INDEX

1. INTRODUCTION OF NAPS

 DESCRIPTION OF NAPS
 LAYOUT OF THE PLANT
 NUCLEAR POWER STATIONS IN INDIA
 SOME IMPORTANT DATA ABOUT NAPS
 WORKING OF NUCLEAR POWER PLANT: NUCLEAR CHAIN REACTION
 PRINCIPLE OF NUCLEAR REACTOR
 HEAVY WATER AND ITS USE
 MODERATOR SYSTEM
 HEAT TRANSPORT SYSTEM
 REACTOR FUEL
 FUEL HANDLING MACHINES
 REACTIVITY CONTROL
 SHUTDOWN SYSTEM
 STEAM TURBIMES
 TURBOGENERATORS
 COOLING TOWERS

2. REPORT ON THE WORKING OF SOME IMPORTANT SYSTEM

 STEAM CYCLES
 PHT SYSTEM
 FUNCTION OF IMPORTANT VALVES AND PUMPS

3. SYSTEM COVERED DURING TRAINING

 TURBINE GENERATOR
 MOISTURE SEPERATOR AND REHEATER SYSTEM
 FEED WATER SYSTEM
 CHLORINATION SYSTEM
 COOLING WATER SYSTEM
 CHILLED WATER AND COMPRESSED AIR SYSTEM
 INTRODUCTION OF NAPS

One of the chief aim of the Department Of Atomic Energy is the development of
Nuclear Energy for economic generation as an alternative source of electric
power when in due course the conventional sources will be exhausted in the
country.

Petroleum prices are escalating. The amount of coal required for 400 MWe
power generations of the order of 5 x 10 6 kgs per day. Whereas a nuclear power
station of the same capacity need only 200 kg of Atomic Fuel per day.
Transportation of coal of such magnitude over long distance is not economical.

The strategy adopted for Indian Nuclear Power program is that heavy water
power reactors using natural uranium would produce power and plutonium in the
first stage. The plutonium produced from these reactors would be used to set
high breeding ratio fast reactors to produce additional power and plutonium in the
second stage. In the third stage thorium would be utilized in both the fast and the
thermal reactors which would give unlimited source of power.

Consequently it was decided to build twin “PHWR” (pressurized Heavy water

reactor) type of power reactors. The site is selected by a high powered
committee, based on the need of electrical power, the potential of industrial
expansion, availability of large quantities of water and less population.

NARORA, a small ancient village, is situated on the bank of holy river Ganga in
the district Bulandshahr in Uttar Pradesh. The plant is about 60 km from Aligarh
which is the nearest population centre.

With the synchronization of the Narora Atomic Power Station with northern grid
through five lines of 220KV, it occupied an important place on the power map of
the India. With this, yet another important milestone in the Indian nuclear
programme has been achieved as NAPS is an effort towards standardization of
PHWR units and a stepping stone to the 500MWe units. A significant and unique
feature of this project has been the evolution of the design suitable for seismic
sites.
The NAPS is a twin unit module of 220MWe each of pressurized heavy water
reactors. The reactors use natural uranium available in India as fuel and heavy
water produced in the country as moderator and coolant.

The execution of this project, including design, engineering erection,

commissioning, and operation has been done by the Indian engineers and
Scientists. The foreign exchange component is about only 10% of the project
cost of Rs. 723 crores- mostly for the import of special materials and equipment.

NAPS is the fourth Nuclear Power Station in the country after Tarapur in
Maharasthra, Rawatbhata in Rajasthan & Kalpakkam in TamilNadu. NAPS is the
1st indigenous nuclear power plant of India. The station has two pressurized
heavy water reactors with an installed capacity of 220 Mwe each using natural
uranium as fuel.

The station is connected to high voltage net work through five 220 KV lines, one
to Moradabad, one to Harduaganj, one to Simboli, and two to khurja. It is
designed for base load operation as a commercial station.
NARORA ATOMIC POWER STATION
 NARORA ATOMIC POWER STATION
PLANT LAYOUT

Reactor building houses the reactor primary heat transport system,

moderator system, reactivity system, fuel handling system and some of the
auxiliaries. The turbo-generator and its associated conventional equipment,
emergency diesel sets, control and power MG sets, station batteries, electrical
switch gear compressors, chillers and main control room are located in turbine
building. Both the units share common facilities such as service building, spent
fuel storage bay and other auxiliary devices such as heavy water upgrading and
waste management facility.

NAPS has two natural draught cooling and two induced draught cooling
towers.

NAPS has the following main parts:-

1. Administration Building.
2. Overhead water tank.
3. Canteen
4. Natural Draught Cooling Towers
5. 220KV Switch Yard
6. Stack.
7. Service Building
8. Small LOCA Room.
9. Reactor Building.
10. Purification Building
11. Turbine Building
12. Pump house
 NAPS MODEL LAYOUT

SOME IMPORTANT DATA OF NAPS

 S.NO DATA SPECIFICATION
1. Transmission Lines Five
230KV Narora-Moradabad Single Line
230KV Narora-Harduaganj Single Line
230KV Narora-Shimboli Single Line
230KV Narora-Khurja Double Line
2. Stack Height 142 Meters
3. NDCT Height 128 Meters
4. NDCT Top Dia. 107 Meters
5. NDCT Base Dia. 58 Meters
6. NDCT Throat Dia. 53 Meters
7. Steam Flow 1314 Tonnes/hour
8. PHT Flow 12700 Tonnes/hour
9. Steam Pressure 48-40 kg/cm2
10. PHT Pressure 87.0 kg/cm2
11. CCW Flow 39000 Tonnes/hour
12. Coolant Tubes 306
13. No. of Fuel Bundles in one channel 12
14. Fuel Bundle Weight 15 kgs
15. Condenser Pressure 680 mm of hg
16. RB Design Pressure 1.25 kg/cm2
17. Station Load 18-20 MWe
18. Generator Power 220 MWe
19. Grid Voltage 220 KV

IMPORTANT DATES OF NARORA UNITS

PARAMETERS UNIT-1 UNIT-2

Foundation Stone 4th Jan. 1974 4th Jan. 1974
Excavation Started 15th Feb. 1976 15th Feb. 1976
Fuel loading 11th oct. 1988 9th Aug. 1991
Ist criticality 12th march 1989 24th Oct. 1991
Ist synchronization 29th July 1989 5th Jan. 1992
Commercialization 1st Jan. 1991 30th June 1992
ISO-14001 Certification 19th August 1999
ISO-18001 Certification 6th February 2006
Total MUs generated 18110.466 17554.088
(up to June-2005)
NUCLEAR POWER STATIONS IN INDIA

Following are the India’s atomic power stations operating as on today:-

S.NO. PLACE CAPACITY

1. TAPS (1 & 2) 2X160MWe
2. RAPS (1 & 2) 2X220MWe
3. MAPS ( 1 & 2) “
4. NAPS( 1 & 2) “
5. KAKRAPAR ( 1 & 2) “
6. KAIGA ( 1 & 2) “
7. RAPS ( 3 & 4) “
8. TAPS ( 4) 1X540 MWe

Following are the power stations under construction:-

S.NO. PLACE CAPACITY

1. TAPS ( 3 ) 1X540 MWe
2. RAPS ( 5 & 6 ) 2X220 MWe
3. KAIGA ( 3 & 4 ) 2X220 MWe
4. KUNDAKULAM ( 1& 2 ) 2X1000 MWe
WORKING OF NUCLEAR POWER PLANT

Nuclear Power Plants generate electricity. A Thermal Power Plant burns coal to
produce heat. The heat converts water to steam, which in turn drives the turbine
and the generator to produce electricity. The main difference between the
Nuclear Power Plant and the Thermal Power Plant is that Thermal Power Plant
gets heat energy by burning coal whereas the Nuclear Power Plant produces
heat by the process called Fission of U-235 Nuclei. The heat produced is used to
convert water into steam. The steam runs the turbine and generator and the
electricity is generated by the generator.

The fission energy is transported from the fuel bundle with the help of high-
pressure heavy water called Primary Heat Transport (PHT). The PHT System
takes away the heat from the fuel bundles and exchanges this heat to the
Demineralised water (Feed water) into the steam generator and the steam at a
pressure of 40-48 Kg/cm2 is generated in the steam generator. This steam is then
transported through pipes to turbine hall where the turbine and the generator are
installed. This steam is then admitted to the turbine, which runs at a speed of
3000 rpm. The generator also runs at the same speed as both are coupled
together with the coupling. The generator rotor is excited here with the DC
voltage and EMF is produced at the stator of generator at 16.5 KV. This
generated voltage is then stepped up from 16.5 KV to 230 KV by a three phase
transformer and this stepped up electricity is then sent to the station switchyard
for the further transmission to the Northern Grid. This steam after working in the
turbine is condensed into a surface type of condenser and the condensed steam
are again fed back to the steam generator through a chain of six reheaters.

NUCLEAR REACTION

In a fission reaction, besides the two fission products, a few (in the case of U-235
2.47 on the average) neutrons are emitted . The principle of chain reaction is
very easy therefore: a U235 nucleus is hit by a neutron, upon which fission
occurs at a high probability. The neutrons produced in this process can cause
more fissions, 200 MeV energy is released each time. Consequently, the process
becomes self-sustaining and no external neutron source is needed any longer.

If the neutrons produced from a fission induce only one new fission (because of
escaping from the system or being captured inside) we say that the chain
reaction is of constant intensity. If the neutrons generated from a fission reaction
induce more than one fission than more and more fission reactions will take
place in a unit time and the chain reaction will be diverging.
The probability that a high energy neutron emitted in a fission reaction can
directly cause fission is quite low. In order to build a system in which fast
neutrons sustain the chain reaction, very highly enriched uranium is needed,
which is very expensive. A more easily feasible way is to use materials that slow
the neutrons down to such low energies at which the probability of causing
fission is significantly higher. These neutrons slowing down materials are the so
called moderators. With the aid of some adequate moderator one might as well
achieve chain reaction using natural (0.7% U235 content) uranium.

If we simplify things a little, there are two major requirements that a moderator
material should meet: it should have as low atomic mass number as possible and
its neutron absorbing ability should be as low as possible. In practice four
elements meet these requirements: water (H2O), heavy-water (D2O), graphite
(C) and beryllium (Be). Among these water is the most widespread moderator.
The properties of heavy-water are actually better but its disadvantage is the very
high price.

If we start to put together more and more uranium (of course mixed with some
moderator), the expected chain reaction will not start for a good while. The
reason for this is that in the case of a small amount of fissile material large part of
the neutrons that originate in fission will leak out of the pile and therefore they will
not be able to cause fission. By increasing the amount of fissile material there will
be a moment when we reach the so called critical mass and a self sustaining
reaction starts. For example, for pure metal U235 (without moderator) the critical
mass is somewhat less than 50 kg. Because of the very high density (19.2
g/cm3) this amount of uranium makes a sphere whose diameter is about 17 cm.

