TABLE OF CONTENTS

LIST OF FIGURES.......................................................................................................................................... 1
CHAPTER 1........................................................................................................................................................ 3
INTRODUCTION ................................................................................................................................................ 3
1.1. Introduction ...................................................................................................................................... 3
1.2. Technical Parameter ......................................................................................................................... 4
1.2.1. About Pressurization System......................................................................................................... 4
1.3. Main Components of Pressurization System .................................................................................. 6
1.3.1. Pressurizer .................................................................................................................................... 7
1.3.1.1. Spray Unit .................................................................................................................................. 7
1.3.1.2 Protective Thermal Screen ............................................................................................................ 7
1.3.1.3 The injection Pipeline Thermal-insulation ..................................................................................... 7
1.3.1.4 28 Blocks Electrical Heaters ......................................................................................................... 8
1.3.2 Pressurizer Relief Tank / Bubbler Tank............................................................................................ 9
1.3.3. PORV (Pilot Operated Relief Valves) ........................................................................................... 11
REFERENCES .................................................................................................................................................. 19

LIST OF FIGURES

FIGURE 1.2 PRESSURIZER WITH AUXILIARY PIPING AND BUBBLER-CONDENSER ......... 5

FIGURE 1.3 PRESSURIZER. ........................................................................................................... 6

FIGURE 1.4 BLOCK DIAGRAM OF ELECTRICAL HEATING OF HYDRO TANK . ................... 8

FIGURE 1.5 COMPONENTS OF THE BUBBLER TANK . ............................................................. 9

FIGURE 1.6 PRESSURIZER OPERATION (SCHEMATIC REPRESENTATION) ........................11

FIGURE 1.7 VVER-1000 PRESSURIZATION SYSTEM (SIMPLIFIED PRESENTATION. ..........14

FIGURE 1.8 FUNCTIONAL GENERATOR PPTY102 [6] . ............................................................16

FIGURE 1.9 FUNCTIONAL GENERATOR PPTY105 [6] . ............................................................18

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 LIST OF TABLES

TABLE 1.1 TECHNICAL CHARACTERISTICS OF PRESSURIZER SYSTEM VVER-1200 . ..... 4

TABLE 1.2 TECHNICAL CHARACTERISTICS OF BUBBLER TANK ......................................10

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 Chapter 1

Pressurization System
1.1. Introduction

The pressurization is a most important function in PWR Nuclear reactor. It’s basically a system
includes a pressurizer, a bubbler tank, PORV (pilot operated relief valves), pipeline, control
instrumentation and so on. A Pressurizer is a component of a pressurized water reactor. The basic design
of the pressurized water reactor includes a requirement that the coolant (water) in the reactor coolant
system must not boil. Put another way, the coolant must always remain in the liquid state, especially in
the reactor vessel. To achieve this, the coolant in the reactor coolant system is maintained at a pressure
sufficiently high that boiling does not occur at the coolant temperatures experienced while the plant is
operating or in an analyzed transient. To pressurize the coolant system to a higher pressure than the boiling
point of the coolant at operating temperatures, a separate pressurizing system is required. That is the
function of the pressurizer.

The Pressurization
System

Pressurizer Bubbler Tank PORV Pipeline, Valves

& Control
Spray unit Instrumentation

Protective thermal screen

28 Blocks of electrical heater

Thermal insulation of the connecting pipelines

Ladder and service platform

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1.2. Technical Parameter

The pressurizer is a vertically positioned pressurized cylindrical vessel with elliptic bottoms installed on
a cylindrical support. The pressurizer performance and main dimensions are given in Table 1.1

TABLE 1.1 TECHNICAL CHARACTERISTICS OF PRESSURIZER SYSTEM VVER-1200

Sl.
Parameter Value
No.
01 Nominal pressure of the steady-state conditions, MPa 16.1
02 Nominal temperature of the steady-state conditions. ℃ 347.9
03 Design pressure (gauge pressure), MPa 17.64
04 Design wall temperature, ℃ 350
05 Internal diameter, mm 3000
06 External diameter, mm 3330
07 Capacity (full volume), m3 79
08 Water level at nominal power operation, m3 55
Water level under steady-state conditions (level gauge
09 8.17±0.15
readings), m
Steam and water.
10 Working medium Nitrogen under heat up /
cooldown conditions
11 Power of electrical heating blocks 90
12 Total power of all heating blocks 2520
13 Steam flow rate through PORV 150

