very low. These peak relevant limit values consider mainly the “Departure of Nucle-ate Boiling” (DNB), Pellet Cladding Inter-action (PCI) and condition limit values for the LOCA accident analysis (LOCA: Loss of Coolant Accident).

An adaptive Power Distribution (PD) con-troller driven by a 2-point Xe-calculation (Xe: Xenon-135, a fission product which influences the reactivity balance) for the upper and lower core half helps to keep the axial power distribution shape nearly con-stant for the whole fuel cycle which inhib-its the beginning of any axial Xe oscillation. This helps to return to the conditioned full load situation – after having part load con-ditions. Furthermore, reactivity balances – including the calculation of the integral Xe-non reactivity (regarding to the complete core) and dead time effects in the Chemical

Volume Control System (CVCS) – help to return to full-load operation.

These mentioned ingredients are the basic necessities for a fully automated flexible load operation.

Besides all these technical aspects, we had a first positive response in the Ger-man press (e.g., in the “Frankfurter Rund-schau”) after implementation of ALFC in the NPP Brokdorf (KBR):

“ […]the control of the reactor power was improved to be able to support the energy transition with increasing renewable energy in the grid by flexible load operation accord-ing to the need of the load dispatcher[…]. ”

Self-adapting power distribution controller

Deborating the reactor coolant system in order to compensate the fuel burn-up leads to a redistribution of the power density into the lower core half. This redistribution means the plant engineers have to consid-er the following as part of their operating strategy:

– This redistribution can, in principle, be compensated by withdrawing the entire L-bank (= power distribution relevant control bank) in the first fuel cycle phase so that the axial power distribution sig-nal of the in-core instrumentation re-mains constant.

– If the L-bank has reached a strategic up-per position (either top of the core or a strategic upper position in which it is still capable of moving in both directions), further power density redistributions downwards can no longer be compen-sated. The power distribution controller does not detect this redistribution as a xe-non oscillation. This – slightly changing – equilibrium power distribution, which is important as target value for the part load transients, is automatically memo-rised in equilibrium conditions which occur between the Begin Of fuel Cycle (BOC) over the Mid Of Cycle up to the End Of Cycle (EOC); see Figure 2. The situation in which it can be automatically memorised is the constant load operation with Xe-equilibrium. Normally this con-dition occurs every fortnight for physical calibration/measurement activities.

As a result, manual actions are not needed at all to adjust the power distribution con-troller because the controller adapts itself to the equilibrium power distribution. Therefore, only the corresponding L-bank manual set point adjustment is needed to define the long-term nuclear strategy with-in a fuel cycle. Regarding further future optimisations this shall also be automated. That means that in stationary conditions the PD-controller adapts the L-bank set-point with the focus to optimise all margins to relevant limitation margins in the upper and lower core-half.

D, L: Bank position PD: Power distribution

BOC720 ppm

MOC220 ppm EOC

20 ppm

Automatic memorising of the PDif Xe-equilibrium is at 100 % PR

DNB

PCILOCA

DNBPCILOCA

PD: Relevant limit values

PD in W/cm

0

1

2

3

4Coreheightin m

Fig. 2. Self­adaptation to fuel burn­up dependent PD change and PD­relevant limit values.

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Automated load flexibility of NPP VGB PowerTech 5 l 2016

If load changes have to be carried out, this memorised equilibrium power distribution shape shall be kept as constant as possible (F i g u r e 3) to inhibit any axial Xenon os-cillation in the beginning. Following this objective, it is the best prerequisite to reach full load without any conflict with limita-tion values. This is managed impressively by the new PD-controller of ALFC, which is triggered by an axial 2-point Xe-calculation and which has (compared with older solu-tions) a very fast dynamic behaviour which is additionally adapted to control rod-posi-tions and to load gradients. After damping the Xenon oscillation to nearly zero, the PD controller adjusts the actual axial power density distribution to the above-described memorised shape exactly. Principally, the axial power distribution in the reactor core is disturbed by the control rod movement which is needed on the one hand to com-pensate the reactivity effects due to reac-tor power change and on the other hand to local reactivity effects due to the reactor coolant temperature changes caused by the temperature part load diagram. Principal-ly, this triggers an axial Xenon oscillation; which can increase in larger reactor cores.Summarised, all these measures allow:

– Maintaining the control of the PD do not require manual intervention of the reactor operator because the adaptive PD controller keeps the – automatically memorised – axial equilibrium PD shape nearly constant and hereby inhibits any axial Xe-oscillation – even in load follow-ing operation.

– And hereby the operation of the reactor within very small margins to the limit values of the limitation system (Figure 3) is possible.

ALFC ensures the very fast damping of any PD oscillation which is the prerequisite for accumulative stochastic load changes – even with small operating margins – as you will see in the following.In parallel the reactivity management of ALFC ensures the optimal bank position

with boric acid and demineralised water (BODE) injections considering the integral Xe-reactivity effects.For cases in which a sufficient margin to limitation values cannot be ensured by the normal control algorithms the ALFC auto-matically uses the possibility to stop the load increase in the setpoint generation module in the turbine load controller as long as the normal control algorithms are able to increase the margins again. After this the turbine controller continues with the desired load increase.