At the fission of U-235 on the average 2.5 neutrons are released but not all of
these cause fission. The neutronic state can be characterized by the so called
multiplication factor (k). This is the ratio of the number of neutrons in a neutron
"generation" and the number of neutrons in the preceding generation. (Neutron
generation is the time that elapses between the birth of a neutron and the birth of
neutrons from the subsequent fission which is caused by the given neutron. Its
tipical value is about 10-9 second for pure U-235.)

If the value of the multiplication factor is 1, we

talk about a critical reactor. In this case the
number of neutrons in the system is constant,
i.e. they cause the same number of fissions in
every second. If k<1, the reactor is subcritical
and the number of neutrons is going down. On
the other hand, if k>1, the system is
supercritical.

Obviously, the number of neutrons present in the reactor must be regulated or

controlled since this determines the rate of fission and thus the energy released
per second. In order to control the chain reaction one should use materials which
tend to capture neutrons at a high probability. The most widespread neutron
absorbers are cadmium (Cd) and boron (B).

The so called control rods are important tools of control and can be found in
every reactor. These are made of neutron absorbing materials and can be moved
between the fuel assemblies. For example, if one wishes to decrease the power
of the reactor it is sufficient to push a control rod a little inner. The control rods
are particularly useful for the short term control and stopping the reactor. For long
term regulation usually boric acid dissolved in the coolant is used.

The majority of the emitted neutrons leave the place of fission within an
extremely short time. However, about 0.64% of them (in the case of U-235) only
leave the fission product significantly later. These are the so called delayed
neutrons, which play a vital role in the controllability of reactors.
The fission reaction of the Uranium-235 atom with the thermal neutron in the
nuclear reactor follows:

92 U235 + 0N1 38 Sr94 + 54Xe140 + 2 0N1 + γ (Energy)

Distribution of Fission Energy

Kinetic Energy of fission fragments : 168MeV

Energy of fission neutron (0n1) : 5MeV
Energy of prompt gamma : 5MeV
Energy of decay products : 22MeV
------------------------------------------------------------
Total energy released per fission : 200Mev
------------------------------------------------------------

Number of fissions required

1 fission = 200MeV= 200x106eV

= 200x106x1.6x10-19 joule (1eV=1.6x10-19 joule)
= 200x1.6x10-13 Watt-sec. (1 joule=1 Watt-sec.)
or

1 fission/sec. = 200x16x10-13 Watt

or

1 Watt = 1/(200x16x10-13) fission/sec.

= 3x1010 fission/sec. (approx.)
or

1 Watt-sec. = 3x1010 fission

or

220 MW-day. = 3x1010x106x3600x24x220 fission

= 5.7x1023 fission (approx.)
NOTE: -

Uranium is available in the form fuel bundles, which once loaded in to the reactor
core, provide energy for 1.5 to 2, years at a stretch before discharge.
1 Kg of Uranium provides energy equivalent to that of 25000 Kg of coal.

Uranium-235 atom when struck by a slow neutron splits into two or more
fragments and release enormous amount of energy. This energy is used to
produce steam, which in turn rotates Turbo generator to produce electricity.
PRINCIPLE OF NUCLEAR REACTOR

A Nuclear power reactor is only a source of heat, the heat being produced when
the uranium atom splits (fissions). The heat produces steam, which drives the
turbo-generator & produces electricity. Natural uranium, the fuel used in this
reactor, consist of two types (isotopes) of uranium namely U-235 and U-238 in
the ratio of 1:139. It is the less abundant U-235 isotope that fission’s and
produces energy. When a U-235 atom is struck by a slow (or thermal) neutron, it
splits into two or more fragments. Splitting is accompanied by tremendous
release of energy in the form of heat, radioactivity & two or three fast neutrons.
These fast neutrons, which fly out of the split atom at high speeds, are made to
slow down (thermalised) so that they have high probability to hit other U-235
atoms which in turn releases more energy & further sets of neutrons. Attainment
of self-sustained Fission of uranium atoms is called a ‘Chain Reaction’. At this
stage the reactor is said to have attained critically.

The slowing down of neutrons is achieved by the ‘Moderator’, which is heavy

water.

HEAVY WATER AND ITS USAGE

Heavy water is used both as the moderator (140 tones) and coolant (100 tones).
Heat energy is transported by coolant form reactor to the vertical, integral U-
tubes in shell type of heat exchangers, which function as a boiler to produce
steam and drive Turbo Generator. The heavy water (D 2O) is identical to the
ordinary water (H2O) as far as the chemical properties are concerned. But in
physical properties there are minor variations (boiling point 101.4 oC and freezing
point 3.82oC). The deuterium (D2) in heavy water is an isotope of hydrogen (H 2)
having one neutron and one proton in its nucleus. The absorption cross-section
of heavy water for neutron is far less than the ordinary water, which helps in
neutron economy.
MODERATOR SYSTEM

The heavy water moderator is circulated through the Calandria by the aid of low
temperature and low-pressure moderator system. The system circulates
moderator through Heat Exchangers, which remove moderator heat. The cooled
moderator is returned to Calandria via moderator inlet nozzles. Chemical purity
and activity levels of moderator are maintained through moderator purification
system. Helium is used as cover gas.

HEAT TRANSPORT SYSTEM

The heat generated in the fuel bundles, as a result of uranium fission, is removed
by the heavy water serving as primary coolant. The coolant transports this heat
to the four steam generators. The circulation through pressure tubes around the
fuel bundles is maintained by four pumps, each having a capacity of 3560m 3/hr.
The coolant temperature at inlet and outlet of a reactor are 249 oC & 293.4oC
respectively at a pressure of 101 kg/cm2 and 87 kg/cm2 respectively. A
pressuring pump maintains the system pressure using automatic feed and bleed
principle instrument relief valves and suitable regulating and protective system
action limit the system pressure to 93.91 kg/cm 2.High pressure, high temperature
heavy water areas have been separated from high pressure, high temperature
light water areas for recovery of high isotopic purity heavy water.

REACTOR’S FUEL

Fuel from the reactor is in the form of bundles 49.53 cm long and 8.17cm dia and
each bundle consists of 19 hermetically seal zircaloy tubes containing compact
and sintered pallets of natural uranium. Twelve such bundles are located in each
fuel channel.
FUEL HANDLING MACHINES

Loading new fuel or removing spent fuel from the reactor is carried out by Tow
fuelling machines (Robots). At both end of Calandria, which is computer
controlled and mounted on a bridge and column assembly, on power fuelling is a
requirement for the reactor operation to maintain reactivity besides maintaining
the power level. Bi-directional fuelling is resorted to maintain the symmetry. As a
result of this the coolant also moves through the reactor in both directions, thus
necessitating two sets of inlet and two sets of outlet header. 56 tones of natural
uranium oxide are required for each reactor. Subsequently only 100 kg of fuel
per day is adequate to produce to power equivalent to that produced by 2500
tones of coal in a thermal station. All structural components within the reactor
core are made of Zircaloy.

REACTIVITY CONTROL

The most important method of reactivity addition is by on power fuelling by Tow

remote controlled fuelling machines. Additional reactivity control on a continuous
basis is done by automatic movement of regulating rods with stainless steel
absorbers in the top & bottom of the core moving inward or outward. During
initial period of operation until equilibrium fuel burn-up is reached, a uniform flux
control is achieved by the addition of Boron solution to moderator heavy eater or
removal of the same by valving in ion exchangers. Shim rods are provided for
start up & power reduction during set back. Adjuster rods are provided for Xenon
overrides.
SHUTDOWN SYSTEMS

NAPS are provided with two diverse and independent, one fast acting and other
slow acting, shutdown systems. The primary shutdown system has shutoff
mechanism at 14 locations in the reactor. Each of the 14 mechanism has
cadmium shutoff elements. These rods drops in the core under gravity whenever
a trip signal is received, and make the reactor sub-critical in less than two
seconds. The secondary shutdown system is a fast acting back up system to the
primary shutdown system. This system provides sufficient reactivity worth by
promptly filling twelve vertical tubes in the reactor core with a neutron poison,
Lithium Pentaborate solution.

Both the fast shut down systems are backed by Automatic Liquid Poison addition
system injecting controlled quantities of boron into the moderator after receiving
the appropriate signal to ensure guaranteed sub-criticality of the reactor for
prolonged periods. Whenever there is total blackout of the station and automatic
liquid poison system is not available, addition of poison, under gravity, to
moderator is incorporated.

STEAM TURBINES

The turbine is an impulse reaction type, designed for saturated steam duty,
revolving at 3000 rpm with steam condition of 39.71 kg/cm 2 (g) pressure and
0.26% wet and 250.3oC at inlet to stop valves. After expansion in a single flow
high-pressure turbine, moisture is extracted in separator cum re-heater units
where steam is reheated to 233 oC before it enters the double flow low-pressure
turbine. Steam is extracted from suitable stages of the turbine to provide for 6
stage regenerative feed heating, with a final feed water temperature of 169.05 oC.
TURBO GENERATOR

The total quantity of steam flow to the turbine is around 1333.58 tones/hr and
design rate of heat turbo-generator is 2758 Kcal/KWh. The generator is rated
264 MVA, 16.5 KV, and 0.9 PF. Stator conductors are water-cooled. The stator
bore and rotor are cooled by hydrogen, since excitation current requirement is
large with a maximum of 5000 amps, inductor-type high frequency exciter is
chosen to avoid commutation problems which are experienced in DC exciters.

COOLING TOWERS

NAPP has two 128m high natural draught cooling towers, the most imposing civil
structures at site. These are used for dissipation of heat from the condensers and
non-acting auxiliary coolers, in addition, two induced draught cooling towers are
provided to remove heat from the heat exchanger of the active process water
system. To ensure containment of potentially active cooling water with the
provision of cooling towers, we draw very little water from the Ganga .

STEAM CYCLE

The cycle used in Nuclear power plants is Reheat rankine cycle. The moisture
content is quite high when steam leaves the high pressure turbine , which can
cause serious erosion of the turbine blades thus the moisture is reduced by
reheating the steam in a moisture separator and thus a steam with low moisture
content reaches the low pressure turbine and this increases the efficiency of the
system.

