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Design, Safety and Operability Performances of 220 MWe, 540 MWe & 700 MWe PHWRs in India
Design, Safety and Operability Performances of 220 MWe, 540 MWe & 700 MWe PHWRs in India
U.C.Muktibodh
NPCIL, India
Lecture Outline
Introduction to Indian PHWR designs Nuclear Steam Supply Systems Safety Systems and ESFs Turbine Generator Systems
Current Status
FIRST STAGE
Established Comprehensive Indigenous Capabilities for Designing, Equipment Manufacturing, Constructing, Commissioning, O&M of 220 MWe PHWRs
SECOND STAGE
THIRD STAGE
Experimental reactor with U233 fuel in operation. Thorium Bundles in PHWRs. AHWR-300 MWe being developed in BARC. Technology Demonstration for electricity generation from Thourium. Bridge between the I & III Stages to be Launched in X plan
Developed 540 Mwe PHWRs & operating experience gained; Unit size scaled up to 700 MWe Developed Front End & Back End Technologies of Complete Fuel Cycle
MWe 4 units of 700 MWe under construction. More PHWRs of 700 MWe capacity planned in other states of India. Design of PHWRs in India has evolved over the years to grow into a robust and a proven model
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
1 Tarapur Maharashtra Site (TMS) TAPS-1&2 TAPS-3&4 2 Rawatbhata Rajasthan Site RAPS-1&2 (RRS) RAPS-3&4 RAPS-5&6 RAPP-7&8 3 Madras Atomic Power Station MAPS-1&2 4 Narora Atomic Power Station NAPS-1&2 5 Kakrapar Atomic Power Station KAPS-1&2 KAPP-3&4 6 Kaiga Atomic Power Station KGS-1&2 KGS-3 KGS-4 7 Kudankulam Atomic Power KKNPP-1&2 Project KKNPP-3&4
BWR Operating PHWR Operating PHWR Operating PHWR Operating PHWR Operating PHWR Under construction PHWR Operating PHWR Operating PHWR Operating PHWR Under construction PHWR Operating PHWR Operating PHWR Operating LWR Under construction LWR Under construction
1969 2005, 2006 1973, 1981 2000 2009 2016 1984, 1986 1991, 1992 1993, 1995 2015 2000 2008 2010 2011 2017
2 X 160 2 x 540 100, 200 2 x 220 2 x 220 2 x 700 2 x 220 2 x 220 2 x 220 2 x 700 2 x 220 220 220 2 x 1000 2 x 1000
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
line with the internationally evolving safety standards and to cater to the seismic environment at the site. KAPS-1&2, KAIGA-1&2 and RAPS-3&4 saw further improvements leading to standardisation in design and layout for 220 MWe PHWRs. 2 units of 220 MWe each were constructed subsequently at KAIGA3&4 and RAPP-5&6. 2 units of 540 MWe have been constructed at TAPS-3&4 with minimum import content. 4 units of 700 MWe are under construction and many more planned.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
RAPS to current 700 MWe units. Enormous amount of construction, operation & maintenance experience and adoption of state of the art technology for engineering and analysis has contributed in development of a proven, robust, safe and reliable model of the Indian PHWR, which will fulfil the energy requirements of the country to a large extent. Indian PHWR is a combination of inherent and engineered safety features, incorporating defence in depth through active and/or passive means to cope with DBA.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
concrete structure Calandria Vault On-power refueling Double containment Suppression Pool (220 MWe, 540 MWe)
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
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220 MWe
755 MWth 235 MWe 210 MWe
27.8%
40 yrs. Heavy Water Light Water
28.08 %
40 yrs. Heavy Water Light Water
29.08 %
40 yrs. Heavy Water Light Water
Moderator material
Heavy Water
Heavy Water
Heavy Water
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
220 MWe
10-5 / Year 10-6 / Year 20 mSv/Yr * 30
540 MWe
10-5 / Year 10-6 / Year 20 mSv/Yr * 30
700 MWe
10-5 / Year 10-6 / Year 20 mSv/Yr * 30
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
540 MWe
28.1x106 kg/h 100 kg/cm2g (nom.) 44 deg. C 40.1 kW/m Natural UO2
700 MWe
28.9 x106 kg/h 100 kg/cm2g (nom.) 44 deg. C 50.2 kW/m Natural UO2
Zircaloy - 4
19 elements 6700 MWd/T
Zircaloy - 4
37 elements 7500 MWd/T
Zircaloy - 4
37 elements 7050 MWd/T
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
540 MWe
7800 mm
32 mm Austenitic SS 304 L 392 28.6 sq lattice 103.4 mm 5.940 m
700 MWe
7800 mm
32 mm Austenitic SS 304 L 392 28.6 sq lattice 103.4 mm 5.940 m
5996 mm
25 mm Austenitic SS 304 L 306 22.86 sq lattice 82.6 mm 5.085 m
Zr 2.5% Nb
Zr 2.5% Nb Zr 2.5% Nb
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Number of SGs
SG tube material
Type of coolant pump
Incoloy 800
Vertical, Centrifugal, single stage.