1.2.1. About Pressurization System

The pressurizer is the component in the reactor coolant system which provides a means of
controlling the system pressure. Pressure is controlled using electrical heaters, pressurizer spray, power

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operated relief valves and safety valves. We know that water has relatively large thermal expansion
coefficient and is practically incompressible. Such as, In the heating system VVER reactor from cold state
(t = 700℃) to the hot state (t = 2800℃) the water density decreases by approximate 30%. Considering
small compressibility of water, this circumstance makes it necessary to install a special system in the
primary circuit, which allows to compensate for such significant changes of the volume and hence of the
pressure.

FIGURE 1.2 PRESSURIZER WITH AUXILIARY PIPING AND BUBBLER-CONDENSER

This system is referred to as the pressurization system. This system is a consistent part of the
reactor installation and is intended:

- to create the initial pressure in the primary circuit to starting up the main circulation pump;
- to maintain the pressure in the primary circuit within predefined limits at the steady state
operation;
- to limit the pressure in the primary circuit in transient and emergency regimes.
The parameters of the pressurization system are chosen with the purpose of preventing the boiling of the
coolant in the primary circuit both in steady state and in most of transient regimes.

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The pressurizer operates with a mixture of steam and water in equilibrium. If pressure starts to deviate
from the desired value, the various components will actuate to bring pressure back to the normal operating
point. The cause of the pressure deviation is normally associated with a change in the temperature of the
reactor coolant system. If reactor coolant system temperature starts to increase, the density of the reactor
coolant system will decrease, and the water tank take up more space. Since the pressurizer is connected to
the reactor coolant system via the surge line, the water will expand up into the pressurizer.

1.3. Main Components of Pressurization System

Pressurization system is combination of some components. Such as electrical heaters, pressurizer

spray, power operated relief valves and safety valves. A flowchart given below:

FIGURE 1.3 PRESSURIZER.

1 – upper nozzle, 2 – cover, 3 – upper head, 4 – ladder, 5 – vessel,
6 – heating element barrel, 7 – lower bottom, 8 – heating element, 9 – water injection header, 10 –
service platform.

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 1.3.1. Pressurizer

The main component of the pressurizer system is a steam pressurizer. It is a vertical cylindrical
vessel with elliptical bottom, the lower part of which is filled with water and connected with the hot leg
of the loop no. 4 of the main circulation pipeline through Dn350 pipeline. In the lower part of the
pressurizer shell 28 blocks of thermal electrical heaters are mounted on flange connection.

1.3.1.1. Spray Unit

The spray system is connected to the 1st loop and the “hot leg” connection is connected to the 4th
loop. Also, it is connected to “cold leg”, through which the coolant is transported to the reactor vessel.
The spray system injects the coolant either from the “cold leg” or from the boron acid replenishment
systems into the vapor cushion inside the pressurizer. The spray unit is intended to uniformly spray water
from the injection pipeline. It consists of distributing header (U-Shape tube, 114 ×5mm) and four spray
nozzles. The spray itself is composed of two pipelines that are drawn into one with the dimensions of DN
200.

1.3.1.2. Protective Thermal Screen

The protective thermal screen serves to prevent direct inflow of relatively cold water on the hot
vessel of the pressurizer during injection. The screen is made from separate removable sheets free-
hanging on the vessel cantilevers. Such a structure provides rapid access to inspection of the vessel
metal. The screen is 1600mm high.

1.3.1.3. The injection Pipeline Thermal-insulation

The injection pipeline thermal insulation is designed to protect the welded connections from
temperature stress. The insulation is made from two concentric shells welded to each other, which
is connected by a flange in the upper part.