At normal full load a flow of 1.33 ×10 6 kg/hr of 0.26% of wet steam at a pressure
of 40.7 kg/cm² is delivered to the turbine throttle. After expansion in H.P. turbine,
steam is exhausted at a pressure of 6.05×10 6 kg/cm² with a wetness of 11.5%.
Then it passes through external moisture separator reheater. Moisture separator
section of separator reheater reduces the wetness to 1%. Subsequently the
steam is reheated in bled steam reheater and live steam reheater suctions to a to
a temperature of 233.33ºC.
The steam enters the low-pressure double flow turbine at this temperature and
pressure of 5.68 kg/cm² where it expands to a backpressure of 0.095 kg/cm².
The condenser parameters have been optimized and a condenser pressure of
87.12 mm Hg has been selected for cooling water temperature of 32ºC at
condenser inlet.
The steam is condensed in a surface condenser and the condensate is
withdrawn from the condenser at approx. saturation temperature. Heat is
recovered by the condensate from the steam air ejector inter after condenser and
turbine gland steam condenser before entering the L.P. feed water heater train.
This train consists of a drain cooler, three (3) low-pressure tubes in shell type
heaters namely LP 1, LP 2 and LP 3 are with integral drain cooling zone.
The feed heating train also consists of the direct contact type deaerating heater
with external vent condenser and two tubes in shell type HP heaters namely HP
5 and HP 6. HP 5 is only with condensing zone and an external drain cooler is
provided. HP 6 is with integral drain cooling sections. While passing through the
feed heating trains the feed water is heated to a temperature of 170.8ºC.
The feed water returns to the main and auxiliary feed nozzle of steam generators
through two feed mains, one main serving a bank of two boilers having individual
sets of flow control system.
The reheater drains from both the live steam reheaters tube nests are collected
in a live steam reheater drain tank and pumped back to the auxiliary nozzle of the
steam generators via down stream of the 10% control station.
Passing the turbine has made a provision of dumping the live stream in the
condenser. This dumping operation is made by means of steam dump valves.
Steam pressure is further reduced by break down orifice and the steam
desuperheated before entering the condenser. These steam dump valves take
signal from boiler pressure controller.

STEAM MAINS

The boiler steam pressure is programmed to rise linearly from 40 kg/cm² at 100%
load to 48.6 kg/cm² g. at no load fro swell and shrinkage considerations ih the
PHT system described in section 4 and steam generator design constraint.
The design pressure of the steam system has been taken as 50 kg/cm² g.
considering transient pressure variations over no load boiler pressure of 48.6
kg/cm² g. The design temperature of 264ºC is the saturation temperature
corresponding to the above design pressure. The main steam headers have
been designed to allow a total steam flow of 1.33×10 6 kg/hr and to limit the
pressure drop to 0.32kg/cm². Considering the turbine capability, loss and cost of
pipes arrives at this pressure drop. The steam mains are 711.2 mm OD ×
17.5mm thick fabricated pipes made to ASTM A 155 kc 70 and other smaller
steam pipes to ASTM A 106 GrB have been used. The fittings are as per A 234
gr. WPB> the piping is of welded constructions of nuclear power plant
components – class 2 components.
The number of headers have been chosen as two considering the number the of
steam generators, their layout, the size of the individual and the two feeding
points required for the turbine. The main steam has been designed for Sse and
has been dynamically analyzed for both SSE and OBE conditions by response
spectrum method. The codes and safety guide followed are ASME sec. III NC
and IAEA safety guides 50 SG-S2 and 50-SG-D1.
Two 500mm NB steam outlet connections, one each from the two steam
generators are connected to a 700 mm NB header in each bank with no
intervening valves. These mains carry steam from the two boiler banks I reactor
building to the turbine.
Inside the reactor building each main is suitably anchored at the boiler end. The
design of anchors take into considerations apart from the load due to thermal
expansion and earthquake, the thrust exerted upon it is eventuality of the main
steam pipe rupture. Further to prevent the pipe whip of the main steam pipe in
the reactor building in case of severance occurring to the west of the anchor, a
limit stop has been provided at the end of the pipe header to stop excessive
movement of the pipe. The limit stops will allow a deflection of 10mm and are
designed to take a load of 200 tones.
The steam mains leave the reactor building through wall penetrations at C.L.
elevation of 127.1 m on the perimeter wall. These penetrations are closed by
steel plates 25mm thick and are attached through pipe sleeves and penetration
bellows to the steam mains. The steam mains before entering to the turbine
building are laid over a pipe bridge and on another outdoor run carry the
controlled steam discharged valves and safety relief valves
The mains enter the turbine building at an elevation of 122.6 m and then it comes
below the mezzanine floor 106.6 m. inside the turbine building the two mains are
inter connected by an equalizing line of 400 mm NB just before the connections
of the CISE valves. The equalizing line permits the testing of the CIES valves
one by one for up to 60% load. Connection for this dumping has been taken from
the equalizing branch. The steam lines are provided with adequate slopes. Drain
points have been provided on the steam mains for ensuring drainage for starting
and power operation.
Steam required for reheating in live steam reheaters, air ejectors and turbine
gland sealing systems under normal operating conditions have been tapped at
suitable locations from these mains. However during part load below 55% and
steam dumping operation, main steam is also supplied to the deaerator for
heating the condensate for the desired temperature.
PRIMARY HEAT TRANSPORT SYSTEM

General
The main function of primary heat transport system is to transport the heat
produced in the fuel (located inside the pressure tubes of reactor) to steam
generator, in which the steam is generated from ordinary water (i.e.
Dematerialized Water, DM) to run the turbine.
The heat transport medium is pressurized heavy water and is circulated through
the main circuit by Primary coolant pumps (PCP’s).

Principal Features
The following features are incorporated in PHT system: -
(1). Continuous circulation of coolant through the reactor at all times by various
modes as listed below:-
(a). In normal operations circulation of coolant is by primary circulating
Pumps (PCP’s).
(b). Flywheel is provided in the PCP motors to extend the pump rundown
time so that in case of loss of power the flow reduction is gradual.
(c). After loss of power to pumps, adequate circulate would be maintained
through thermos phoning.
(d). When main circulating pumps are not operating, arrangement for
cooling the fuel is done by means of shutdown cooling, exits below
150ºC.
(e). In case of loss of coolant, there is provision for emergency injection of

coolant from D2O accumulator when the pressure falls down to

55kg/cm² and continues to fall by light water at 32kg/cm².

Description

PHT system is pressurized heavy water system (Pr = 87 Kg/cm²).It forms closed
loop. Heavy water (PHT) passes over the fuel bundles through 306 coolant tubes
and gets heated. Each coolant tube is connected to outlet feeder. All feeders are
connected to reactor outlet header (ROH). From reactor outlet header (ROH)
PHT passes through steam generator (SG) in tube side. Shell side of SG is filled
with light water, which gets heated up and converts into steam. Thus PHT
transfers its heat and gets cooled. Cold D2O outlet from steam generator is
pumped by primary coolant pump (PCP) to reactor inlet header (RIH). From
reactor inlet header PHT passes through reactor inlet feeders and through
coolant tubes. While in coolant tubes D 2O picks up heat. Hot PHT reaches in
ROH through outlet feeders. It again passes through SG and transfers its heat to
light water. Cool D2O is pumped to reactor inlet. Thus heavy water is continuously
circulated through coolant tubes and steam generators.

NAPS PHT system has four PCP and each PCP is connected to one steam
generator. There are two-reactor outlet header one on both side and another one
on south side of reactor. Similarly two reactor inlet headers are also in either
side. There is bi-directional flow through coolant tubes. Out of 306 tubes, PHT
flows from north side to south side in 153 tubes and from south side to north side
in 153 tubes. Adjacent tubes have reverse flow direction. PHT inlet and outlet
temperature to and from calandria are 249ºC and 293ºC respectively.
PHT SYSTEM OF THE NAPS IS SHOWN BELOW

PHT is kept constantly pressurized at 87kg/cm² to keep it in liquid form at 295ºC .

Emergency core (fuel) cooling system has been provided for cooling the fuel if
there is any break in PHT system. Shutdown cooling system provides facility for
heat removal during shutdown period to remove decay heat.

AUXILIARIES OF THE PHT SYSTEM

Purification
Corrosion products and fission products are removed from the system by
purification. The circuit also helps to achieve a pH value between 9.5 to 10.5 and
maintain the conductivity of D2O to 30µsiemens/cm.

Stand By Cooling System

For cooling the system temperature below 150ºC and for holding the system at
low temperature during plant maintenance an auxiliary cooling system is
provided which is known as standby cooling system or shutdown cooling system.
The system is connected between the reactor outlet and inlet header at each end
of the reactor.
Primary Relief
Once the reactor has been operated at significant power the fuel will continuously
supply heat. If normal heat removal fails and normal pressure control fails or their
capacities are exceeded, the increase in coolant volume caused by the reactor
would be passed out of the primary system by relief valves (RV’s), one relief line
connects the pressurized end of south shutdown cooling loop to the bleed
condenser through 3 instrumented relief valves in parallel.

Leakage Collection
Leakage from potential leak source in the system e.g. valve stem packing,
double gasket joints, flanged connections and pump seals etc. is collected in a
tank and then returned to the system through purification circuit or sent to heavy
water transfer system.

FUNCTIONS OF IMPORTANT VALVES AND PUMPS

(1). RELIEF VALVES

PHT system relief valves are designed to open simultaneously at system

pressure of 93.90 Kg/cm² (at ROH). These control valves (CV’s) are “Air to close”
and “spring to open” type. Air being supplied to the CV’s through solenoid valves
(SV’s) in series. Air is exhausted from the exhaust port when SV’s are energized
and when any one of the SV’s in series is energized the corresponding CV
opens.

(2). PRIMARY CIRCULATING PUMPS (PCP’S)

Primary circulating pumps are vertical single, radial impeller, double volute
casing, bottom suction and horizontal radial discharge type. Each pump is
coupled with a 2.8MW motor. The coupling between pump and motor is self-
aligning curved tooth gears coupling and hence require lubricating oil supply.
They are designed to provide a flow of 3560 m³/hr at a system temperature of
266ºC. the PCP’s are equipped with 3 mechanical seals and a back up stein
seal. At each mechanical seal, pressure drops occurs nearly 2/3 rd of its initial
value.

TURBINE

The main steam lines described above terminate at the common inlet chamber of
CIES valve steam chest in which two CIES valves are housed inside steam
strainers. From the common outlet chamber of the CIES valve steam chest, two-
loop pipe lead the steam to two governor valves located on either side of the H.P.
turbine. From the governor valves, two more loop pipes lead the steam to the
H.P. cylinder. All these loop pipes are sufficiently flexible to allow the thermal
movements in the system without creating excessive forces and moments.

The turbine is a tandem compound horizontal impulse reaction type, which when
running at 3000r.p.m. Will drive a 235 MW generator. It consists of a single high-
pressure cylinder and one double flow lo pressure cylinder. The high-pressure
section has five sections in one cylinder. Steam is bled for feed heating before
stage 4 of the H.P. cylinder and for feed heating before stage 5 and from the
exhaust of the H.P. cylinder. The 0.26% wet steam at pressure of 40 kg/cm² and
250ºC is supplied to CIES valves (combined isolating and emergency stop
valves). The turbine is pressure compounded to expand the steam in two
cylinders, one HP and one LP. After expansion in HP cylinder the steam is
exhausted into two separators cum reheaters where moisture is separated and
steam is reheated to 233ºC before it enters the double flow low-pressure turbine.

