Design of Monju Steam Generator

- with regard to Maintenance an.fi Repair -

T. Takahashi, Y. Yamagishi, R. Mukaibo
Abstract
The steam generator design of "Monju" started in 1963 .and
since then, extensive research and design work has been done.
"Monju" steam generator consists of one evaporator and
one superheater to each of the three independent cooling
systems. Ultrasonic and eddy current tubing inspection de-
vices have been developed for maintenance. And for failed
tubes, welding or explosive plugging is applied.
Following the completed safety review and the coming
design and construction licensing, "Monju" is expected to reach
criticality in fiscal year 1990.
Introduction
"Monju" is the first power generating fast breeder
reactor in Japan. The design, which started in.1968, la now
in the final stage and the construction is targeted to reach
initial criticality in fiscal year 1990.
In the steam generating system, the helical coiled tube
type steam generator has been chosen and. at the same tiiie,
the straight tube type has been under consideration as a
second choice.
Research work on the steam generator, using mock-up nodels,
has been extensively done at Oarai Engineering Center. In
1971, a l.MV steam generator started testing and since 1974
2 different pOMlv steam generators have been installed and
tasted. The first ran about 3500 hours and the second about
14,000 hours, now under endurance testing. In parallel to
these mock-up tests, material tests, tube to tube-sheet
welding tests, sodium-water reaction tests, development of
leak detectors have been under way. These significant base
technologies have been a great support to the development of
the "Monju" steam generator.
"Monju" Power Station, which is rated at 7l4MVth, 28OMW
in electric power generation, has 3 separated once through
cooling systems and each has one evaporator and one super-
heater. In 1984, the evaporator of "Monju" was awarded to
Mitsubishi and the superheater to Hitachi.
For Presentation at IAEA IWGFR Specialist's Meeting on
"Maintenance and Repair of LMFBR Steam Generators" (Oarai,
Japan, June 1984)
Design of Steam Generator
The steam generator is composed of a separated evaporator
and superheater, both helically coiled tube type with free
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surface iodiun inside. The water stsani cycle is a once through
tvoe arvi the reheater which was installed in the original
ddiiin was eliminated.
The steam generator system is shown in Fig. 1 and the
structure in Fig- 2. The input heat condition from the ec-
ondary sodium coolant system is 5Q5C sodium at the entrance
of the superheater and 32?'C at the exit of the evaporator.
Steam condition at the outlet of the superheater is kS7"C
2
and 133 "=c?/c:n s
an
d the feed water during normal operation
is 2'iO"C. The material used for the evaporator is 2-^-Cr-lMo
far both the heat transfer tubes and the shell of the evapo-
rator. For the superheater, considering the high temperature,
SUST21 material has been selected. The outer diameter of the
heat transfer tube is 31.8mra and the number, 1^7. Sodium
level control is done by cover gas pressure for the super-
heater and overflow line for the evaporator.
Specific numbers for the steam generator are shown in
table 1.
In a rare case when water/steam leaks inside the steam
generator and sodium-water reaction occurs, it will be detected
by a hydrogen detector system which is installed both inside
sodium and in cover gas. In order to accommodate the pres-
sure rise, a pressure relief and reaction product separator
system is prepared. They are normally isolated from the so-
dium system by a rupture disc at the cover gas. This system
is shown in Fig. 3-
Vhen the plant is shut down, for instance, by reactor
scram, during power operation, the steam generator is isolated
from the plant cooling system anrf the decay heat is removed
by an air blast cooler which is installed in the secondary'
main cooling system, parallel to the steam generator.
Desizn Base yents of "Monju"
As a design base' accident for the "Monju" steam gener-
ator, a double ended guillotine failure of a single heat
transfer tube is the basic condition and in order to accommo-
date the successive rupture propagation, a maximum of 1 + 3
guillotine failures of neighboring tubes is considered.
Mien the accident occurs, it is recognized by a rupture
signal from the rupture disc and the steam generator is iso--
lated from the cooling system. The water/steam will blow
down and when the pressure reaches down to a certain degree,
nitrogen gas is supplied.
In a case where the leak rate of water/steam is small,
and the leak detection is done by the hydrogen detector,
rather than by the burst of the rupture disc, manual scram
of the reactor by the decision of the plant operator is
achieved and, consequently, the steam generator is isolated
from the cooling system.
In both cases mentioned, the sodium inside the steam
jeneratar will be drained after a total inspection of the
5y stem.
Valves and process instrumentation are shown in Fig. ^t.
Design Considerations for >fainxenanc e and Repair
Durini_N'or^ial Operation
The three sxaam generators belong to three independent
cooling systems and are all located in the reactor auxiliary
building where access is free. The evaporator and superheater
are each located in separate rooms and the reaction producxs
tank is installed on the roof of the building. This enables
easy access for maintenance and repair. The steam generator
is installed in each room in such a way that access is pos-
sible not only from the sides, but also from the top and
from the bottom.
The hydrogen detectors are designed so that absolute
correction can be done, as installed, independently from the
system,
Small_Leaks Occurrences
Inspection technology of heat transfer tubes, after
small leaks have occurred, has been developed and established
using either ultrasonic testing devices or eddy current test-
ing devices for defect indication detection. However, in
order to facilitate accessibility and have direct access to
the water/steam inlet and outlet tube to tube-sheet area,
a cao cover type structure has been introduced. Furthermore,
to help -nake the insertion of the detector into the tube
smoothly, certain limits co [he curvatures of the tubes have
been applied.
Tube plugging technology by explosives and by welding
has been developed. The height of stand pipes are decided
to enable easier access for the plugging.
