Technology Development, Design and Safety Features of PHWR and Their Operating Performance

7/29/2019 Technology Development, Design and Safety Features of PHWR and Their Operating Performance

1/57

U.C.MuktibodhNuclear Power Corporation of India Limited

Workshop on

Technology Assessment of SMRs forNear Term Deployment

Dec 5th 9th , 2011IAEA Headquarters,

Vienna, Austria


2/57

Lecture Outline

Technology Development

Design features of 220, 540 & 700 MWe Indian

PHWRs

Safety features of 220, 540 & 700 MWe IndianPHWRs

Operating Performance of Indian PHWRs


3/57

Technology

Development


4/57

Launch of Nuclear Power Program

1964

Construction

work at First

NPP Began

1948

Atomic

EnergyCommission

1954

Department of

Atomic Energy

Bhabha

Atomic

ResearchCentre

Research

Reactor

APSARA

1956

Training

School

(Nuclear

Science &Technology)

Research

Reactor

CIRUS

1957 1960

Before setting up the first NPP, we had the basic infrastructure Policy,

Knowledge Base, Research Reactors, Radiation Protection, Human Resources

and since then moving continuously

and moving responsibly


5/57

PHWR Program

1970s

TECHNOLOGY

DEMONSTRATION

1980s

INDIGENISATION

1980s

STANDARDISATION

1990s

CONSOLIDATION

2000s

COMMERCIALISATION

ECONOMY

OF SCALE

RAPP-3&4 KAIGA-3&4

RAPS-1&2 MAPS-1&2 NAPS-1&2 KAPS-1&2 KGS-1&2 RAPP-5&6

TAPS-3&4

220 MWe

540 MWe

700 MWe Reactors

2005-2006


6/57

Development of Nuclear materials Mining and processing of nuclear fuel Uranium and

Thorium were developed.

Fabrication of all types of fuel required for reactors

Production of Heavy Water

Back end technology of Waste Management


7/57

Calandria- Reactor pressure vessel for PHWR

Development of Manufacturing Technologyfor Class-1 Components


8/57

REACTOR END SHIELD

Development of ManufacturingTechnology for Class-1 Components


9/57


Steam Generator


10/57


Fuelling Machine


11/57

Development of Manufacturing Technologyfor Class-1 Components

Technology development for Zr Components


12/57

Precision component manufacturing


13/57

Development of inspection techniquesConcurrent with manufacturing technologies, NonDestructive Examination techniques and equipment

for these techniques were developed indigenously.

Optical instruments Laser technology


14/57

Development of Instrumentation & Control


15/57

Back-end technology development

Densification unit for plastic waste Simultaneous incineration of low level solid waste along with organic

liquid waste

Immobilisation of spent resins in polymer matrix

Special slag cement developed as an alternate matrix for spentresin, to avoid potential hazards in using polyster styrene

Special tile holes with higher integrity and shielding developed for

storing spent SPNDs

Evaporation system developed to reduce tritium discharge to waterbody


16/57

Other advancements in Reactor technology

Analytical capabilities Reactor core design / burn-up optimisation studies

Seismic input parameter generation & evaluation / re-

evaluation (walk-throughs & re-analysis)

Probabilistic Safety Assessment

Ageing Management techniques Coolant Channel replacement

Feeder replacement

Robust monitoring & inspection plan

Control & Instrumentation From relay-based technology to Computer-based

Full scale simulator

St t f th t T i i


17/57

17

State of the art TrainingFacilities: Simulator


18/57

Erection ofTurbo Generator

SG Erection Calandria

Erection

End ShieldErection

Improved construction methodology

Open top construction

Steam GeneratorErection


19/57

Growth of Nuclear Reactor Technology

Research reactors to commercial power

reactors with emphasis on self reliance

Innovations

Evolutions

Improvements

Capacity

Safety

Reliability

Economics

Sustainability


20/57

Design Features of220, 540 &700 MWe

Indian PHWRs


21/57

Design Features (PHWR-220)