The exhaust steam from H.P. cylinder is led to the two moisture separator cum
reheaters units (Separator – Reheaters) through 42" cold reheat pipes, made
from 21/45 Cr, 1% Mo steel; steam from separator-reheater is taken to the LP
cylinder by 54"/48" hot reheat pipes. One L.P. interceptor emergency and
governor valve is installed in each reheat line. Bellow type steam expansion
joints are provided on H.P. cylinder exhausts, separator- reheater inlet and outlet
side and at L.P. interceptor valves to take care of thermal expansion of the pipes.
LP cylinder has five stages in each flow. Steam is bled before stages 2,3,4 and 5
of L.P. cylinder for feed heating. The exhausts from the L.P. cylinder are led
through the diffuser to the condenser. Steam extracted from suitable stages of
HP and LP turbine to provide for 6 stage regenerative feed heating with a final
water temperature to 170.7ºC.
The rotating element of the turbine consists of the H.P. rotor and L.P. rotor solidly
coupled together to fore a single shaft. This shaft is rigidly coupled to the rotating
element of the generator on the L.P. out board bearing side. The thrust bearing is
provided in the pedestal between the H.P. and L.P. outer cylinder.
Cooling water sprays are provided at either end of the L.P. cylinder, which
automatically come into action in case of excessive rise in exhaust hood
temperature.
Gland seals are provided to prevent the leakage of steam to atmosphere from
the high-pressure ends of the turbine and ingress of air into the turbine at the
low-pressure ends between rotary and stationary components. Live steam is
tapped from the steam line and supplied to the L.P. and H.P. turbine glands
through pressure regulating valves.
An A.C. motor barring gear is provided for turning the turbine rotors when starting
up and shutting down so as to prevent rotor distortion due to unequal heating or
cooling. Because of the use of saturated steam, special provision has been
necessary to limit erosion. H.P. casing is made of 2-1/4" Cr. , 1% Mo steel
castings. L.P. casings are made of mild steel fabrication. HP rotor and LP mono
block rotor are made of Ni, Cr, Mo, V steel. HP and LP moving blades are made
of stainless steel 12-14% Cr.. Internal passages of turbine cylinders are arranger
to avoid removal of water with steam bled off for feed water heating and
reheating of steam. The last row of moving blades on the LP side are welded with
stellite strips on the leading edges by electron beam welding to protect the
blades from erosion. High chrome stainless steel metal has been deposited on
the internal surface of HP cylinder and CIES valves seats are stellited to reduce
the effect of suspended water in steam impinging on these surfaces. Each
turbine rotor has been dynamically balanced and over speed tested at 20%
above rated speed.
TURBINE OIL SYSTEM

A single oil system serves both the turbine hydraulic control system and
lubrication system. During normal operation of the turbine, the main oil pump, the
impeller shaft of which is directly coupled with turbine shaft, takes suction from
the oil tank , provides the oil to the oil system. A portion of the main oil pump
discharge drives the oil turbine driving the booster pump and discharge into lower
pressure header for bearing lubrication oil.

This oil system provides oil for bearing lubrication and high-pressure oil for the
turbine control gear and generator shaft sealing system.

FUNCTIONS OF SOME IMPORTANT VALVES USED

(1).Combined Isolating And Emergency Stop Valve (CIES)

The CIES valves may be operated either by hand wheel provided on the turbine
operating floor or by electric motor remotely operated from control room or from
turbine gauge board.

The CIES valves are a single seated valve with venturi type steam passage. The
valve seat assembly incorporates a steam strainer. The valve body contains an
integral bypass valve, capable of passing sufficient steam for starting and light
loading.

The CIES valve is provided with built in safety feature against the inadvertent
opening of the valve after the turbine trip. When the turbine trips, both the valves
close. They cannot be opened again even after the turbine is reset unless the
CIES valve is itself reset by bringing its hand wheel to the fully closed position.

(2) Non-Return Valves (NRV’s) On The Turbine Extractions

Non- return valves are provided in the bled steam connection no. 2,3,4,5,6 and 7
to prevent turbine over speed due to back flow of the steam into the turbine
which is likely to occur during turbine unloading. All the NRV, s except that on
bled steam connection no. 2 is of power assisted fast closing type for greater
protection. As for the steam connection no. 5 leading to HP heater no. 5, this is
tapped from cold reheat pipe connected between separator- reheater and HP
exhaust. The valves are solenoid air to open type. Solenoid valve will be
energized normally. Solenoid valve will get deenergises to drain the
compressed the compressed air and NRV will be closed by spring force acting
until the turbine speed falls. The differential pressure switch between the
deaerator and the condenser ensures that the solenoid is reenergized.

As such the interceptor and emergency valves provided after separator- reheater
take care of over speeding problem as stated above. Hence, NRV on the bled
steam connection no. 5 is considered superfluous and therefore is not provided.
Additional power assisted fast closing butterfly valve is provided on bled steam
connection no. 4 to deaerator as extra protection considered necessary in view of
large stored heat energy in deaerator and provision of pegging steam bringing
extra energy to deaerator. No NRV is provided in bled steam connection 1 to LP
heater no 1 . Since differential pressure between the LP heater and turbine is too
small to warrant use of NRV even during unloading.

(3). PRESSURE RELIEF VALVES

The pressure relief valves are provided in Re-heater shells to protect from
internal excessive pressure by providing 3 Nos. relief valves on the left hand side
of the hot reheat pipe and one number bursting diaphragm to burst at a pressure
of 7.05 kg/cm². The relief valves are set to open at a pressure of 6.0 kg/cm².

Pressure relief valves are usually spring loaded and valve opening pressure is
adjusted by tightening and loosening the spring. The valve is activated by static
pressure under the disk. When the line pressure exceeds the preset of the spring
the valve is opened and the excess fluid go out of the system itself.

Diaphragm valves offer advantages not only possible with other types of valves.
Absolute isolation of the working parts from the fluid stream prevents product
contamination, and corrosion of the operating mechanism. They provide smooth
streamlined passage without pockets as well as flow controls and leak tight
closure even with suspended solids in the pipe line.
Some Important Devices In Turbine Governing System

Function of the governing system is as follows:

(a). To run up the turbine up to the rated speed.

(b). Maintain the speed, while no load.

(c). When connected with grid, it should be able to follow the reactor power.

(d). To trip or safeguard the turbine under any abnormal condition.

To perform the above functions, the turbine oil of various pressures is used to
control various units. The oil, which is used to drive CIES valves, is called relay
oil.

Main Components are:

(1). Speeder gear: -

The speeder gear is mounted in the front pedestal. It is used ton raise and lower
the compensating sleeve of the governor pilot valve, thus varying the H.P.
sensitive oil pressure to control the degree of opening of the H.P. governor
valves and thereby the output of the governor.

(2). Speed governor: -

It is of centrifugal type. It consists of two weights, which are connected by spring.

On change in speed, centrifugal forces causes the weights to swing outwards or
inwards on their pivots against the tension of the spring in turn changes the
position of H.P. & L.P. pilot valves, mounted above the speed governor and
thereby varying the H.P. & L.P. sensitive oil pressure to control the opening of the
H.P. 7 L.P. governor valves respectively.

(3). H.P. governor valves: -

H.P. governor valves regulate the steam admission to the turbine. These are
opened or closed as per the H.P. sensitive oil pressure. This pressure is adjusted
by the action of centrifugal governor or by the action of speeder gear. Centrifugal
governor gets signal either from the turbine speed when turbine is
unsynchronized or from the grid frequency when turbine is synchronized.
Each HP governor valves is provided with a steam strainer. The valve is provided
with spindle leak off arrangement. The force of relay oil pressure opens the valve
and the closing force is obtained by powerful springs on draining of relay oil
pressure.

(4). L.P. interceptor emergency stop valves(LPIESV):-

These valves are of the butterfly design operated by a spring loaded power
piston. The valves are fitted with mechanical stops at each end of their strokes.
Relay oil trip valves directly control these valves. With relay oil established they
open and when relay the trip valves they automatically close under spring force
cut off oil.

(5). L.P. interceptor governor valves:-

These valves are also of the butterfly design. The L.P. sensitive oil pressure
controls interceptor governor valves. L.P. sensitive oil transmitter unit depends
only on the speed of the turbine. These valves are never disturbed by the
operation of the turbine. L.P. sensitive oil pressure starts dropping above 103%
above the rated speed and valves start closing. At 106% above the rated speed,
L.P. sensitive oil pressure reaches a minimum value and valves are fully open
and closed.

(6). Acceleration governor:-

The acceleration governor is incorporated to reduce the speed rise of the turbine
on sudden loss of the load. On constant speed, H.P. and L.P.sensitive oil supply
ports provided on acceleration governor are not open to drain, when rotor
acceleration high, it will temporarily open both the H.P. and L.P. sensitive oil
system to drain, thereby closing all H.P.and L.P governor valves in less time than
is possible under normal governor action.

MEASUREMENT OF SPEED

The main turbine speed is measured in to ranges. Turbine high speed channel
measures the speed between 0-4000 RPM and turbine low speed channel
measure the speed between 0-75RPM.Barring gear motor speed is also
measured in the range 0-2000 RPM (local instrument). The main turbine high
speed, low speed and barring gear motor speed are measured by separate
proximity probe detectors. The proximity probe detector for turbine low speed
and high-speed measurement are mounted in the front pedestal adjacent to the
flywheel of the acceleration governor, which has 24 teeth. Barring gear motor
speed is mounted adjacent to the 4-start worm on main turbine barring gear. The
proximity probe detector, which is, mounted close to a toothed wheel experiences
a sudden change in the air gap when a tooth is in the target area of the probe.
This sudden change of air gap is converted into a square wave with a magnitude
independent of tooth velocity but with a frequency, which is a function of shaft
speed, by electronic circuits. The frequency represents turbine and barring gear
motor speed.

Some Important Parameters In Turbine

(1). AT THE INLET OF H.P. TURBINE:

Pressure = 40kg/cm²².

Temperature = 250ºC

Moisture = 0.26 or 26%

(2). AT THE OUTLET OF THE H.P. TURBINE:

Pressure = 6 kg/cm²

Temperature = 150ºC

Moisture = 11 – 12%.

(3). AT THE INLET OF L.P. TURBINE:

Pressure = 5.5 kg/cm²

Temperature = 233ºC

IMPORTANT DATA:-

(1). Mainstream pressure before stop valve in kg/cm² gauge.

At 0% load = 40.58 kg/cm²

At 100% load = 39.03 kg/cm²

(2). Main steam temperature before stop valve;

At 0% load = 262.1ºC

At 100% load = 2500C

(3). Re-heater outlet temperature = 233.33ºC.

(4). Final feed water temperature = 170.72ºC.

(5). Condenser back pressure = 63.5 cm Hg abs.

(6). Maximum continuous generator rating = 264 MVA (at 0.9 power factor)

(7). Rated speed = 3000 RPM

(8). Speed on turning gear = 34.5 RPM

(9). Maximum throttle flow = 1333.6 tons/hr

(10). Number of extractions =7

(11). Number of exhaust paths =2

(12). Last stage blade length = 944mm.