Operational experience

Regarding the remote secondary control the load dispatcher changes or can change the load set point of the plant every 15 min-utes according to the load balance of the grid and the prices in the electricity stock exchange. The experience in this operating mode is very impressive:

– F i g u r e 4 shows this operation mode with a time scale of one day. The graph depicts the stochastic changes of the generator power within a band of ap-

proximately 500 MW and the fully au-tomated compensation of the short term reactivity effects with the control rods of the D-bank (D: Doppler relevant reactiv-ity) and the control of the axial power distribution mainly with the L-bank.

– F i g u r e 5 shows this operation mode with a time scale of nearly one month. The graph depicts the stochastic changes of the generator power within a band of approximately 600 MW and the fully au-tomatic compensation of the long-term reactivity effects of the Xenon reactivity with boric acid and demineralised water (BODE) according the basic design of any PWR. Additionally, the impressive correlation of Xenon in upper and lower core half is to be noted as the result of the new ALFC PD-controller.

– The increase of the demand for deminer-alised water – to compensate the marked integral Xe-oscillation (Figure 5) – de-pending on the reference boric acid con-centration CR is shown in F i g u r e 6 in relation to the capacity of the evaporator in the coolant treatment system. Here you can see that there is no limitation for this operation mode up to the end of the fuel element cycle with approximately 80 ppm boric acid concentration.

Besides the remote secondary control of the plant by the load dispatcher the pri-mary frequency control with larger load jumps becomes more and more important and well-paid by the electricity stock ex-change. F i g u r e 7 shows the successful qualification test of a -200 MW (–14 % at 1,460 MW) load jump downwards within 30 seconds and after 15 minutes back to 100 % – also within 30 seconds – and after a break of 15 minutes the same again. This qualification test – which is a worldwide record – was carried out in in the EnBW Philippsburg 2 NPP, which has a nominal generator power of 1,460 MW.The quantity of load changes during the last entire fuel cycle of KKI 2 (2014/2015)

100 % PG 100 %Xe-Max.

40 MW/min

6 h at 30 %

Coreheightin m

Conditionlimitations

relatedto PD

PD in W/cm

D, L

D,L: bank positionPG: generator power

Fig. 3. Load ramp with constant axial power distribution (PD) shape “100 % – 30 % – 100 %” (commissioning test in E.ON NPP KKI 2).

30 MW/min

1,018 MW

PG1,483 MW

D-bank

L-bank

1 day

∆PG =approx.500 MW

Fig. 4. Stochastic load changes by load dispatcher with fully automatic control of short­term reactivity and axial power distribution (E.ON NPP KKI 2).

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VGB PowerTech 5 l 2016 Automated load flexibility of NPP

is shown in F i g u r e 8. Besides the impres-sive behaviour of new implemented ALFC the increasing plant stress is considered by the manufacturer and the utility:

– The general German plant design by the manufacturer considers load following operation from the beginning. A part load diagram with a constant Average Coolant Temperature ACT minimises thermal stress and is optimal regarding reactivity effects; the in-core instrumen-tation with SPND (Self Powered Neu-tron Power Detectors) ensures an opti-mal surveillance of the power density in the reactor core, a fatigue monitoring system allows the surveillance of the thermal stress of relevant components, a reasonable quantity of load collectives is the basis of the plant design, etc. The licensing situation also considers this.

– The utilities are checking the load and stress collectives, observing the relevant measurements and adapt/modify – where required – the maintenance con-cept.

Benefits

Besides the described technical benefits of improved load flexibility, there are further economic benefits:

– Often a more precise reactor control al-lows a nominal power uprate and/or sav-ing of fuel elements, as it was shown in the KKP2 NPP (the first ALFC project), because this control can operate with smaller margins regarding the discussed limitation values. Both – namely the nominal power uprate and/or saving of fuel elements – lead to an increased local power density.

– A load following operation with more part load conditions reduces the fuel burn-up and can lead to the minimi-sation of loading new fuel elements. Ac-cording to actual experience of E.ON, it can be possible to save a quartet of fuel elements.

– The prices which can be obtained for the discussed grid operating modes lead – besides the two above-mentioned bene-fits – to a further economic benefit. This benefit alone allowed amortisation of the ALFC software upgrades of the three mentioned E.ON NPP within one year.

Additionally, there is a benefit for the nu-clear safety:

– by minimising the needed manual inter-ventions,

– by an automatic reactivity management with special process computer diagrams which inform the reactor operator,

– and by the automated flexible navigation depending on limitation margins regard-ing Pellet Cladding Interaction (PCI), analysis of Loss of Coolant Accident (LOCA), analysis of Reactivity Insertion Accidents (RIA).