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 1.3.1.4. 28 Blocks Electrical Heaters

FIGURE 1.4 BLOCK DIAGRAM OF ELECTRICAL HEATING OF HYDRO TANK

The power of each electrical heater block is 90KW & operation lifetime is 5 years. The heater
is a spiral dielectric wire. There are 28 holes with diameter of 205 mm used for 28 blocks of electric
heaters (EH). These heaters are assembled in groups, where the power output of the I. and II. group
is 540 kW and they are controlled continuously by continuous regulation. The power output of the
III. group is 720 kW and of the IV. group is 1260 kW. Control and regulation of the heaters is
performed by the YPC01 regulator. The lower part of the body has a wall thickness of 175 mm
and is equipped with the pipe system with diameter of 426x40 mm that is connected to the
“hot leg”. This is the part of the pipe system through which the coolant is connected to the “hot
leg”. This is the part of the pipe system through which the coolant is transported from the reactor
to the steam generator. The heater itself is a spiral of nichrome wire in dielectric. The dielectric is
pressed crystal powder of molten magnesium oxide – periclase.

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 1.3.2. Pressurizer Relief Tank / Bubbler Tank

The bubbler tank is a large tank containing water with a nitrogen atmosphere. The water is
there to condense any steam discharged by the safety of relief valves. Since the reactor coolant
system contain hydrogen, the nitrogen atmosphere is used to prevent the Hydrogen from existing
in a potentially explosive environment.

FIGURE 1.5 COMPONENTS OF THE BUBBLER TANK.

1 – protective membrane, 2 – cap, 3 – access hatch, 4 vessels, 5 – steam header, 6 – heat
exchanger tubes, 7 – level vessel, 8 – immovable support, 9 – movable support, 10 - steam
discharge nozzle (from pressurizer), 11 – cooling water inlet nozzle.

Bubbler tank is intended to condense steam discharged from the pressurizer. It also receives and
condenses steam from leaks through pilot operated relief valves (PORV) when they are not leak
tight with the low rate up to 250m3/h. When PORV’s of the pressurizer actuate, the bubbler tank

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 condense steam with the steam flow rate up to 150kg/s no more than for 9s until the membrane
rupture.

The bubbler tank is a horizontal cylindrical vessel, consisting of vessel shell and two elliptical
bottoms. It is filled with pure condensate. Inside the bubbler tank are located heat exchanger and
two distributing headers. Steam from pressurizer is transformed to these headers through Dn250
pipelines. Along the entire length of each header nozzles are located which contribute to quick
discharge of explosive mixture continuous blowout of gas volume in the bubbler tank with nitrogen
implanted.

TABLE 1.2 TECHNICAL CHARACTERISTICS OF BUBBLER TANK

Parameter Dimension Value
Volume total m3 30

Volume of water m3 20

Membrane rupture pressure MPa 0,69-0,86

Water level mm 1700

Intermediate cooling water flow m3/h 14

rate

Surface area of heat exchanger m2 35

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 1.3.3. PORV (Pilot Operated Relief Valves)

FIGURE 1.6 PRESSURIZER OPERATION (SCHEMATIC REPRESENTATION)

In accident-related increase of pressure in the primary circuit (Fig. 7b), then PORV will operate when
control valve and duty valves are at pressure P ≥ 18,2 MPa and P ≥ 18,6 MPa. On the other hand, it will
close when control valve and duty valve are at pressure P ≤ 17,6 MPa and P ≤ 17,8 MPa.

When the PORV operates, the steam or coolant passes on to the bubbler tank through Dn250 pipeline.
The steam is condensed in the water volume of the bubbler tank and the heat is removed by the
intermediate cooling water. To protect the bubbler tank from excess pressure, protective membranes are
installed on the tank nozzles.

Automatic regulation of the pressure system includes:

- primary circuit pressure (above the reactor core);

- the coolant level in the pressurizer;

- the rate of heating/cooling of the pressurizer.

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Maintaining the pressure of primary circuit at normal operation and in the hot state is provided by the
pressure regulator. The accuracy of pressure maintaining is ± 0,15 MPa. The pressure regulator maintains
the pressure of primary circuit by acting on electrical heaters and on quick-acting injection valves.