(13). Last stage mean diameter = 2633.9 mm

MOISTURE SEPARATOR REHEATER SYSTEM

Separator Drain System

Description

The exhaust steam from the high pressure turbine contains a large quantity of
moisture so before admitting the steam to low pressure turbine. It is passed
through combined moisture separator and reheater unit, which remove the
moisture from the H.P exhaust steam.
The large quantities drain produces from the moisture separator section is
drained into tanks (4112-TK-1). The drain from TK-1 is normally pumped to H.P.
drain cooler by means of two pumps 4112-P1 and P2. In case H.P, drain cooler is
not available or deaerator level is high the drain is returned to condenser through
flash tank.
The small baffles of the moisture separator section in MSR ensure an even
distribution before steam passes through the separator pad. The separator pad is
designed to remove moisture from the steam, this moisture is collected from
each unit of MSR via drain connection fitted at bottom of the shell.

Description of the Control

Two 100% capacity pumps (4112-P1 & P2) are there to take suction from the
moisture separator drain tank (TK-1) to and to discharge through control valve
4112-CV-30. A drain tank level controller (LC-2) regulates this control valve. Two
level switches LS-67 and LS-68 are provided for low level pump trip and other for
high level annunciation and opening of the bypass valve MV-26 to flash tank.
(refer the flow diagram on the next page ).

LINE DIAGRAM OF MOISTURE SEPERATOR REHEATER

DRAIN SYSTEM
Description
The exhaust steam from the high pressure turbine is initially passed through the
moisture separators of combined separator and reheater units which remove the
moisture from the H.P. exhaust steam. The outlet steam from the moisture
separators is routed inside the shell foe reheating in two stages first in bleed
steam reheaters and subsequently in the live steam reheaters. The bleed steam
and live steam give their latent heat to the H.P. exhaust steam and in turned get
condensed.
The drain condensate from bleed steam reheaters is collected in two bleed
steam drain tanks TK-1 and TK-2 and condensate from live steam reheaters in
live reheaters drain tank TK-3. The drain from the TK-3 is normally pumped back
to the boilers. The drain from TK-1 and TK-2 is returned normally to H.P. heater
#6. No drain pumps are used for this purpose. The differential pressure between
TK-1 and TK-2 and H.P. heater #6 is utilized for transferring the drain condensate
to H.P. heater # 6 is out of service due to any reason,the drain is returned to
moisture separator drain tank.

Description of the control

Two 100% capacity pumps 4113-P-1&P-2 are arranged to take suction from the
live steam reheater drain tank TK-3 and to discharge through two control valves
(4113-CV-48 and 4113-CV-47) to boilers. A drain tank level controller LC-1
regulates these two valves. Two switches (LS-66 and LS-65) are provided for
high and low annunciations. When both the pumps trip, 4113-MV-20 valve will be
opened for allowing the condensate to go to L.P. flash tank.
As already stated from bleed steam reheaters is collected in two bleed steam
reheaters drain tanks. The level of TK-1 is controlled in split range by 4113-CV—
49&50. Depending on the level of TK-1 LC#3 allows condensate to discharge
through CV-49 or CV-50 to H.P. heater #6 or to moisture separator drain tank.
As the steam expands in H.P. cylinder, the moisture content of steam goes up to
about 11-12% at the H.P. exhaust. Pressure of so high moisture would de
detrimental to L.P. blades and would adversely affect the efficiency of the cycle.
Hence the steam is reheated before allowing it to enter the L.P. stage by means
of two combined MSR’s, which are provided in each of the two crossover lines
from H.P. turbine to L.P. turbine.

The MSR’s are of single shell design having two parallel circuits. In each circuit
there is one moisture separation stage followed by 1 st and 2nd reheating stages.
The moisture separators are of demister stainless steel mesh type. The moisture
content of the steam after passing through the separator stage reduces to 1%.
The first reheating is done by means of four bled steam tube nests in each MSR
getting steam from extraction No. 7. The 2 nd stage reheating is done by of two
live steam tube nests in each MSR’s. Live steam and bled steam tube nests are
made up of U bent, finned, mild steel tubes.
In order to protect the tube nests from damage due to impingement of steam
coming out of moisture separator an item called 'Vent Element' is provided
between moisture separator and bled steam tube bundles on main steam path.
There are two vent elements in each MSR placed below each bled steam tube
nest. The vent element is formed of one layer of mild steel finned tubes through
which vent steam from bled steam tube header is circulated.
Three relief valves are provided on one of the hot reheat lines i.e., one of the
MSR’s outlet lines with a set pressure of 6 kg/cm² g for protecting the MSR’s from
high pressure. The relief valves are designed for 10% capacity only. Two bursting
diaphragms on each MSR shell is also provided as extra protection device. The
bursting pressure of these discs is 7.05 kg/cm² ± 2% max. The bursting
diaphragm is designed for 90% capacity. The MSR shell design pressure is 9.36
kg/cm².
The internal layout of equipment within the reheater shell is listed below in order.
1. Steam distribution plates.
2. Moisture separator mesh.
3. Vent element heater tubes.
4. Bleed steam heater tube nest.
5. Live steam heater tube nest.
(1). Shell: -
Support foot shell is provided by 4 pairs of fabricated support feed welded to the
shell. The unit is anchored in position by one fixed support foot. The remaining
support feed is of the sliding type to allow for the expansion and contraction of
the hell.

(2). Distribution plates: -

Distribution plates are fitted below the separator pad and above the cold reheat
steam inlet connections to ensure an even steam distribution through both
separator pads and reheater.

(3). Separator pads: -

The separator pad is made up from a number of woven stainless steel pads six
inches deep and supported on a stainless steel grid. They are placed
horizontally.

(4). Vent element heaters: -

Vent element heater is fitted above the separator pad and comprises a single row
of tubes. Steam and non-condensable gases are supplied to the vent element
from the bleed steam heater header. After passing through the vent element, the
steam and gases are finally vent to the deaerator. The use of a vent element
heater provides the following advantages:
(a). A through put of steam in the bleed steam heater is assured with purging of
non-condensable and assists condensate drainage.
(b). Steam leaving the separator pad may still be in slightly in wet condition and
to reduce the possibility of corrosion and erosion on tubes contained within the
bleed steam heater tube nests, vent element is fitted beneath the main tube
nests. The vent element tubes are access and can be replaced in a simple
operation in the event of its failure due to corrosion/erosion.

(5). Bleed steam reheaters: -

Four steam heaters operating from bleed steam supplied from the HP turbine are
fitted to each reheater shell. Necessary shrouding are provided to prevent the
short circuiting of vent elements by the LP steam.
(6). Live steam reheaters: -
Two steam reheaters operating from live steam supplied from the main steam
line are fitted on each reheater shell.

FEED WATER SYSTEM

Feed water system consists of the deaerator feed water line from the deaerator
to feed water pumps, H.P. drain cooler, H.P. heaters 5 & 6, the boiler feed control
station and inter connecting valves and piping between these equipments. This
system ensures the continuous supply of deaerated water to the steam
generator.
The condensate which is extracted from the hot well is passed through number of
heaters and is finally stored in the deaerator. Deaerator is kept pressurized at 2
kg/cm² by bleed steam taken from L.P. turbine. Steam also heats the feed water
up to 120ºC. When bleed steam is not available pegging steam fulfill the
purpose.

There are three 50% main Boiler feed pumps (BFP’s). Two pumps are required to
run normally. They take suction from deaerator and discharges through HPDC,
HPH-5 & HPH-6 to steam generator. Steam generator level is controlled by a set
of feed water control valves to SG. Feed water enters SG at 171ºC being heated
by bleed steam in HP heaters. Two auxiliaries BFP act as stand by when main
BFP’s are not running. The water fro-auxiliary BFP’s bypasses the heaters. One
emergency feed water line connects auxiliary BFP discharge to SG in case of
any break in main header.
Hydrazine and Morpholine is injected in BFP suction & CEP discharge to remove
oxygen and control pH respectively.
Main Components of feed water system are:

(1). Deaerator:-
The primary function of deaerator is to remove oxygen and other non-
condensable gases in the feed water and also to heat up the feed water with
extraction steam to increase the turbine cycle efficiency. The deaerator consists
of a cylindrical horizontal storage tank upon which is mounted the deaerator
heater and a vent condenser. The deaerator chamber contains a foue tier trays
nest consisting of four perforated stainless steel trays in each tier bolted to frame
work which in turn is attached to the chamber. Immediately about the tray nest is
stainless steel distribution plate which cascades the water evenly in aero plated
from the top to down words. Arim is provided around each tray to ensure that no
spillage occurs and that all water is passed through the holes and broken into
droplets A tray assembly has been provided in the storage tank in the passage
of falling condensate, which further reduces the concentration of non-
condensable gases. The steam and gases thus liberated are vented through two
connections in the steam space of vent condenser. The steam and non-
condensable gases are cooled & condensed by the main condensate water
flowing in the tube side of the vent condenser.
The above drain condensate is drain to deaerator storage tank. The oxygen and
non-condensable gases are let out to the atmosphere through the vent
condenser. The deaerator will reduce the oxygen contain in feed water to 0.005
cm³/lit. The pressure and temperature of the water in the tank corresponds to that
of the extraction steam supply. Four-pressure relief valves provided on the
storage tank to protect the vessel from over pressure.

(2). HP heaters 5 & 6:-

These heaters are of condensing and integral drain cooling type mounted
vertically. These are shell withdrawal type hence all connections on shell are
flanges and whereas the connections on the water sided are welded type. The
tubes are ‘U’ shaped and made of 90/10 cupro nickel. The ends of the tubes are
expanded into forged steel tube plate. A fabricated steel shell encloses the tube
bundle and is fitted with lighting trunion and provided with a steel inlet, vent drain
connection and relief device and stand pipe connections.

(3). H.P. Drain Cooler:-

The function of H.P drain cooler is to take heat out of drains from H.P. heater
before being led to the deaerator storage tank. This is mounted horizontally on
these supports, two caster wheels, support on shell and one fixed support on
water box. This is shell with drawel type hence all connection on water box are
welded type.
The drain cooler has a nest of 90/10 cupro nickel ‘U’ tubes. The ends of the tubes
are expanded into forged steel tube plate. The tube bundle is enclosed in a
fabricated steel shell. The shell is provided with drain inlet and outlet, vent and
relief device mounting connections. Feed water flows through the inside of tubes
and drain on out side.

(4). Boiler Feed Pump:-

The boiler feed pumps take their suction from the deaerator storage tank and
discharge the feed water through the high-pressure feed water heaters into the
boiler. There are 3 No.’s BFP’s and three stage horizontal centrifugal are
provided to meet the requirement. These pumps are 50% capacity pumps.
Suction and discharge valves are provided to transfer the feed water. Hydrazine
and morpholine are injected in the BFP’s two-remove oxygen and control pH.