∆PG =approx.560 MW

1,508 MW

946 MW

PG

30 MW/min

Xe upper core half

Xe lower core half

Xenon in 6 days => 6 times ±400 pcm=> Compensation by boric acid and demineralised water (=BODE)=> Besides: Impressive correlation of Xe in upper and lower core half is the result of the new ALVC-PD-controller

27 days

Fig. 5. The long­term integral reactivity effects are automatically compensated by BODE (E.ON NPP KKI 2).

Dem

in. w

ater

[Mg/

d]

Limitation bythe evaporation capacity(coolant treatment)170 Mg/d

Demin. water(=> BODE)due to Xenon

BOC

EOC300

250

200

150

100

50

0

< 80 ppm0 100 200 300 400 500 600 700 800 900 1,000

CR in ppm

Fig. 6. Long­term reactivity effects – according Figure 5 – can be compensated up to approx. 80 ppm by BODE.

Activation<30 s

Deactivation<30 s

Activation<30 s

Deactivation<30 s

-200 MW= -14 % = + 0.2Hz

PG(measured value)

PG setpoint(frequencydependent change)

PG = 100 %

Delivery15 min

Break15 min

Delivery15 min

Fig. 7. Successful qualification test of 14 %­PG­jumps in Philippsburg 2 (pre­Konvoi Plant KKP 2) with ALFC.

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Perspective

Besides the capability for further increased load gradients and jumps, which can lead to a further increased economic benefit, a feasibility study of a “predictive Xe-re-activity calculation input” for the reactor control shall be the next step to improve the reactivity management. This reactivity management leads to further minimisa-tion of boric acid and demineralised water injection. An improved visualisation of the complete reactivity balance shows how the target power (e.g. 100 %) can be reached from a part load situation.

Start of a new ALFC project

All the new ALFC projects started with a small feasibility study which analysed the relevant boundary conditions to other au-tomation systems, to the control room, the affected software modules, the required process-related tests, etc.Regarding an ALFC implementation in other PWR than those of AREVA/SIEMENS-

KWU the approach should be started with a more detailed feasibility study which analyses mainly the following aspects:

– I&C architecture, – process analysis,

– possible load range and gradients for the several grid-relevant operating modes,

– suitable load controller for the turbine control,

– control rod movement concept, – core instrumentation – capability re-

garding surveillance and control of the local power density,

– condition limitations regarding the rel-evant accident analysis,

– automatic sliding limit values for each core half regarding Pellet Cladding In-teraction (PCI),

– part load diagram regarding ACT, main steam pressure, pressuriser level,

– load collectives regarding thermal component stress in the plant design,

– fatigue monitoring system,

Month/year

MW

ALFC implementation; BOC

EOCnat.Stretch-out

PG

1,600

1,400

1,200

1,000

800

600

400

200

0

1,513 MW

426 MWload gradient 30 MW/min

22.5 MW/min

2 to 5 MW/minCommissioning with 30/40 MW/min

08/2014 09/2014 10/2014 11/2014 12/2014 01/2015 02/2015 03/2015 04/2015 05/2015 06/2015

Surveillance of increasing plant stress by EON:General plant design considers load following operation

Observation of measurements(e.g. at turbine control valves)

Checking and – where required – modificationof maintenance concept

Fig. 8. Fuel cycle 2014/2015 in E.ON NPP KKI 2 with ALFC and surveillance of plant stress.

– license situation of the NPP regarding load following operation,

– plant-specific simulator for training and test aspects,

– training needs, – stepwise modular implementation of

ALFC, e.g., implementing a reactivity management control regarding BODE-injection first.

The utility E.ON, which implemented three ALFC-projects in their NPPs Isar 2 (KKI 2), Brokdorf (KBR) and Grohnde (KWG), would support new ALFC projects – if desired – with its experience and know-how regarding:

– operation, – maintenance, – licensing of the NPP, – evaluating component stress.

References[1] Innovative Control Concepts for German

Pressurized Water Reactors. Authors Kuhn (AREVA) and Brzozowski EnBW, atw Inter-national Journal for Nuclear Power, www. atomwirtschaft.com; May 2010.

[2] Innovative Control Concepts for German Pres-surized Water Reactors.Paper presented at the Annual Meeting on Nuclear Technology (KTG German Nuclear Society), Authors Kuhn (AREVA) and Brzozowski (EnBW) Berlin; May 2010.

[3] Adaptive Reactor Control to minimize man-ual interventions. Presentation on the IAEA Technical Meeting (TM-49423) on Flexible Operation for Load Following and Frequen-cy Control in New NPP, Author Kuhn (ARE-VA)Erlangen, NH-Hotel; September 2014.

[4] Adaptive Reactor Control to Minimize Manual Interventions during Flexible Load Operation. Paper presented at the Annual Meeting on Nuclear Technology (KTG German Nuclear Society), Authors Kuhn (AREVA) and Peter Klaus (E.ON) and Brzozowski (EnBW), Ber-lin; May 2015.

[5] Improving automated load flexibility in Nu-clear Power Plants (NPP). Paper presented at the VGB-Congress “Energy Transition”, Authors Kuhn (AREVA) and Peter Klaus (E.ON), Vienna; September 2015. l

 

 

 

 

 

 

 

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