Thermal Outp ut : 756 MWt

Gross Electr ical Output : 235 MWeModerator/Coolant Heavy Water

No. of chann els 306

Reactor Coolant Pressure 8.5 MPa

Reactor Coolant temp. 293 deg. C

Coolant Loops Single, 4 SGs

Moderator temp . 44/65 deg. C

Steam pressur e 4.03 MPa(a)

Steam temperature 250 deg. C

Natural Uranium (UO2), 19 el em en t Fu el Bund le

12 bundles per channel

Average disc harge bur n-up : 6700 MWD/TeU

On-power refuel ing

2 independent of fs i te pow er sourc es

3 X 100% DGs as Class-3 power s upply

3 tier Emerg ency Pow er Supply (Class -3,2&1)

Main Contro l Room for no rmal operat ion &

Backup Contro l Room for independent Safety System

operat ion & monitor ing o f cr i t ica l parameters

Plant Design L ife : 40 years

Core Damage Frequency : 10-5

Large Early Release Frequenc y : 10-6


22/57


Thermal Power Output : 1700 MWtGross Electr ical Output : 540 MWe

Moderator/Coolant

Heavy Water


Reactor Coolant Pressure 98 MPa

Reactor Coolant temp. 304 deg. C

Coolant Loops Two (Vert ically s plit), 4 SGs




Natural Uranium (UO2), 37 el em en t Fu el Bund le

13 bundles per channel


On-power refuel ing


4 X 50% DGs as Class-3 pow er supply

3 tier Emerg ency Pow er Supply (Class -3,2&1)







PRESSURISER


23/57


Thermal Power Output : 2166 MWtGross Electr ical Output : 700 MWe

Moderator/Coolant

Heavy Water


Reactor Coolant Pressure 98 MPa

Reactor Coolant temp. 310 deg. C (3% part ial bo il ing )

Coolant Loops Two(Inter leaved feeders), 4 SGs




Natural Uranium (UO2), 37 el em en t Fu el Bund le12 bundles per channel


On-power refuel ing


4 X 100% DGs as Class-3 power s upply

3 tier Emerg ency Power Supp ly (Class-3,2&1)

Alternate AC Source located at higher elevat ion







PRESSURISER


24/57

Reactor Vessel (Calandria) inside waterfilled Vault


25/57

Reactor Coolant System layout to assist Naturalcirculation

Steam GeneratorCoolant Pump

PHWR-220PHWR-540 / 700


26/57

Bi-directional On-power refueling


27/57

Inherent Design Safety Features of PHWRs

Higher neutron generation time Low fissile content

Passive core cooling

Online re-fuelling and low excess reactivity in the core.

Short bundle length limits consequences in case of singlebundle failure

On power detection & removal of failed fuel.

Moderator as heat sink in the event of LOCA.

Reactor vessel surrounded by large pool of water

Reactivity Devices located in low pressure moderator : Rod

ejection ruled out


28/57

Fuel Bundle

Fuel Bundle

End Plate

Fuel Element

Pellets

Spacers

Fuel Bundle Dia : 81.7 mm

Length : 495 mm Fuel Bundle Dia : 102.4 mm

Length : 495 mm

PHWR-220 PHWR-540 / 700

19 Element37 Element


29/57

Fuel Transfer Scheme (PHWR-220)

REACTO

R

NEW FUEL MAGAZINE

TRANSFER MAGAZINE

FUELLING

MACHINE

FUELTRANSFER

PORT

TRANSFER MAGAZINE

SHUTTLE

TRANSFER

STATION

CONTAINMENT WALL

SHUTTLE TRANSPORT TUBES

TRANSFER ARM

SHUTTLE

RECEIVING STATION

SPENT FUEL BAY

NEW FUEL LOADING TROUGH


30/57



31/57


MOBILE TRANSFER

MACHINE


32/57

Control & Instrumentation

Use of digital technology for alarm generation

Adoption of Computer Based Systems (CBS) for data

acquisition for major process and reactor control application.