Pump specifications:-
Capacity = 675 T/hr (724.2 m³/hr)

Head = 548 meters.

Speed = 2975 rpm

Efficiency = 77.5%

Condensate is heated from 49ºc in hot well up to 171ºC on SG inlet by a train of

heaters. The water is in tube side and bleed steam is in shell side of feed
heaters. Bleed steam is extracted from various stages in HP turbine and LP
turbine.
Advantages of bleeding steam: -
1. To improve the efficiency of the cycle:- by bleeding latent heat of steam is
utilized which otherwise would go to condensate cooling water system.
2. To remove moisture content inside turbine & thus erosion & damage to
turbine is prevented.
3. To avoid thermal shock to SG. SG is at 250ºC and condensate in hot well
is at 49ºC.
4. To reduce turbine size:- Bleed steam if not taken would increase volume &
turbine size is thus reduced by bleeding.

LINE DIAGRAM OF MAIN BOILER FEED WATER SYSTEM

MAIN CONDENSATE SYSTEM

The main condensate system ensures the continuous supply of feed water to the
deaerator . This condensate is pumped by two main CEPS’ to main Condenser,
Air ejector condenser, and gland steam condenser, LP. Drain cooler, Low
pressure feed heaters 1,2 & 3 and finally to the deaerator.
The exhaust steam from LP cylinder is condensed by cooling water flowing
through the tubes in the main condenser. The condensate is pumped by the
condenser extraction pumps to the deaerator through the inter after condenser,
gland steam condenser, L.P. drain cooler, L.P. feed heaters 1,2 & 3. The main
condensate that passes through the inter after condenser absorbs the heat from
the steam that is used in ejectors and the steam gets condensed. Gland steam
condenser condenses the steam that is used for sealing the turbine glands, as
the main condensate water passes through the tubes. Drain cooler receives the
steam drain that is condensed on shell side of L.P. heaters and is drained to the
condenser by pressure difference. In the drain cooler the heater’s drain give the
sensible heat to the main condensate. L.P. heater # 1 gets the extraction from
L.P. turbine before stage 5. Heater #2 & 3 get the extraction from the L.P. turbine
before stages 4 & 3 respectively. Water sealing provided at the valves packing of
some of the valves in the condensate system directly connected to the
condenser to avoid ingress of atmospheric air.

The deaerator heater is a spray and tray unit with external vent condenser,
guaranteed to reduce the oxygen to less then 0.005 cm³/lt. The operating
pressure of deaerator storage tank is 3.02 kg/cm² at the full turbine load. The
corresponding temperature of water in the deaerator storage tank is 133.81ºC.
However this pressure is reduced with the reduction in turbine load condition and
a separate steam supply is provided from main steam line. This pegging steam is
designed to maintain deaerator pressure at 1.75 kg/cm² so that minimum
temperature of feed water to the steam generators can be 115.5ºC. The
deaerator is designed for 3.5 kg/cm²g pressure and 195ºC temperature.

The deaerated condensate is stored in the deaertor storage tank, which has a
capacity of 240cm³ at normal operating level. The capacity of storage tank at
very low level i.e.; centerline of tank is 140cm³. Reactor trip is initiated at very low
level in deaerator storage tank and after some time delay main Boiler feed pump
(BFP) is tripped and auxiliary Boiler feed pump(ABFP) starts to feed water to the
steam generator for decay heat removal . The inventory in the deaerator storage
tank is expected to be 102cm³ at the worst condition of reactor trip at deaerator
storage tank very low level and simultaneously unavailability of both ACEP’s. The
inventory is sufficient for normal cool down of PHT with ABFP running.

Along with two 100% CEP’s, two auxiliary condensate extraction pumps (ACEP)
each rated for 27 m³/hr have been provided. Only one pump is required to
operate at a time, however redundant pump has been provided as a stand by
considering single component failure. These pumps have been selected as
27m³/hr taking into consideration the requirement of decay heat removal from
reactor. The head of the pump selected is 125 MLC same as that of MCEP to
allow on line testing of ACEP’s.

The ACEP’s take suction from condenser hot well and discharge into the main
condensate header. The ACEP supply water to deaerator to maintain its level in
the event of a reactor trip and class IV power failure. ACEP is also used for filling
up condensate system and steam generators through deaerator storage tank and
auxiliary boiler feed pump during start up.

CONDENSER

The condenser is a single pass surface type with four inlet water boxes and all
the water boxes are provided with vent and drain connection. Manholes are
provided for maintenance and tube plugging facility. The cooling water inlet and
outlet are connected to the water boxes through expansion joints for arresting
vibrations and allowing thermal expansion without generating undue stresses.
The condenser is mounted rigidly on the foundation to take care of the differential
of the thermal movement between the turbine exhaust and the condenser shell.
Expansion joint is provided at the common exhaust of the double flow L.P.
turbine. A transition piece connects the turbine exhaust to the condenser shell
holding the tube bundle known as the condenser neck. Adequate space is
provided in the condenser neck for all the low-pressure extraction lines to pass
through it. Nozzles for makeup, re-circulation and deminerailised water are
provided at the neck section of the condenser, so that incoming water is de-
aerated with its airs at right angles to the turbine airs. The tubes are provided
with a gentle slope towards the outlet water boxes for draining facility. The
condenser is provided with a hot well having storage capacity of 40 tones with
normal level, these correspond to two minutes full power flow. For handling the
dump steam in the condenser, suitable distribution header is provided inside the
condenser. Four-dump steam inlet connection is provided in the steam space just
above the hot well level. Prior the entry, steam pressure is reduced, de-
superheated and partially by spraying condensate water. The cooling water-cools
the non-condensable gases along with the steam. The lower portion of the tube
bundle is separated to permit the cooling of the air vapour mixture. Adequate
spaces have been provided for the re-circulation of the gases. This section of the
condenser is connected to the suction of the ejector.

The various level figures for alarm and control in the hot well are follows:

(1). Normal operating hot well level 275mm above bottom of the hot well.
(2). Low level set at 175mm above the bottom of the hot well provided a storage
capacity of 25.4 tones in condenser hot well this ensures NPSH margin for
condensate extraction pumps.
(3). High-level alarm set at 350mm above the bottom of the well. This setting
provides minimum steam space required between bottoms of dump steam
header and hot well. Under no circumstances the level should be allowed to
reach the opening in the dump steamer header to prevent water ingress into the
dump steam line.
Condenser Data

Condenser Pressure = 0.1185 Kg/cm² abs.

Inlet Cooling Water Temperature = 32ºC

Temperature of Condensate at hot well outlet = 49ºC.

Steam flow to the condenser = 65527 Kg/hr.

Drain flow from feed water heater = 117356 Kg/hr.

Drain flow from air ejector condenser = 450 kg/hr.

Cooling water flow = 38942 m³/hr.

Total heating cond. = 450.67×10 6 kcal/m.
Water velocity = 1.6 m/sec.
Number of tubes = 16420
Effective tube length = 13.41 mts.
Number of water boxes =8
Design pressure = 3.5 kg/cm².

Condensate Extraction Pumps

Two 100% capacity condensate extraction pumps and two 2.5% auxiliary
condensate extraction pumps are provided to pump the condensate from the hot-
-well to the deaerator. During normal operation one of 100% CEP’s will be in
operation and other will be as standby for auto cut in if the discharge header
pressure drops below 11 kg/cm² or when the running CEP trips due to some
reason. Also standby pump will start during deaerator low level.

The auxiliary 2.5% CEP’s are used during shutdown and for filling the system
with condensate after the system is drained for maintenance the auxiliary
condensate extraction pumps will be normally kept in auto and starts
automatically when both the pumps trips.
 FUNCTION OF THE MAIN CONDENSATE EXTRACTION PUMPS
AND AUXILLIARY CONDENSATE EXTRACTION PUMPS

(1). MAIN CONDENSATE EXTRACTION PUMPS

It is a vertical multistage centrifugal barrel pump of sectional type. Power is

supplied to the pump through a flexible coupling. Barrel, which is lowered on the
pit and bolted on the foundation base frame. The distributor casing is mounted on
barrel flange with o-ring required for sealing. The suction and delivery
connections are located on distributor casing above which bearing stool is fixed.
The pumps are capable of delivering 1111 m³/hr at a delivery head of 125-mts.of
water columns.

The arrangement for lubrication of the pumps is self-contained. The glacier thrust
bearing and radial bearing are filled in the oil bath of the bearing, cooled by
cooling coils which are installed in the bearing housing. The oil level gauge is
mounted on the outer bearing housing from which the oil level inside the bearing
housing can be read.

The bearings are cooled by non-active low-pressure water. Normal cooling water
flow for each bearing is 8.5 lit/min. The CEP motors are rated 6.6 KV for direct on
line start and supplied with class IV power supply. 600 watt, 240 volts space
heaters are provided in each motor for eliminating the moisture from the air
during shutdown.

(2). AUXILLIARY CONDENSATE EXTRACTION PUMPS

There are two pumps 2.5% duty. The pumps are vertical multistage, centrifugal
barrel type and are provided with deep groove ball type thrust bearing for which
are cooling water is required. The drive of the pumps is affected by a electric
motor through a flexible coupling. On the bottom section of the distributor casing
suction and delivery nozzles are located.
The condensate pressure is developed by transformation of velocity into
pressure through the diffuser. The normal required suction head is 0.314 kg/cm²
for a discharge of 27 m³/hr, with the total head of 125 mts. Of the water column.
The speed of the pump is 2890r.p.m. . The motor is 18.5 KW, 415-volt class III
power supply.

AIR EJECTOR CONDENSER

The removal of air from main condenser is accomplished by steam air ejector
with inter and after condenser. For both the service air ejector a common inter
after condenser has been used, the drain from the inter after condenser shell
side, which is condensate of steam, used for air removal is connected it to main
condensate through a 4mm high loop seal.

GLAND STEAM CONDENSER

Gland steam condenser is located in the main condensate circuit next to the air
ejector condenser and mounted horizontally. The main condensate outlet from
the air ejector condenser passes through the gland steam condenser where it
absorbs heat from the steam drawn from the turbine gland seals. The gland
steam condenser is provided with two vapour extractors (fans) to extract mixture
of steam and air in leakage through the turbine shaft from the maintaining a
negative pressure in the steam space of the gland steam condenser. As the
steam comes into contact with the tubes it gets condensed and the air and non-
condensable gases are driven out to the atmosphere by the fans of the gland
steam condenser.

As the gland steam condenser is not designed for the full capacity of the
condensate flow, a part of the condensate flow is directed through the bypass of
the gland steam condenser. 410 T/hr of CEP is passed through GSC and the
remaining 700 T/hr is passed through the bypass of GSC.

