Helwan University Faculty of Engineering

Mechanical Power Department

A Technical Report on:

Genkai Nuclear Power Station

Prepared by: Osama Mamdouh Mostafa

4th Year Undergraduate Mechanical Power Student
Section (2)

Reported to:
Assoc. Prof. Mohamed Nawar

October 2023
 Preface
This report provides a comprehensive overview of the Genkai Nuclear Power
Station, focusing on its operation, layout, components, and specifications. The
report delves into the Rankine Vapor Cycle and its relevance to nuclear power
plants, highlighting the importance of Genkai Nuclear Power Station in the
context of the energy industry. The detailed analysis of this facility's layout and
components, along with its safety and environmental specifications, offers
valuable insights into its functioning and environmental impact. By the end of
this report, readers will have a well-rounded understanding of the Genkai
Nuclear Power Station, making informed decisions regarding nuclear power and
its role in our energy future.

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Table of Contents
Preface ....................................................................................................................i
List of Figures ..................................................................................................... iii
List of Tables ........................................................................................................iv
1 Introduction ................................................................................................... 1
1.1 Rankine Vapor Cycle ................................................................................ 1
1.2 Nuclear Power Plants ............................................................................... 2
2 Genkai Nuclear Power Station ...................................................................... 3
2.1 Overview .................................................................................................. 3
2.2 Genkai Nuclear Power Station: Layout & Components .......................... 4
2.2.1 Station Working Principle ............................................................... 4
2.2.2 Reactor Pressure Vessel .................................................................. 6
2.2.3 Steam Generator.............................................................................. 7
2.2.4 Genkai’s Power Station Site Layout ............................................... 8
2.3 Genkai Nuclear Power Station Specifications ....................................... 10
2.3.1 Safety specifications ..................................................................... 10
2.3.2 Environmental Specifications ....................................................... 12
2.3.3 Units 1,2,3 and 4 technical specifications .................................... 13
Conclusion .......................................................................................................... 14
References ........................................................................................................... 15

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 List of Figures
Fig. 1.1: Typical Rankine Cycle Layout ............................................................... 1
Fig. 1.2: T-S Diagram of Ideal Rankine Cycle ..................................................... 1
Fig. 1.3: Nuclear Power Plant Layout for a Pressurized Water Reactor (PWR) .. 2
Fig. 2.1: Footage of Genkai's Four Units .............................................................. 3
Fig. 2.2: Genkai Nuclear Power Station Layout (Units 3 and 4).......................... 5
Fig. 2.3: Reactor Pressure Vessel of Units 3 and 4 ............................................... 6
Fig. 2.4: Steam Generator of Units 3 and 4 .......................................................... 7
Fig. 2.5: Site Layout of Unit 3 .............................................................................. 9
Fig. 2.6: Safety Futures of Nuclear Plant Design ............................................... 11
Fig. 2.7: Reactor Containment Vessel Five Wall Protection of Units 3 and 4 .... 11
Fig. 2.8: Radiation exposure during everyday life (unit: Millisieverts) ............. 12

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 List of Tables
Table 2.1: Technical Specification for Genkai Nuclear Power Station Units ..... 13

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 1 Introduction
A power plant is an industrial facility that generates electricity from primary
energy. Most power plants use one or more generators that convert mechanical
energy into electrical energy to supply power to the electrical grid for society's
electrical needs. The Rankine cycle or Rankine Vapor Cycle is the process
widely used by power plants such as coal-fired power plants or nuclear reactors.
1.1 Rankine Vapor Cycle
In this mechanism, a fuel is used to produce heat within a boiler, converting
water into steam which then expands through a turbine producing useful work.
This process was developed in 1859 by Scottish engineer William J.M. Rankine.
This is a thermodynamic cycle which converts heat into mechanical energy
which usually gets transformed into electricity by electrical generation.
The steps in the Rankine Cycle as shown in Fig. (1.1) and the corresponding
steps in the (T-S) diagram in Fig. (1.2) are outlined below:
1) Process (1-2): Isentropic compression
in a pump. The working fluid is
pushed from low to high pressure.

2) Process (2-3): Heat addition at

constant pressure in the boiler. The
high-pressure liquid is introduced to
the boiler and cooked at constant
pressure to become a dry saturated
vapor in this process.
Fig. 1.1: Typical Rankine Cycle Layout
3) Process (3-4): Isentropic expansion
in a turbine. Power is generated as the
dry saturated vapor expands through
the turbine.