Incoloy 800
Vertical, Centrifugal, single stage.
Incoloy 800
Vertical, Centrifugal, single stage.
Pressurizer volume
--
30 Cub M
45 Cub M
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
220 MWe
540 MWe
700 MWe
Prestressed ICW, Prestressed ICW, Prestressed ICW, Reinforced OCW Reinforced OCW Reinforced OCW 42.56 m dia 55.35 m ht 0.27 MPa (a) 1 % V / day 49.5 m dia 50.1 m ht 0.24 MPa (a) 1 % V / day 49.5 m dia 53.1 m ht 0.26 MPa(a) 1 % V / day
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
540 MWe
Active- SD cooling system Passive Thermo syphon through SGs
700 MWe
Active- SD cooling system Passive Thermo syphon through SGs
ECCS
ECCS
ECCS
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
540 MWe
Tandem compounded, Horizontal impulse reaction type. 1 HP + 2 LP Direct coupled, Hydrogen cooled rotor
700 MWe
Tandem compounded, Horizontal impulse reaction type. 1 HP + 3 LP Direct coupled, Hydrogen cooled rotor
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
single bundle failure. Passive core cooling feature. On power detection of failed fuel. Online fuelling and low excess reactivity in the core. Moderator as heat sink. Reactivity Devices located in low pressure moderator : Rod ejection ruled out
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
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Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
control
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
helped to decongest the layout in the pump room Better maintenance approachability, less maintenance and lesser dose uptake
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Passive Decay Heat Removal System (PDHRS) has been introduced for the first time in 700 MWe units to ensure removal of decay heat in Station Blackout condition
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
and a Calandria with the latter being submerged in the water filled vault. Fuel bundles are contained in 306 / 392 Zr-2.5%Nb pressure tubes, arranged in a square lattice. At each end, the pressure tubes are rolled in AISI 403 modified stainless steel end fittings, which penetrate the end shields and extend into the fuelling machine vaults so as to facilitate on power fuelling
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Calandria
Calandria is a horizontal vessel containing the coolant
channel assemblies, moderator and internal components of various shutdown mechanisms and reactivity control devices. The Calandria structure is fabricated from Austenitic stainless steel type 304 L. The design, fabrication, inspection and testing is in accordance with ASME Section III NB
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
End Shield
The end shield is a cylindrical box whose ends are closed by the Calandria side tube sheet (CSTS) and the fueling side tube sheet FSTS). The box is pierced by 306 / 392 Stainless Steel Lattice tube arranged in a square lattice. The box is filled with water and carbon steel balls in the ration 47:53. The End shields are designed, fabricated and tested as class II components according to the ASME section III NC.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Fuel Bundle
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
fixed column & moving bridge was introduced, which is better suited for high intensity seismic events. Transit equipment called Transfer Magazine was introduced in Fuel transfer system in place of Air Lock and Transfer Arm used in RAPS / MAPS. This facilitates the parallel simultaneous operation of refueling by FMs on the reactor and transferring of irradiated fuel from the Transfer Magazine to the storage pool through Shuttle Transport Tube .
While earlier fuel handling controls employed hard wired system, for
standard PHWRs, computerized control system has been provided. This has resulted in flexibility and better manmachine interface.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
test various sub-assemblies like ram assembly, separators, B-ram drive, various process devices and control equipment was introduced . This is specifically meant for performance testing after major maintenance.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
220 & 540 MWe PHWRs. Based on operating experience, Fuel Transfer system is based on a unique concept of Mobile Transfer Machine, which receives spent fuel from the Fuelling Machine & discharges it to the spent fuel bay. Accordingly, shuttle transport system has been eliminated.