1.4. Mechanism of Controlling Pressure

• If pressure increase:
If pressure starts to increase above the desired setpoint, the spray line will allow relatively cold
water from the discharge of the reactor coolant pump to be sprayed into the steam space. The cold
water will condense the steam into water, which will reduce pressure (since steam takes up about
six times more space than the same mass of water). If pressure continues to increase, the pressurizer
relief valves will open and dump steam to the pressurizer relief tank. *If this does not relieve
pressure, the safety valves will lift, also discharging to the pressurizer relief tank*.

• If pressure decrease:
If pressure starts to decrease, the electrical heaters will be energized to boil more water into steam,
and therefore increase pressure. *If pressure continues to decrease, and reaches a predetermined
setpoint, the reactor protection system will trip the reactor*.

1.5. Function of The System

The pressurizer is during normal operation partially filled with liquid and partially with
vapor. All valves, regulating the coolant injection, are closed. The spray system pipeline is
continuously heated by the flow rate of 1 m3/h. Parameters inside the pressurizer are equivalent to
a saturated steam state. In case of small pressure drop, the balance is violated and due to the
pressure drop, the evaporation is more intense.

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 This phenomenon is caused by the temperature in the pressurizer being higher than the
saturated steam temperature. Due to the evaporation of the coolant, the steam volume is increased
and so the pressure is increased.

Hence the parameters are re-balance. If the pressure in the pressurizer is slightly increased,
the balanced is violated and condensation occurs, due to the temperature inside the pressurizer
being lower than the saturated steam temperature. Due to condensation, volume of the steam is
decreased and thus the pressure is decreased again. Parameters are re-balanced again. This so-
called self-regulation can handle small pressure differences. If the differences are higher, the spray
system and electric heaters are put into operation. These are controlled by the regulator. [3] [4] [5]
When electric heaters are in operation, the coolant temperature is increased, evaporation occurs
and the steam volume is increased, so the pressure is increased.

These electric heaters are divided into four groups. First two groups are working in a
parallel regime and are controlled by thyristor continuous regulation. Continuously regulated
heaters are always in operation so that they can compensate heat losses. [3] [4]. The spray system
is connected to the “cold leg” of the 1st loop. The pipeline has dimensions of 219x20 mm and is
connected to pressurizer in its upper part. In case of small pressure increase, the surge is performed
via pipeline with a full open flow rate of 24,88 kg/s. This pipeline has dimensions of 133x14 mm
and is equipped with a non-return valve, regulation fitting, and closure fitting.

If this system is not efficient enough, the coolant flows through second spray pipeline.
There are two wedge gate valves and two quick acting wedge gate valves. Each branch may have
different coolant flow rate. If only one branch is opened, the flow rate is 29,4 kg/s, with both
branches opened, then it is 44 kg/s. If none of these systems can prevent pressure from increasing,
then relief or safety valve systems are actuated2. [3]

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 FIGURE 1.7 VVER-1000 PRESSURIZATION SYSTEM (SIMPLIFIED PRESENTATION).

For low temperature and pressure in the primary circuit, there is a nitrogen cushion in the
pressurizer. This nitrogen cushion is present only if the temperature is < 230°C, otherwise, a steam
cushion is present. [3] During nominal operation, the volume compensation system maintains the
pressure value in primary circuit at 15,7 MPa and temperature at 346°C by the regulator (electric
heater groups I. and II. and valves). The coolant level in the pressurizer is maintained at 8,77 m by
the regulator (replenishment system). If the pressure is increased to more than what these
regulators can handle, other systems are put into operation to compensate this deviation. [3]

1.6. Regulators of the volume compensation system

This section describes the settings for control and regulation of pressure in the pressurizer,
temperature and coolant level in a simplified way. Such simplification does not influence the
functionality of the system though.