Lar-re Leak Accidents
When a large leak inside the steam generator occurs,
inspection of heat transfer tube bundles ar*ri repair work is
required. In order Co do this, a flangs structure is adopted
at the top of the steam generator and this enables the tube
bundle to be pulled out together without cutting off any part
of the shell. This method of inspection and repair has al-
ready been applied and experienced at the 50>flv* mock-up steam
generator facility. The space above the steam generator at
the plant is left open and vacant in spite of the rather
high elevation where it is installed, and this is to accommo-
date the withdrawal.
The layout of the steam generator is shown in Figs. 5
and 6. Fig. 7 shows the features that have been mentioned.
Conclusion
Following the conceptual design of the steam generator
of "Monju," the related safety review, including the evalua-
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/~\ Water/steam
" ^s e p a ra t o r
Evaporator}
Prim a ry System
Secondary System
Ste a in/ W a te r System
Aux. Cooling System
Heater
CbPeoeraton
Condensate
| ) w o l e r '
pump
. feedwoter
r
J
pump j
J u
Fig. 1 Schematic Flow Diagram of the Plant
to
i
Sodium , 11
Inlet f / f
Reaction
Product Exit /[
D o w n c o m e i
F eed W ater
S team Outlet
Upper S hell
Sodium
Inlet
Reaction
Product Exit
Support
^St r uct ur e ,
.Downeomer,
ewer. Shell.
H e lica L Co ilJube .
Superheater
S team Inlet
S team Outlet
Upper S hell
Support
Structure.
Helical Coil
Jube . _.
L ower. Shell
Evaporator p i : 2 S team Gen r jtor
Sodium-Water
R eaction
R elief Sys.
i rR up . Disc
487
9
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Super Heater
T-GeneratoT
jFo o ling Water
Condenser
Reactor
Guard Vessel
Pry. Sys .
Ins i de o f Containment
il\
p ) Evaporator
ixl=
Sec. Pump
S dry. S ys.
Outside of Containment
W a te r Ste a m Sys .
Fig. 3 Generator Sr
+
e rn of Monju
COVER GAS CONTROL
PU MP OVER FL OW
COL U MM
IHTS PU MP
< IHX < <
IHTS
PU RIFICATION
SYSTEM E MF O
C
0 E MP
SU PER HEATER
OVER FLOW TANK
Fig. 4 Valves and IntiiJme nta tio n
PLANT LAYOUT OF MONJU
00
1 Spent re s in TOOTTI
2 Concentrated miscellaneous waste tank room
3 Monitor tank room
4 Miscellaneons waste collector tank room
5 Components cleaning orea
6 Fuel storage pool
7 Pool water cooling and p urifica tio n room
8 Fuel cleaning equipment room
9 Fuel inspection e quip me nt room
10 Ventilator and conditioner room
11 EVST room
12 Cold tra p room
13 FFDL room
14 Fuel handling facilities
operation room
15 Main control room
16 Relay room
17 Low voltage switchgear room
18 Piping room
19 IHX
20 Primary sodium pump
21 Primary Argon gas system room
22 R eactor vessel
23 SG room
24 Maintenance cooling system room
25 Preheat poweT system room
26 Switchgear room
27 High v o lta ge switchgear room
(EL +290 in)
0 5 1 ) 15 20 25m
F ig.5 H o rizo n il Cross Section *vf Main Buildings
CO
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1 V e nti l ator and c ondi ti one r room
2 Maintenance room
3 Switchgear room
4 Monitor la nk room
5 Miscellaneous waste collector tank room
6 Concentrated miscellaneous waste tank Toom
7 Maintenance aTea
8 FHM cleaning "room
9 Cleaning v e nti l ati on s y s te m Toom
10 Ex-vessel tra ns fe r ma chine area
11 Fuel canning room
12 Fuel cleaning room
13 Fuel ins p e ctio n equipment ro o m
14 Gaseous radwasle processing s ys te m room
15 Ex-vessel s'kmige tank
16 Sodium o v e rflo w lank
17 Polar crane
18 Operation floor I
19 IllXhe a da ie a . [_
20 Reactor vessel f
A
21 IHX
22 Dump la nk
23 Storage tank
24 Secondary sodium p urifica tio n s ys tem room
25 Superheater
26 Evaporator
27 R eaction product storage tank
28 Switchgear room
29 Crane
30 Turbine generator
31 Transformer area
0 5 10 15 2(1 2bi n
Fig. 6 sectional Viow of Ja in Buildings
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Table 1 Design Specification
Type
No. of U ni t / L o o p
Thermal Power
Sodium Side Condition
Flow R ate
Inlet Temperature
Outlet Temperature
Steam Condition
Flow R ate
Inlet Temperature
Outlet Temperature
Outlet Pressure
Tube Bundle
Tube Outer Diameter
Tube Thickness
No. of Tubes
Material Tube
Shell
Sodium Level Control
Component Class
Superheater
Helical Coil
1
~ 47 MWt/ U nlt
3.73 X1O
6
kg/lv
5O5C
469C
3.79X10 kg/h
367C
487C
133.0 kg/ cm
2
a
31. 8 mm
3. 5 mm
1 4 7
32l s s
3O4ss
Pressurized Cover
Class 3
Evaporator
Helical Coll
i
~191MWt/U ni1
3.73 xiO
6
ka / h
469C
325C
Water Condition
3.79 X1O kg/ h
24OC
369C
31.8 mm
3. 8m m
1 4 7
STB A 24
SCMV 4
Over Flow System
Class 3
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