There is a single Spent Fuel Storage Bay (SFSB) in 220
MWe PHWRs, whereas for the later 540 & 700 MWe units, separate SFSB for each unit has been incorporated.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
FM Head
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
BALL VALVE
FT PORT NEW FUEL PORT INDEXER
SUPPORT FRAME
CYLINDER
43
systems was introduced in standard 220 MWe reactors. Primary Shutdown System (PSS) using gravity fall of cadmium absorber elements, and Secondary Shutdown System (SSS) injecting liquid poison column in vertical tubes located inside the core.
Each of these systems is independently capable of
terminating all conceivable fast reactivity transients from any state of the reactor. The reactivity transients considered include those from a large loss of coolant accident, which result in the fastest reactivity addition rate in a PHWR due to coolant voiding in the core.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
called Liquid Poison Injection System (LPIS) to augment the negative reactivity worth to take care of xenon decay during long term shut down.
For 540 Mwe / 700 MWe PHWRs, each of the two shut
down systems have adequate worth for long-term shutdown. These systems are :
SDS#1 : Cadmium rods that fall under gravity SDS#2 : Direct injection of poison in moderator inside
calandria
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
heavy water available in the moderator system is used for emergency injection into the PHT system and long term recirculation for postulated LOCA. Subsequently ECCS for these plants were upgraded by retrofitting high pressure injection system.
For standard 220 MWe units, the ECCS was modified to
All actions up to and including the establishment of longterm recirculation from suppression pool are automatic.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
water accumulators. A simple scheme of injecting light water into all reactor headers followed by low pressure long term recirculation has been adopted. In 700 MWe PHWR, there are two trains of ECCS injection and long term recirculation
2x100% trains of high pressure light water injection system
followed by 2x100% trains of low pressure long term recirculation system by ECCS pumps.
The equipment/components of two trains are located diversely to avoid any common cause failure. Pump suction of each train has got multiple strainers protected by coarse screen to assure continued long term recirculation flow from ECCS sump.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
modifications in successive projects. The first Indian PHWR (RAPS) reactors have a single containment envelope of reinforced concrete cylindrical section and a prestressed concrete dome. In RAPS, pressure suppression in the containment is provided by a dousing system where water stored in a very large tank, at the topmost floor of the containment establishes a curtain of water in the path of releasing steam during postulated loss of coolant accident to limit the building pressure. In MAPS and all standard 220/540 MWe reactors a pressure suppression system is used where the released steamair mixture is led to a large body of water (suppression pool) stored at the bottom of the containment. In MAPS, a partial double containment was used with primary containment of pre-stressed concrete, and secondary of rubble masonry.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
full double containment design has been adopted with primary containment of pre stressed concrete and Secondary containment of Reinforced concrete.
In 700 MWe PHWRs, a containment spray cooling
system is provided for dual functions of fission product mop up and depressurisation of containment to reduce ground level releases in place of pool-based vapour suppression system.
The primary containment for 700 MWe units is lined with
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
50
Purge system.
Primary containment Controlled Discharge
system.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
52
TG & Auxiliaries
Steam turbines for PHWRs are configured as follows :
One single flow high pressure (HP) turbine and one double flow low
pressure (LP) turbine tandem compounded and coupled to 2-pole generator for 220 MWe PHWRs. One single flow high pressure (HP) turbine and two double flow low pressure (LP) turbine tandem compounded and coupled to 2-pole generator for 540 MWe PHWRs One double flow high pressure (HP) turbine and three double flow low pressure (LP) turbine tandem compounded and coupled to 2-pole generator for 700 MWe PHWRs As the steam at the exhaust of HP turbine is around 12% wet, it is routed through moisture separator and re-heater before it is led to LP turbines.
The TG sets for the latest plants are designed to operate on
continuous basis in the band of 47.5-51.5 Hz as against 48-51 Hz to improve availability of the units considering prevailing variation in grid frequency.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
provided
Non-return valves are provided in almost all extraction
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
56
centralization of acquisition of control room data with improved humanmachine interface. The introduction of digital systems (computers) did away with the problems of analog circuit design.