For one of the Reactor Protection Systems, hardwired logics

are retained to achieve diversity

Operator interface with menu-driven screens for control action

and system information

Computer Based Systems developed and qualified in a

systematic manner with extensive documentation forverification and validation


33/57

Control Room (PHWR-220)


34/57

Control Room (PHWR 540)


35/57

35

Control Room (PHWR 700)


36/57

Safety Features of220, 540 &700 MWe

Indian PHWRs


37/57

Safety Features (PHWR 220)

ShutdownSystems

Core CoolingSystems

ContainmentSystems

PSS SSSECCS Double Containment

Engin eered Safety

FeaturesHigh pressure D2O

in ject ion

Low pressure H2O

inject ion

Long term

recirculat ion

S.

No.Device

Neutron

Absorber

1Primary Shutdown

SystemCadmium

2Secondary

Shutdown System

Natural

Boron

3 Liquid PoisonInjection System

NaturalBoron

Passive VapourSuppression Pool

Primary Cont. FiltrationSystem

Secondary Cont. Clean-up

& Purge SystemPrimary Cont. Controlled

Discharge System

RB Cooling SystemGROUP-1 GROUP-2

PSS SSS

ECCS Cont. Sys.

Two Group Concept :


38/57

Reactor Shutdown Systems (PHWR 220)

ASSEMBLY.TOP HATCH

GUIDE TUBE ASSEMBLY

STOPPER PLATE

CENTRAL BEAM

GUIDE TUBE LOCATOR

ASSEMBLY.

(PARKED OUT POSITION)ROD BOTTOM TIP

HORIZONTAL CENTRAL

PLANE OF CALANDRIA

CALANDRIA TUBE

CALANDRIA NOZZLE

GUIDE TUBE EXTENSION

SPRING ASSEMBLYINITIAL ACCELERATION

SHUT-OFF ROD ASSY.

CALANDRIA VAULT

SUPPORT SLEEVEDECK PLATE

DECK PLATE

SHIELD PLUG

DRIVE MECHANISM

STANDPIPE THIMBLE

HELIUM LINE

Primary Shutdown System

S.No. Device Absorber Features

1 Primary Shutdown System Cadmium 14 Rods, Gravity driven

2 Secondary Shutdown System Li Pentaborate 12 locations, Stored Energy

3 Liquid Poison Injection System Natural Boron Direct inj., Stored Energy


39/57

Emergency Core Cooling System(PHWR 220)

High Pressure

Injection

Long Term Re-circulation


40/57

Containment Systems (PHWR 220)

Design leakage rate through Containment : 1% volume per day


41/57


ShutdownSystems

Core CoolingSystems

ContainmentSystems

SDS#1 SDS#2 ECCS Double Containment

Engin eered Safety

FeaturesHigh pressure H2O

in ject ion

Long term

recirculat ion

S.

No.

DeviceNeutron

Absorber1 Shut Down System # 1 Cadmium

2 Shut Down System # 2 GadoliniumNitrate

Passive VapourSuppression Pool

Primary Cont. Filtration &Pump Back System

Sec. Cont. Cleanup & PurgeSystem

Primary Cont. ControlledDischarge System

RB Cooling SystemGROUP-1 GROUP-2

SDS#1 SDS#2

ECCS Cont. Sys.

Two Group Concept :


42/57


S.