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 – Regulation of pressure/temperature in pressurizer

This regulator maintains the pressure level during start-up, operation (15,7 ± 0,2 MPa), shut down
and cooling down the reactor. It uses I. to IV. group of electric heaters, opening/closing regulation valve
and quick acting gate valves. The I. and the II. group of electric heaters and regulation valve are controlled
continuously with respect to the regulation deviation. The III. and the IV. group of electric heaters and
quick acting gate valves are controlled discretely based on the deviation from the setpoint. Control of
pressure in the pressurizer is performed in two regimes [3]:

✓ Pressure control regime “P”

✓ Temperature control regime “T”

Temperature control regime “T” is used when there is nitrogen cushion in the pressurizer. This is present
during heating up and cooling down the primary circuit since the ordinary relation between temperature
and saturated pressure is violated. This regime can be only maintained if Tmax < 230°C, otherwise the
“P” regime is set. [3]

-Temperature control regime “T”

In this regime, the regulator maintains the required temperature difference between the primary circuit
and the pressurizer. This difference is set by the personnel in the range of 40 – 60°C. This value is then
added to the Tmax in the “hot leg”, but only if Tmax is higher than 145°C. The regulation deviation
between the setpoint and the measured temperature of the pressurizer and the primary circuit enters the
PID regulator PPTC101. This regulator has a gain dependent on the Tmax in the “hot leg”. This gain
increases with the temperature from 0,05 to 0,07 MPa/°C by the functional generator PPTY102 in fig. 9
[6]

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 FIGURE 1.7 - FUNCTIONAL GENERATOR PPTY102 [6]

The PID output enters the common regulation part if the “T” regime is set. This regime contains
also an alarm signalization in case of failure. This signalization informs the personnel, that the
difference between the setpoint and the measured value is higher than 10°C or lower than -10°C.
This signalization is blocked in case, if “T” regime is not active. [6]

-Pressure control regime “P”

In the “P” regime, the regulator maintains the pressure in the pressurizer at the required value. The
regulation deviation between the setpoint and the measured value enters the PID regulator
PPPC101. PID output of which under “P” regime enters the common regulation part. The gain of
this regulator is dependent on the Tmax in the “hot leg”. This value, however, is currently equal to 1
MPa/MPa in the whole temperature range. Due to the setting, the derivation constant is equal to
zero. [6]
The setpoint is calculated based on the following equation [6]:

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 A,B,C – constants, where A = 11,2 MPa; B = 0,44 MPa/°C; C = 265 °C

The behavior of the pressure dependence on the temperature, with the temperature difference
between the pressurizer and the Tmax in the “hot leg” being dT = 55 °C, is set by the functional
generator PPTY105 in the fig. 10. [6]

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 FIGURE 1.8 - FUNCTIONAL GENERATOR PPTY105 [6]

The value entering the regulation is determined by the pressure measured in the pressurizer or
below the reactor lid. In the range from 0 to 14 MPa, the real value is the one measured below the
reactor lid. If the pressure is higher than 14 MPa, then the real value is an average from three
sensors in the pressurizer, which is more accurate. [6]
This regime contains an alarm signalization in case of failure, as in the case of the “T” regime. This
signalization informs the personnel, that the difference between the setpoint and the measured
value is higher than 0,3 MPa or lower than -0,3 MPa. This signalization is blocked in case if “P”
regime is not active. [6]
The continuous regulation is composed of the PID regulator and functional generators
PPPY102 and PPPY103. They transfer the PID output into the required positions of valves or power
output of the EHs. The discrete regulation is controlled by the pressure difference between the
setpoint and measured value as described further. [6]

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 1.7. REFERENCES

[1] USNRC Technical Training Center, Reactor Concepts Manual [Virtual Medical Centre]-[Online].
Available: https://www.nrc.gov/reading-rm/basic-ref/students/for-educators/04.pdf. [Accessed: 20-
Jan- 2019].
[2] C. Ing. Jaroslav Rubek, Control and Automation of Nuclear Energy Devices, 2016
[3] CEZ, Monitoring and Control System VVER 1000, Instumenration and Control System, 2008.
[4] CEZ, Primary circuit VVER 1000, 2008.
[5] IAEA, WWER-1000 Reactor Simulator, 2003.
[6] IAEA, Pressurized Water Reactor Simulator, Vienna, 2005.
[7] CEZ, Main Regulation on VVER 1000, 2004.
[8] (2002) The IEEE website. [Online]. [Cited: December 1, 2008.] Available:
https://aris.iaea.org/PDF/VVER-1200(V-491).pdf/. [Accessed: 20-Jan- 2019].

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