For KAPS-1&2, more steps were taken towards utilizing the
flexibility of computer-based systems. The boldest of the steps was to computerize the alarm and trip contact generation function. The system was called Programmable Digital Comparator System.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
standard 220 MWe, 540 MWe and 700 MWe PHWRs for process and reactor control applications. For one of the Reactor Protection Systems and other safety systems, hardwired logics are retained. In 700 MWe PHWRs, Computer Based Systems are being designed in clusters. This will ensure uniform architecture for systems in a cluster. Operator interface with menu driven screens for control action and system information were also introduced. Upgradation of old projects was started in decade of 1990s and lot of old systems were re-engineered with computerbased systems.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
incidents such as fires that could affect many safety systems at the same time, the I&C of safety systems are located in distinct, physically separate rooms / panels in control building (control equipment room). Each of the safety systems viz. reactor shutdown systems, emergency core cooling system, containment isolation system are provided with a triplicate channel philosophy with 2 out of 3 coincidence logic. This permits one channel to be tested without affecting normal plant operation. It also allows one faulty channel to be put in a safe state. It facilitates inter-channel comparison among the signals
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Control Room
The main control rooms (MCR) have conventional control
room design, which has evolved from plant to plant with incremental improvements based on the plant design and technology available. Hybrid control rooms, wherein computer based operator information displays and parameter selection and settings facilities have been provided. The normal operations are mostly carried out from discrete hardwired controls at the panels. The operator consoles located in the center of these control rooms provide facilities for detailed presentation of data in various formats and also provide capabilities for changing operational parameters using Visual Display Unit (VDU) consoles of individual systems.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
manner, with systems associated with various associated functions suitably located nearby for ease of operations.
Control Room is located in the seismically qualified
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
operator can view the indications & annunciations on the MCR panels from his seat.
The MCR panels and OICs of both the units are arranged in
L shape having linear image with the other unit. The use of computerized systems has reduced the density of components on Main Control Room panels.
A separate Back up Control Room (BCR) has been provided
for each unit. Essential safety functions can be carried out from BCR to bring the unit under safe cold shut down state in case of unavailability of MCR.
BCR has been back-fitted in older units.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
(MCR) is provided. MCR comprises of sitting console based operations with computerized operating procedure, advance fault diagnostics and intelligent alarm system. Plant over view panels and limited hardwired back up control panels are provided. Separate Back up Control Room (BCR) is provided for each unit. Essential safety functions can be carried out from BCR to bring the unit under cold shut down state in case of unavailability of MCR.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
KAPP-3&4 MCR
66
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Electrical Systems
Offsite Power System 400 kV and 220 kV switchyards, 400kV and 220kV grids. Start up power for each reactor unit is derived from 220
kV switchyard through one start-up transformer (SUT) having two secondary windings. Two main cum transfer switching is adopted for 220 kV switchyard. Station Auxiliary Power Supply System (SAPSS) Normal Power Supplies and Emergency Power supplies
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
system
Class-I 48 VDC SCPS system (220 & 540 MWe)
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Operating Modes
Normal operation
Shutdown state of the reactor with primary coolant temperature (inlet to reactor) and pressure close to normal operating condition and the primary coolant pumps (PCPs) running is defined as hot shutdown state.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Reactor maintained sub-critical with specified subcriticality margin and temperature of the PHT system at inlet to the core is less than 550C.
Guaranteed shutdown state(GSS)
A specified shutdown state of the reactor with sufficiently large reactivity shutdown margin, established by the addition of liquid poison into the moderator to provide positive assurance that an inadvertent increase in reactivity by withdrawal of all other reactivity devices cannot lead to criticality.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
recycled in PHWRs.
The Front-End of this cycle like mineral exploration, mining
and processing of ore and fuel fabrication; and back end of the cycle, which includes fuel reprocessing, re-fabrication and nuclear waste management are carried out by different units of Department of Atomic Energy (DAE), Government of India.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
materials like slightly enriched uranium and Mixed Oxide fuel elements have been studied for use in 220 MWe PHWRs. Studies showed that burn-up can be increased up to 30000 MWd/ TeU.
Studies on reactor physics characteristics like reactor control,
shut down margin, fuel, systems thermal-hydraulics and material compatibility have been carried out for each fuel type before taking up actual loading in the reactor.
Reprocessed depleted uranium dioxide fuel bundles, Slightly
Enriched Uranium Bundles (SEU), MOX bundles and thorium dioxide bundles were designed, developed and successfully irradiated in different 220 MWe reactors.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
bundles were used for flux flattening in the initial core such that the reactor can be operated at rated full power in the initial phase.