No.Device

Neutron

AbsorberFeatures

1Shutdown System#1

(SDS#1)Cadmium 28 Rods, Gravity driven

2Shutdown System#2

(SDS#2)

Gadolinium

Nitrate

6 LPI perforated tubes,

Stored Energy

SDS#1

SDS#2


43/57


High Pressure Injection

Long Term

Re-circulation

Pumps :

4 X 50%

Heat Exchangers :

3 X 50%

C i S


44/57


Design leakage rate through Containment : 1% volume per day

S f t F t


45/57


ShutdownSystems

Core CoolingSystems

ContainmentSystems

SDS#1 SDS#2 ECCS Double Containment

Engin eered Safety

FeaturesHigh pressure H2Oin ject ion

Lon g term

recirculat ion

S.

No.

DeviceNeutron

Absorber1 Shut Down System # 1 Cadmium

2 Shut Down System # 2 GadoliniumNitrate

Containment Spray System

Sec Cont. Clean-up & PurgeSystem

Primary Cont. ControlledDischarge System

GROUP-1 GROUP-2

SDS#1 SDS#2

ECCS Cont. Sys.

Two Group Concept :



46/57


S.

No.Device

Neutron

AbsorberFeatures

1Shutdown System#1

(SDS#1)Cadmium 28 Rods, Gravity driven

2Shutdown System#2

(SDS#2)

Gadolinium

Nitrate6 PIU tubes, Stored Energy

SDS#1

SDS#2

Emergency Core Cooling System


47/57

High PressureInjectionTRAIN-2

Long Term Re-circulationTRAIN-1


High PressureInjectionTRAIN-1

Long Term Re-circulationTRAIN-2

P i D H t R l S t


48/57

Passive Decay Heat Removal System(PHWR 700)

C t i t S t (PHWR 700)


49/57


Design leakage rate through Containment : 1% volume per dayNo emergency counter measures anticipated after Severe Accident.

2 Trains, each trainhaving 2 X 100% pumpsand 2 X 100% HeatExchangers

P i i f S A id t M t


50/57

Provisions for Severe Accident Management

Independent Fire Water injection provision (Diesel drivenpumps)

Hook-up provisions for :

Steam Generators

Reactor Vessel

Calandria Vault

End Shields

Reactor Coolant System

Alternate AC Source located at higher elevation


51/57

OperatingPerformance of

Indian PHWRs

PHWR U it i O ti


52/57

PHWR Units in Operation

S.

No. Site/Station/Project Units Status

Year of

commercialoperation

Rated

capacity(MWe)

1 Tarapur Atomic Power Station TAPS-3&4 Operating 2005, 2006 2 x 540

2 Rajasthan Atomic Power Station RAPS-1&2RAPS-3&4RAPS-5&6

OperatingOperatingOperating

1973, 198120002009

100, 2002 x 2202 x 220

3 Madras Atomic Power Station MAPS-1&2 Operating 1984, 1986 2 x 220

4 Narora Atomic Power Station NAPS-1&2 Operating 1991, 1992 2 x 220

5 Kakrapar Atomic Power Station KAPS-1&2 Operating 1993, 1995 2 x 220

6 Kaiga Atomic Power Station KGS-1&2KGS-3KAIGA-4

OperatingOperatingOperating

200020082010

2 x 220220220

More than 300 reactor years of safe & reliable operation


53/57

Availability Factors of Operating Units86 90 91 88 89 85 83 82

9288

0

10

20

30

40

50

60

70

80

90

100

2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11*

Capacity Factors of Operating Units


54/57

54

Capacity Factors of Operating Units

84.89 89.66

81.176.29 74.4

63.04

53.72

49.61

60.8

71.37

0

10

20

30

40

50

60

70

80

90

100

2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11


55/57

Longest Continuous Reactor Operation

289

590

404 394

346

432

250

371

414 407

486

529

0

100

200

300

400

500

600

700

TAPS-1 TAPS-2 RAPS-3 RAPS-4 MAPS-1 MAPS-2 NAPS-1 NAPS-2 KAPS-1 KAPS-2 KGS-1 KGS-2

Days


56/57

P

-Sv


57/57

Thank You for your attention

Documents

Technology Development, Design and Safety Features of PHWR and Their Operating Performance