4) Process (4-1): Heat rejection under

constant pressure in a condenser. A
saturated liquid is formed by
condensing wet vapor at a constant
pressure.
Fig. 1.2: T-S Diagram of Ideal Rankine Cycle

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1.2 Nuclear Power Plants
Compared with oil and other energy sources, nuclear power offers numerous
advantages, including a stable supply of resources, harmony with the
environment, and superior economy.
Nuclear power plants are a type of power plant that use the process of nuclear
fission to generate electricity. They do this by using nuclear reactors in
combination with the Rankine cycle, where the heat generated by the reactor
converts water into steam, which spins a turbine and a generator.
Aside from the source of heat, nuclear power plants are very similar to coal-
fired power plants. However, they require different safety measures since the
use of nuclear fuel has vastly different properties from coal or other fossil fuels.
They get their thermal power from splitting the nuclei of atoms in their reactor
core, with uranium being the dominant choice of fuel in the world today.
The conversion to electrical energy takes place indirectly, as in conventional
thermal power stations. The fission in a nuclear reactor heats the reactor
coolant. The coolant may be water or gas, or even liquid metal, depending on
the type of reactor. The reactor coolant then goes to a steam generator and heats
water to produce steam. The pressurized steam is then usually fed to a multi-
stage steam turbine. After the steam turbine has expanded and partially
condensed the steam, the remaining vapor is condensed in a condenser. The
condenser is a heat exchanger which is connected to a secondary side such as a
river or a cooling tower. The water is then pumped back into the steam
generator and the cycle begins again. The water-steam cycle corresponds to the
Rankine cycle.

Fig. 1.3: Nuclear Power Plant Layout for a Pressurized Water Reactor (PWR)
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 2 Genkai Nuclear Power Station
2.1 Overview
Genkai Nuclear Power Station began commercial operation in October 1975
with the startup of the No. 1 Unit. Since then, three additional units have been
constructed to meet the growing demand for electric energy. As a result of those
expansions, Genkai’s output rose to 3,478 megawatts.
The No. 1 and No. 2 units subsequently ceased operation on April 27, 2015, and
April 9, 2019, respectively, bringing the current total output to 2,360 megawatts.

Fig. 2.1: Footage of Genkai's Four Units

Right now, all Genkai’s employees will continue working together to

accomplish the planned decommissioning of the No. 1 and No. 2 units as well
as the safe, stable operation of the No. 3 and No. 4 units while ensuring that
safety remains the top priority.

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2.2 Genkai Nuclear Power Station: Layout & Components
2.2.1 Station Working Principle
The type of reactor used at Genkai Nuclear Power Station is called a pressurized
water reactor (PWR).
One feature of the pressurized water type, shown in Fig. (2.2), is the complete
separation of the system that circulates water through the reactor (primary
system) from the system that supplies steam to the turbine (secondary system),
through the use of steam generator heat exchanger tubes, ensuring that no
radioactive substances are transmitted over to the turbine side.
In the reactor, the uranium fuel undergoes nuclear fission, generating large
quantities of heat. This heat is transferred to the water of the primary system,
which is then transported to the steam generator by the primary reactor coolant
pump.
The primary system water is transported into the steam generator, where it flows
through the inner side of the heat exchanger tubes, transmitting heat through the
tube walls to the surrounding secondary system water. The primary system
water is then returned to the reactor.
Meanwhile, the secondary system water is transformed into steam within the
steam generator, travels to the turbine, and drives the turbine-generator to
produce electricity.
Once the steam has finished its work at the turbine-generator, it is cooled in the
condenser by tubes filled with seawater, returned to a liquid state, and
transported back to the steam generator.
The fuel handling system (FHS) in the fuel handling building, see Fig. (2.2),
provides a safe means for handling and performance monitoring of fuel
assemblies and control components from the time of receipt of new fuel
assemblies to the shipment of spent fuel. This includes installing and removing
fuel assemblies in the reactor vessel, transferring irradiated fuel assemblies from
the reactor vessel to the spent fuel pool (SFP), and storage of irradiated fuel
assemblies. The system also provides a means of safely receiving, inspecting,
storing, and handling new fuel.