MOX-7 bundle design evolved is a 19-element cluster, with
inner seven elements having MOX pellets consisting of plutonium dioxide mixed in natural uranium dioxide and outer 12 elements having only natural uranium dioxide pellets.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
75
Defence in Depth
Multiple barriers to radioactivity release Prevention is priority and Mitigation if
deviations or accidentt happens To achieve defence in depth - SSCs at first four levels Elaborate emergency plans at the fifth level
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
for operation Licensing and periodic relicensing of operating personnel Single point vulnerability assessment Balanced design, quantification of reliability, absence of cliff edge effects, permissible down time of equipment etc. are overseen by PSA Adherence to normal operating procedures Regular and multi tier review by utility and regulators Operating experience feedback
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Licensing
Identified stages (Siting, Construction, Operation) As per requirements specified by regulators in
codes and guides Periodic safety review at every 10 years Review at the time of renewal of license at every 5 years Internal review within utility Multi tier review by regulators
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
These Committees as a body are comprised of experts in various aspects of NPP safety. The next level of review is conducted through an Advisory Committee on Project Safety Review (ACPSR)
Members drawn from the regulatory body, reputed national laboratories
and academic institutions. Representation from other governmental organizations and ministries.
After considering the recommendations of ACPSR and the first level committee, the regulatory board decides on the authorization.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Licensing
Safety Review Process for Nuclear Power Projects
Consenting Stages: Siting
Construction Commissioning First Criticality / Tests Power Operation (In stages) Regulatory Body
REGULATORY BOARD
ACPSR
LEGEND:
SEC - SITE EVALUATION COMMITTEE PDSC - PROJECT DESIGN SAFETY COMMITTEE ACPSR- ADVISORY COMMITTEE FOR PROJECT SAFETY REVIEW
Utility
NPC-SRC HQ
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Committee Representatives from the regulatory body Representatives from NPP under review and Experts in various aspects of nuclear technology drawn from different institutions. The second-tier of safety review of Indian NPPs is by Safety Review committee for Operating Plants (SARCOP), which is Apex body to decide on the matters of nuclear safety pertaining to NPPs. The third-tier is the regulatory board, which based on the recommendations of SARCOP, considers the major safety issues pertaining to operation of NPPs.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Licensing
Safety Review Process for Operating NPPs
Regulatory Board Safety Review Committee for Operating Plants (SARCOP)
REGULATORY STAFF -INPUTS -INTERNAL REVIEW -CONTINUITY -CO-ORDINATION -ENFORCEMENT -FOLLOW-UP -INSPECTION
Regulatory Body
EXPERT GROUPS -REACTOR PHYSICS -REACTOR CHEMISTRY -CONTROL & INST. -ISI -COOLANT CHANNEL SAFETY
Utility
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
limit hydrogen concentration. Fire water back-up is provided to moderator heat exchangers and ECCS heat exchangers. Provision for manual interconnection of Class-III emergency power supplies between units (700 MWe).
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Safety Assessment
A comprehensive safety analysis by rigorous deterministic and complementary probabilistic methods is carried out covering the following plant states Normal operational modes of plant Anticipated operational occurrences Design basis accidents During combination of events leading to beyond design basis scenarios including severe accidents The deterministic safety analysis is available up to the severe accident and is being utilized in conjunction with probabilistic safety assessment in preparation of severe accident management programme
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Emergency Planning
In accordance with different degrees of severity of the potential consequences, emergency situations are graded as: 1. Plant emergency 2. Site emergency and 3. Off-site emergency.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Emergency Measures
The emergency measures consist of the following Notification Assessment action during Emergency Corrective actions Protective measures (countermeasures) Contamination control measures Infrastructure for Emergency Response Plant Control Room Emergency Control Centre Communication System Assessment Facilities Protective Facilities
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
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changing threat perceptions and the technological developments. NPCIL has established the environment to create and foster characteristics and attitudes in organization and individuals so that physical protection issues receive attention as warranted by their significance. A multi pronged approach is in place to ensure security of the countrys NPPs, which includes the following :
Screening/ongoing intelligence about employees
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Plant Operation
The commencement of operation of a Nuclear Power
Plant (NPP) begins with approach to the first criticality of the station.
Before the start of commissioning activities, the station
prepares a comprehensive programme for the commissioning of plant components and submits the same for review and acceptance of Regulatory body.
The Operation and Maintenance (O&M) department at
the station prepares the Technical specification for operation in consultation with the plant designers before the approach to first criticality, based on the inputs from the design and safety analysis.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
plant is handed over for regular operation and maintenance, to the O&M department which already exists at the Site.
To ensure a high degree of quality in operation, all
operation persons who are at or above the position of Assistant Shift Charge Engineer (ASCE) are qualified graduate engineers who are trained and licensed as per the licensing procedures approved by Regulatory body.
All activities including surveillance testing are performed
clearly defines the lines of responsibility and authority to ensure smooth operation as well as safety during start up, normal and abnormal operations.