L.P. DRAIN COOLER

This is a shell and tube heat exchanger using the main condensate as cooling
water .The main condensate passes through the tube side and the drain from the
L.P. heater 1 pass on the shell side, gives away the heat to the main condensate
before being drained to the condenser hot well.
L.P. HEATER 1

This is a plain condensing type heater having no drain cooling section and
located at 100m elevations in the turbine building. Steam enters through two
connection provided in the middle of the shell. Impingement baffles are fitted in
the path of the incoming steam. The heater has a nest of admiralty brass u
shaped tubes; the ends of the tube are expanded into steel tube plate to which
the water box is welded. A relief is there on the shell side, which is set to relief at
3.5kg/cm². The shell is provided with connections for steam inlet, vent, drain and
inlet from L.P. heater #2 with dispense fitting.

OPERATIONAL PARAMETERS

Condensate extraction flow = 97912 kg/hr.

Condensate inlet temp. = 46.6 ºC.

Condensate outlet temp. = 72.44 ºc.

Extraction steam flow from condenser = 47992 kg/hr.

Drain inlet flow = 69364 kg/hr.

Drain outlet floe from L.P. heater #1 = 117356 kg/hr.

Extraction steam temp. From turbine = 74.72ºC.

Extraction steam condensate outlet = 74.7 ºC.

L.P. HEATER # 2& 3

The L.P. heater # 2&3 are of condensing and integral drain cooling type mounted
horizontally. The main condensate flow through the tubes of these heaters in four
passes commencing at the main condensate inlet it first flow through the drain
cooling section and around the outer tubes into the return through the center
tubes to the feed water outlet. The four passes are shaped as quadrants.

Steam enters the heater in the middle of shell and it is directed across the tubes
by a series of the baffles in a tortuous path. An impingement baffle is fitted
adjacent to the steam inlet for the same purpose as mentioned in L.P. heater # 1.
The steam condensed on the tubes flow into the bottom of drain cooling section,
where it is carried over through cutouts in the baffles. The design is same as for
L.P. heater no. # 1.

The drain from No.-3 heater is sprayed through a dispenser into No.- 2 heater
and drain from No.-2 heater is sprayed into No.-1 heater.

OPERATING DATA: - L.P. HEATER #2 L.P. HEATER #3

Main condensate flow = 97912 kg/hr 97912 KG/HR

Main condensate inlet temp. = 72.44ºC 93.00ºC
Condensate outlet temp. = 93 ºc 111.05 ºC
Extraction steam flow from = 32061 kg/hr 34071 kg/hr
turbine.
Drain inlet flow = 34071 kg/hr -----
Drain outlet flow = 69364 kg/hr 34071 kg/hr
Extraction steam temp. from = 122 ºC 114.16ºC
turbine
Extraction steam condensate = 78.05ºC 98.63ºC

CHLORINATION SYSTEM

In Narora Atomic Power Station, Chlorine is required for controlling the growth of
bio-life in the following systems.

 NDCT- I
 IDCT- I
 NDCT- II
 IDCT- II

This plant has two circulating water chlorination units and one domestic water
chlorination unit. The capacity of each circulating water circulation unit is 150
kg/hr and domestic water circulation unit is 200 gms/hr.
CIRCULATING WATER CHLORINATION UNIT

These units comprise of:

1. Evaporator:
Where the liquid chlorine gets into gaseous state. It consists of a steel
cylinder in a hot water bath. There are three heaters of 6 KW capacity in each
evaporator. There is an arrangement of cathodic protection in each
evaporator to prevent rusting below water level.
2. Chlorine Gas Filter:
The filter also acts as a condensate liquid trap. This filter has two chambers.
The lower portion as a liquid impurities and upper portion has a removable
filter assembly which is especially impregnated, so that the FERIC
CHLORIDE “Plates out” rapidly.
3. Automatic Shut Off Valve:
This valve is air operated ball which is normally closed and opens when hot
water bath temperature reaches above 65 o c and injector inlet water pressure
is more then 2.5 kg/cm2.
4. Chlorine Gas Pressure Reducing Plant :
For safe operation of chlorination plant the pressure of chlorine gas coming
from vaporizers is reduced from 8kg/cm2 to 1.0 kg/cm2.
5. Chlorinator and Injector:
Chlorinator is a chlorine gas measuring device. Chlorine gas enters through a
vacuum regulator which opens only under normal operating vacuum. This
valve also regulates the vacuum ahead of the control valve and shuts off the
gas if an interruption of the injector water supply should destroy vacuum.
During this period some chlorine gas may be trapped in chlorinator system.
This entrapped gas will be released through a pressure relief valve. The pre-
setting of this valve is one foot of water column only. During normal operation
of the plant this pressure relief valve will be in closed condition due to
vacuum. Feed rate is set manually by adjusting flow control valve. Then
chlorine gas flows to differential pressure regulator. The accuracy of any
chlorine metering system depends on the consistency and repeatability of the
density and velocity of gas at any given rate setting which will in turn depend
upon the differential pressure regulator. The other important function of this
valve is to reduce the highly turbulent action from injector suction side,
through a check valve and an isolating valve. At the injector, chlorine gas
mixes with water and chlorine solution thus formed is fed to point of injection.
The vacuum relief valve and emergency drain relief valve keeps the system in
safe condition.
6. Chlorination Pump:
There are two chlorination pumps, one for each unit. In order to create
vacuum, injector requires high water pressure of 4 t0 6 kg/cm 2 and sufficient
quantity of water flow ranging from 60 to 100 m 3/hr. For this purpose two
pumps are installed.
 7. Ton-Container :
The chlorine ton container has two valves for chlorine withdrawal. The bottom
valve is connected to this system for withdrawal of chlorine in liquid form,
which meets the requirement of circulating water system. The top valve
should be connected for gas withdrawal. It may be kept connected but should
be used only when the requirement of chlorine is small for a short duration.

COOLING WATER PUMP HOUSE (CWPH)

Circulating water system is mainly for removing the latent heat from the turbine
exhaust and maintains the desired exhaust pressure in the condenser.

Some portion of circulating water is supplied to

 Turbine oil coolers
 Hydrogen coolers
 Boiler blow down coolers

CONDENSER COOLING WATER SYSTEM

The circulating water is supplied by three vertical mixed flow type ‘Kirlosker’
pumps driven by 960 kW. 66kv ‘BHEL’ motors at 493 rpm. Each pump is capable
of supplying 15,850 m3/hr at total head of 8.9 meters.
Condenser cooling water system is a closed loop, consists of one natural draft
cooling tower for each unit, from where cold water flows by gravity through tunnel
to the pumps house. Each cooling water pump taking suction from the sump of
pump house discharges water through motorized butterfly valve in to a common
header, which split into two headers up to turbine building and then each headers
split into further two headers and thus four headers feed cold water boxes of the
condenser each header having a motorized butterfly valve.
Four headers from the outlet water boxes are coming out warm condenser
discharge water and each header having a motorized butterfly valve. Again these
four headers from two headers by joining two headers in one header. The two
headers carrying condenser warm water is sprayed in the natural draft tower
basin. The circulating water system require some amount of blow down in order
to maintain the concentration of dissolved solids and alkalinity of the water with in
limit. The blow down required is 800m 3/hr which is down from the discharge
headers of condenser. Evaporation and drift loss from natural draft tower is
875m3/hr at full load. So make up is done for these losses at the tunnel between
NDCT and pump house sump from Raw Water Pump House.
NON-ACTIVE PROCESS WATER SYSTEM

Non- active process water system is divided into two categories.

1. Non-active high pressure process water system (7134)

2. Non-active low pressure process water system (7132)

This division is done due to the following reasons:-

1. Requirement of high pressure in reactor building.

2. Requirement of equipments water class III power and under OBE (Safe
shutdown earthquake) condition.
3. Requirement of equipment under class – IV power and under OBE
(Operation basis earthquake) condition.
4. The HP system is safely oriented, therefore utilized pumping system with
rephrase standby pumps for each unit has been adopted. In case of LP
system common pumps for both the units are acceptable.

NON-ACTIVE HIGH PRESSURE PROCESS WATER SYSTEM

Purpose: This system supplies cooling water to:

1. DG set coolers.
2. Air compressors.
3. Aux BFP.
4. Aux CEP.
5. F/M vault cooler.
6. PHT pump room cooler.

SYSTEM DESCRIPTION

These pumps are locked in CW pump house and located in IDCT loop.

HP piping consists of supply to reactor building from pump house and connecting
the return from RB and the return header for active process water cooling
system.

A part of the supply goes to turbine building to meet the requirement of DG, air
compressor and Aux BFP.

Underground pipes in the HP system is laid in trenches, instead of being directly

buried in order to protect them better during earthquake.

Discharge header size is 500 mm. A small portion of the supply piping is
increased to 600 mm in order to restrict the pump head. The size of the common
return header is 1200 mm considering the total HP process water flow and active
process water cooling pump flow. Return header goes up to IDCT.
The static head IDCT w.r.t. the basin water level is 12MWC. Pressure at the
outlet of RB is about 12.7 MWC at 98M.

Motor for NAHP water pumps are 145 KW rating, 415V, 50 cycle/sec power
supply. These are led from class III buses. head required is 37.5 MWC.

NON-ACTIVE LOW PRESSURE PROCESS WATER SYSTEM (NALPPW)

Purpose:

This system supplies cooling water to:-

1. Main BFP
2. Main CEP
3. Live steam re-heater drain pumps.
4. Moisture separator drain pumps.
5. Main transformer oil pump.
6. Status water cooler.
7. Seal oil coolers.
8. Chiller.
9. Analysis panel.

SYSTEM DESCRIPTION

Locked in CW pump house and take water from pump which is for CCW pumps.
These are located in NDCT loop. Low pressure system starts from pump
discharge forming a common header for both the units. Common header size is
800 mm. The header size for chiller units is 600 mm. Return header of 700 mm is
bifurcated for each unit in two branches of 500 mm for connection with 2 Nos. of
2000 CW system header of each unit.

Pipelines from the header are provided for feeding various auxiliaries.

Total head of pump = 28.5 MWC.

Total requirement of lp process water for 2 units is about 3010m 3/hr.

Motor for NALP water pumps are 150 HP, 415V, 50 cycle/sec power supply. They
are fed from class IV buses.

ACTIVE PROCESS WATER SYSTEM

Purpose

This system is meant for the extraction of heat load fro various reactor auxillaries
located in reactor building and service building which handle radioactive process
fluids. For removal of heat, DM water is circulated in closed loop.
Design Basis

APW system is used to cool various coolers in RB and service building i.e.
moderator heat exchanger, calanderia, end shield coolers, spend fuel bay cooler
etc.

System utilities DM water as a cooling agent in a closed loop which imparts the
heat picked up from these cooler to APW cooling water system through plate
type Hx. The final disposal of heat is in IDCT.

Main role for this system is:

To remove heat from various components and heat exchangers and reject the
heat into plate type heat exchangers and to act as a secondary barriers to the
potential release of radioactivity to the environment from there system handling
reactor coolant for other active fluids which are cooled by process water system.