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 The primary containment vessel is an Steam power turns the turbine,
airtight structure of prestressed concrete generating electricity.
The uranium reaction is controlled by inserting or lined on the inside with steel plate and is
withdrawing control rods. If an abnormality occurs, designed to prevent radioactive substances
the rods automatically shut down the reactor. from escaping to the outside.

In the steam generator, hot

water from the reactor
converts secondary system
cooling water into steam.

After driving the turbine, the steam is

cooled by sea water and converted back
into a liquid state.

The pressurizer maintains the reactor water at high

pressure, which prevents it from coming to a boil.

Fuel Assembly
In the unlikely event of an accident in which a rupture in the primary system
piping, etc., results in a loss of water from the system, the emergency core
cooling system, which consists of an accumulator injection system, a high- This is where the uranium fuel is burned
head injection system, and a low-head injection system, injects water into to raise the temperature of reactor water.
the reactor to cool it down, thus ensuring operational safety.

Fig. 2.2: Genkai Nuclear Power Station Layout (Units 3 and 4)

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2.2.2 Reactor Pressure Vessel
Fig. (2.3) shows the reactor pressure vessel with its specification for unit 3 and
unit 4.

Main Dimensions
Inner diameter: 4.4 m approx.
Total height: 12.9 m approx.
Cylinder wall thickness: 216 mm
approx. Weight: 410 tons approx.

Fig. 2.3: Reactor Pressure Vessel of Units 3 and 4

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2.2.3 Steam Generator
Fig. (2.4) shows the steam generator with its specification for unit 3 and unit 4.

Cylinder Inner Diameters

Top: 4.5 m approx.
Bottom: 3.5 m approx.
Total height: 21 m approx.

Heat Exchanger Tubes

No. of tubes: 3382/generator
Weight: 320 tons approx.

Tube support plate

Fig. 2.4: Steam Generator of Units 3 and 4

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2.2.4 Genkai’s Power Station Site Layout
The site layout consists of multiple major components like:
• Reactor Containment Vessel: The main equipment of the primary
system, such as the reactor and steam generator, is installed inside the
reactor containment vessel.

• Turbine-Generator: The steam produced by the steam generator turns

the turbine. Electricity is produced by the generator which is linked
directly to the turbine.

• Transformers/Switch Yard: The electricity produced by the generator is

stepped up to a higher voltage by transformers and sent out over the
transmission lines. The Switch Yard plays the role of switch between the
power station and transmission lines.

• Radiation Controlled Area Access Control Room: Monitoring devices

such as a registration system for entry and a body surface contamination
monitor are installed to control access to the radiation-controlled area

• Central Control Room: The Central Control Room, with its wide variety
of meters, warning and monitoring devices, operating switches and other
equipment is the brain of the power station. Members of the Operation
Section monitor the reactor, turbine-generator, and other equipment under
a 24-hour-a-day system.

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Fig. 2.5: Site Layout of Unit 3

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2.3 Genkai Nuclear Power Station Specifications
2.3.1 Safety specifications
The major premise of safety measures for nuclear power stations is to ensure the
safety of persons in the surrounding area from danger due to radioactive
materials. As a result, multiple layers of safety measures is used based on
acceptance of the idea that machinery will break down, and people will make
mistakes.
The following three safety assurances are done to insure the safe operation of a
nuclear power plant:
1. Prevent abnormalities before they occur: Implementing designs that
ensure ample safety margins and use equipment and materials of the
highest performance and quality. In addition, we utilize systems that are
capable of automatically evading dangerous situations even should the
machinery break down, and that can prevent the equipment from
receiving operating commands issued in error.

2. Prevent abnormalities that do occur from burgeoning into accidents:

Establishing a monitoring system for instant notification of abnormalities,
to ensure that the abnormalities do not lead to accidents. Moreover, the
system can automatically shut down the reactor should the need arise.

3. Prevent the release of radioactive materials in the unlikely

occurrence of an accident: To prevent the abnormal release of
radioactive materials in the unlikely occurrence of an accident, the reactor
shall immediately be cooled down and all radioactive materials be sealed
in.
When an earthquake occurs, the seismic waves are amplified as they travel from
the epicenter to the ground surface. This causes violent shaking in structures
which are built on the ground surface. In contrast, earthquakes have far less
effect on structures such as nuclear power station which are built directly on
strong base rock, because the base rock does not amplify the motion of the
quake.
Fig. (2.6) shows the safety futures of nuclear plant design.