Station Director is the Chief of Station O&M management
at site. He has the overall responsibility for the safe operation of the plant and in implementing all relevant policies and radiation protection rules and other instructions and procedures laid down by the operating organization for plant management, and the statutory / regulatory requirements.
The performance of operating Indian PHWRs has
improved significantly and an overall availability factor of greater than 90% has been achieved.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Indian PHWR and similar plants elsewhere High degree of automation to minimize human error Functionally and physically independent safety systems Basic safety functions carried out by multiple means Online testing and maintenance of a protection channel without affecting reactor operation Use of fire-retardant materials
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
flooding, externally or internally generated missiles, fire, etc. Highly reliable safety systems with very low unavailability targets Defence in Depth Periodic testing and inspection of active components in safety systems - Online
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
greater than 90%, averaged over the life of the plant Targets for different types of outages are planned accordingly. Indian PHWRs are normally designed to have one planned biennial shut down for about one month duration The maintenance programme is put in place to ensure that
Safety Status of the Plant is not adversely affected due to
aging, deterioration, degradation or defects of plant structures, systems or components since commencement of operation and their functional reliability is maintained in accordance with the design assumptions and intent over the operational life span of the plant
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
84.89
63.04
53.72 49.61
60.8
102
86
90
91
88
89
92 85 88 83 82
20
10 0
2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11*
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
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600
590 529
500
486
400
404
414
407
Days
300
289 250
200
100
0
TAPS-1 TAPS-2 RAPS-3 RAPS-4 MAPS-1 MAPS-2 NAPS-1 NAPS-2 KAPS-1 KAPS-2 KGS-1 KGS-2
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
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105
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
5
4.5 4 3.5
Collective Dose/Unit in Indian NPPs for Routine O&M activities (Older units)
Person Sievert
2007 TAPS-1&2
2009 NAPS
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Collective Dose/Unit in Indian NPPs for Routine O&M activities (New units)
1.6 1.4 1.2
Person Sievert
2009
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
P -Sv
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Construction Management
Setting up of nuclear power projects in India in about 5 years has
been demonstrated with the help of developments in construction technology, mechanization, parallel civil works and equipment erection, computerized project monitoring and accounting systems Further reduction of construction time is being aimed at The design of 700 MWe is being carried out in an Integrated Engineering Environment using state of art tools like 3D plant modeling, Prodok etc. The Plant Design, Construction, Operation and Maintenance organizations together develop a detailed overall Project Master Plan prior to the start of construction. This encompasses : Design Procurement Construction Commissioning activities up to the commercial operation
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
compliance with the overall project plan and to identify any deviation requiring corrective action.
The project is monitored using quantitative methods appropriate
to the particular activity. Schedules are maintained using modern technology (Primavera software, etc.) and methods, and updated as work progresses to realistically reflect the actual work status
Regular interaction between the construction engineers and the
design engineers as well as interdisciplinary design reviews are periodically carried out to successfully implement the constructability requirements at the design stage itself.
Standardized component sizes, types and installation details are
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seismic classification in consonance with the classification of the system/ equipment contained.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
maximum extent possible for O & M convenience A separate Control Building has been provided as a common facility. However, the control room and control equipment rooms located in this building are provided to cater for unitized operation. A separate backup Control Room has been provided for each unit Emergency power supply systems such as Diesel Generators, UPS systems and Batteries are separately housed in safety related structures, for each unit.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
means of Central Alarm Station (CAS), physical protection fencing and manned gates. The two unit module in the nuclear island has been so chosen that it is possible to : Enforce single point entry in the radiation zones. Follow radiation zoning philosophy without undue inconvenience to the operating personnel.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
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Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
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Regulatory review
All 220 MWe and 540 MWe units are operating
successfully. Conceptual design review of 700 MWe PHWRs completed and detailed design review is in progress. Regulatory consent for construction of KAPP 3&4 obtained and construction is in progress. Regulatory consent for construction of RAPP 7&8 is expected shortly.
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
Deployment schedule
Sr No. Project 1. Kakrapar Atomic Power Project 2. Rajasthan Atomic Power Project 3. Haryana Atomic Power Project 4. MP Atomic Power Project Expected criticality / Remarks KAPP-3: December 2014 2 X 700 MWe KAPP-4: June 2015 Units 2 X 700 MWe RAPP-7: December 2015 RAPP-8: June 2016
Design, Safety and Operability performances of 220 MWe, 540 MWe and 700 MWe PHWRs in India - U.C.Muktibodh, NPCIL
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