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 Fig. 2.6: Safety Futures of Nuclear Plant Design

Fig. (2.7) shows the five walls of protection of units 3 and 4 reactor containment
vessel.

Fig. 2.7: Reactor Containment Vessel Five Wall Protection of Units 3 and 4

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2.3.2 Environmental Specifications
In order to confirm that there is no change in environmental radiation due to
operation of the Genkai Nuclear Power Station, monitoring stations and
monitoring posts have been installed in the vicinity of the plant to continuously
measure and monitor radioactivity and other parameters. Additionally, crops,
soil, drinking water, fish, seaweed, seawater, and other materials in the area
surrounding the facility are sampled periodically and measured for radioactivity
and radioactivity concentration. Further, monitoring vehicles are used to
periodically measure radioactivity in the area surrounding the power station.
These activities are called environmental monitoring. Measurement results are
published by Saga Prefecture, and the plant publishes environmental
radioactivity results.
Fig. (2.8) shows radiation exposure in everyday life in Millisieverts.

Fig. 2.8: Radiation exposure during everyday life (unit: Millisieverts)

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 2.3.3 Units 1,2,3 and 4 technical specifications
The following table shows the technical specifications of units 1,2,3, and 4.
Table 2.1: Technical Specification for Genkai Nuclear Power Station Units

Unit 1 Unit 2 Unit 3 Unit 4

Site Imamura, Genkai-cho, Higashi Matsuura-gun, Saga Pref.
Site area 870,000 m2 (approx.)
Generated
559 MW 559 MW 1180 MW 1180 MW
output
Reactor
Pressurized Water Reactor (PWR)
type
Thermal
1650 MW 1650 MW 3423 MW 3423 MW
output

Low-enriched uranium dioxide Low-enriched uranium

Fuel type - - (approximately 4%), mixed dioxide
uranium plutonium oxides (approximately 4%)

Fuel
- - 89 tons (approx.) 89 tons (approx.)
capacity
Start of October March
March 1994 July 1997
operation 1975 1981
End of April March
- -
operation 2015 2019

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 Conclusion
In conclusion, this report has provided a comprehensive overview of the Genkai
Nuclear Power Station, shedding light on its operation, layout, components, and
specifications. By exploring the Rankine Vapor Cycle and its integration within
nuclear power plants, we've gained a deeper understanding of the station's
significance in the energy industry. The detailed examination of the station's
layout and components, along with its safety and environmental specifications,
has revealed its intricate workings and its commitment to environmental
responsibility.
The Genkai Nuclear Power Station, with its unique design and adherence to
rigorous safety and environmental standards, stands as a symbol of responsible
nuclear energy production. It exemplifies how careful planning and adherence
to strict regulations can mitigate potential risks associated with nuclear power.
This report serves as a valuable resource for those seeking to understand the
operation of nuclear power plants and their role in the broader energy landscape.
It is my hope that the insights provided herein will contribute to informed
decision-making and foster a more responsible and sustainable approach to
nuclear energy in the future.

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 References
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Thermodynamics: An engineering approach (9th ed.). McGraw Hill.

[2] Environmental and Public Relations Group. (2019, September).

Introduction to Genkai Nuclear Power Station. Outline of Genkai
Nuclear Power Station.
https://www.kyuden.co.jp/var/rev0/0246/5307/genkai_gaiyou-ei.pdf

[3] Nuclear power plant. Nuclear power plant - Energy Education. (n.d.).
https://energyeducation.ca/encyclopedia/Nuclear_power_plant

[4] Power plant. Power plant - Energy Education. (n.d.).

https://energyeducation.ca/encyclopedia/Power_plant

[5] Rankine cycle. Rankine cycle - Energy Education. (n.d.).

https://energyeducation.ca/encyclopedia/Rankine_cycle#:~:text=The%20
Rankine%20cycle%20or%20Rankine,a%20turbine%20producing%20us
eful%20work.

[6] Wikimedia Foundation. (2023, October 11). Nuclear power plant.

Wikipedia. https://en.wikipedia.org/wiki/Nuclear_power_plant

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