LP ACTIVE PROCESS WATER SYSTEM

Total flow requirement per unit during normal operation is 6591 m 3/hr and during
class-III operation 608 m3/hr against heat load of 58.872 MW thermal and 1.65
MW thermal. There are 2 horizantal centrifugal pumps with 6875 m 3/hr flow and
31.5 MWE are provided.

Two numbers emergency LPPW pumps are provided with capacity of 615 m 3/hr
and TDH 49 MWC are provided.

HP ACTIVE PROCESS WATER SYSTEM

Total flow requirement per unit during normal operation is 680 m 3/hr and class-III
operation is 1692 m3/hr against head load of 7.5 MW and 12.453 MW
respectively.

Five horizontal centrifugal pumps with capacity of 440 m 3/hr each and TDH 49
MWC are provided.

Return header of active LP and active HP process water system is joined

together and led to the plate type heat exchanger where it is cooled by active
process water cooling water.
ACTIVE PROCESS WATER COOLING SYSTEM

Purpose

APW cooling system is for cooling of active process water which gets heat from
various equipments in reactor building and service building. Active process water
is cooled by this system in plate type HX. Cooling water is finally dispose its heat
in IDCT.

This system is provided to supply cooling water to NAHP process water system
which cools DG compressors, DG coolers, Aux-BFPs and RB vault coolers.

Design Basis

The total heat load:

Normal Emergency
(K cal / hr) (K cal / hr)

APW cooling system 57.1 X 106 12.2 X 106

NAPH .5 x 106 4.9 x 106

IDCT 59.6 x 106 17.1 x 106

ACTIVE PROCESS WATER COOLING PUMPS

There are two pumps of centrifugal vertical pull out type each for both the units.
One other pump is kept as stand by. Capacity to the pump is 7225m 3/hr with 20.1
MWC head mother for this pump is 535 KW, 50 Hz, class-IV, 750 rpm.

These have thrust pad arrangement attached to column opp. to discharge flange
connection. Thrust pad is provided to take pressure due to provision of
expansion joint at the pump discharge.

EMERGENCY ACTIVE PROCES’S WATER COOLING PUPMS

There are two pumps:

Vertical non-pull out type

Capacity 1575 m3/hr
Head 15.4 MWC
415 V, 50 Hz, Class III rpm

At non availability of class-IV power supply. Total quantity of CW required through

plate type hx is 1530 m3/hr.
One pump with another as stand by is running under class – III operation.

INDUCED DRAFT COOLING TOWER(IDCT)

This is selected due to moderate heat duty. This is generated for safe shutdown
earthquake condition as this system will be used to remove reactor decay heat
after a shutdown.

Available pumps for IDCT are heat load, PW side flow and desired CW tank
temperature for PW after coming out from plate type HX.

HEAT EXCHANGERS

For removal of heat at APW, plate type Hx are selected instead of tube and shell
type Hx because of following reasons:

1.They are compact as heat transfer co-efficient is very high.

2. These are flexible in design since Hx surface and heat transfer capacity can
be increased or decreased as required by adding or removing plates.
3. Because of high degree of turbulence existing in a plate Hx, the fouling
tendency is much less.
4. Leakage in gaskets can be easily detected since the gaskets are open to
atmosphere mixing of hot and cold fluids due to leaking gaskets is thus avoided.
5. Plate type Hx are economical as compared to shell and tube type Hx.

CHILLERS

Chillers are used to cool the water. Chilled water system provides a continuous
supply of low temperature water (6.1ºC) at a predetermined rate as required for
Air-Conditioning, ventilation system as well as cooling process in various other
equipments of system.

Chilled water is required in following areas of NAPS: -

(1). For Air-Conditioning load and other process cooling in reactor building.
(2). For Air-Conditioning and associated area in service building.
(3). For Air-Conditioning and associated area in turbine building.
(4). Chilled water is required in D2O upgrading plant.

For NAPS I & II combined operation two units of 550 TR will be required to
function with two No’s chilled water pumps.
The chilled water system consists of three No’s centrifugal water chilling units
with one stand by, each chiller has net refrigeration capacity of 550 TR and
volume capacity of 600m³/hr and total pressure of 55Mwe.
For condenser cooling, non-active low-pressure process water at a temperature
of 34ºC is used.
To maintain positive pressure in suction line of chiller circulating pump
(centrifugal pump) one make up water tank is used and located on roof of
deaerating area. This tank is also used for initial filling system.

CYCLE USED IN REFRIGERATION SYSTEM

The cycle used in chiller is Vapour Compression refrigeration cycle. The main
components of chiller system are:

(1). Compressor: -
Compressor used in chilled water system is Open type single centrifugal
compressor. The impeller and capacity control device are located in spiral casing
and speed increasing gears (ratio 1:91) and lubricating system contained in gear
box.

(2). Condenser:-
Upper part of unit cooler is condenser. Non-active low-pressure water flow
through tubes of condenser to which heat of compression is rejected.

(3). Expander or Throttle valve: -

In the throttle valve, the refrigerant converts into partially vapour form at the
evaporator temperature.

(4). Evaporator: -
The unit cooler is of horizontal shell and tube type. It is divided into two by
partitioning plate. The bottom section is the evaporator. Chilled water flows
through coil of evaporator, shell side of which refrigerant flows.

Principle of cooling water in chiller: -

Refrigerant used in this system is Freon-11 (R-11) i.e. CCl 2F2
(Dichlorodifluoromethane). Refrigerant boils at low pressure to pick up heat and it
dissipates the picked up heat during condensation at higher pressure.
Above principle is accomplished by having a compressor, condenser, expansion
or throttling valve and an evaporator. At NAPS chiller has a centrifugal
compressor, which sucks vaporized Freon from evaporator and discharges to
condenser. So it maintains vacuum in evaporator and pressure in condenser. In
condenser vapour Freon changes to liquid Freon to liquid Freon by giving its heat
to NALP PW.
One float valve maintains level in condenser and passes extra liquid Freon to
evaporator. In evaporator Freon boils at low pressure (vaccum0 and pick up
latent heat from the water circulated through evaporator. This water becomes
cool. Heat picked up by Freon in evaporator is easily dissipated in condenser to
NALP after it has been pressurized.

REFRIGERATION SYSTEM:-

The working fluid or refrigerant used in this cycle is freon or R-11.Refrigerants

are those substance which are used for cooling. Following are the criteria for the
selection of the refrigerants:

(1).The pressure at which the refrigerant enters the compressor should be

Slightly greater than the atmospheric pressure.
(2).The boiling point of the refrigerant should be lower than the temperature at
which the evaporator is to be maintained.
(3) Refrigerant critical pressure should be high.
(4) Refrigerant should be non-toxic and non-flammable.
(5) Refrigerant should be stable.
(6) It should not be too expensive.

COMPRESSED AIR SYSTEM

The compressed air system provides L.P. and H.P. instrument service air and the
mask air for both units of the station.

The dry and wet air is supplied to the following areas: -

(a). Reactor building-1 & 2.
(b). Service building
(c). Turbine building.
(d). PHCW and plant make up water supply valves.

Six No’s air compressors each having separate air receiver are located. The
compressors are horizontal opposed balanced type double acting having two
stages. Capacity of each compressor is 3Φ induction motor drives 14.85
Nm³/min. Compressor.
There are three No’s air drying plant of capacity 20 Nm³/min. each have been
provided with two No’s adsorbing towers, filled with silica gel, electric heater with
blower for regeneration of silica gel towers, two No’s prefilter and two No’s after
filter. The instrument air should be oil free and having dew point of –40ºC.

Compressed air requirement:- ( Dry & Wet)

UNIT-1 UNIT-2 TOTAL

CL.-IV POWER 33.79 23.61 57.40 Nm³/min

CL.-III POWER 10.20 3.40 13.60 Nm³/min

In order to meet the requirement six compressors (three for each unit) are
provided out of six only four compressors are operating and two are
standby. Class III power supply and rest two are supplied by class IV
supplies two comps for each unit.

MAIN COMPONENTS OF COMPRESSOR: -

(1). SUCTION FILTER: -
Suction valves are provide in the inlet of the suction filter which sucks the air from
the atmosphere and sent it to suction filter, which filters the dust particles in the
air and passes it to LP cylinder.

(2). LP STAGE:-

From suction filter the air enters into the LP cylinder, where the compression of
the air takes place and it is up to 2.8 Kg/cm².

(3). INTER COOLER:-

Now the low-pressure compressed air passes through the delivery valve to the
water-cooled inter cooler. There air is cooled very near to atmospheric
temperature.

(4). HP STAGE:-

Now air is sucked by the 2 nd stage i.e. HP stage through the suction valves and is
compressed to 8.5 Kg/cm².

(5). AFTER COOLER:-

After Hp cylinder, air is again cooled in after cooler and finally passes to air
receiver through a non-return valve. High-pressure water is used for cooling.

(6). RECEIVER:-
With the help of discharge valve, which gets opened because of pressure
gradient, the compressed air is discharged to receiver. The capacity of air
receiver is 4.5m³. Air receiver is provided to dampen the pulsation from the
discharge line and also serve as a reservoir to take care of sudden unusually
heavy demand or in emergency.

The air receiver capacity is being selected in such a manner that it will be able to
supply air for not less then 5minutes at a rate of 13.75 Nm³/min.and pressure
does not drop below 5.0 Kg/cm². Local air receivers have also been provided
near the point of sudden high consumption. They are as follows: -

(a). Air receiver near DM plant, capacity is 0.38m³.

(b). Air receiver, one for each unit near steam discharge valve, capacity is 2.5m³.
(c). Air receiver, 3 for each unit, capacity is 3.7m³.

Automatic moisture drain traps are provided for draining the moisture from inter
cooler, after cooler and receiver.

Lubricating oil is supplied by gear pump, which is driven directly by crankshaft.

The lubricating oil pumps feeds lubricating oil to the main bearings, connecting
rod bearing.

(7). AIR DRYER: -

Air-drying plant is provided to supply dry air (Dew point= –40ºC). This is achieved
by passing air through Pre-filters, Carbon filters, Absorbers, Heaters.

(a). Pre-filters: -
Pre-filters consist of shell ‘D’ made of heavy steel designed as per for 70Kg/cm².
As air passes through the filter element i.e.; Ceramic, the water droplets, dust, oil
droplets are removed.

(b). Carbon filters: -

Air free from water particles, dust and scale forming particles enters the carbon
filter from the top. Carbon filters consists of mild steel cylindrical vessel, which is
duly filled with the required quantity of special grade activated carbon suitable for
adsorption of oil vapours from compressed air stream. From the outlet of the
carbon filter the compressed air passes through the absorber.

(c). Absorbers: -
When rotating the wheel provided opens the non-return valve, compressed air
enters from top to the absorber. The adsorbed is filled with required amount of
solid desiccant and filled with one thermometer for temperature indication. Two
filters are provided, one at the inlet and at the outlet to avoid outflow of particles.

(d). Heaters: -
Heater is provided to heat the air from the absorber and thus the pressure of the
air increases. Pressure reducer should be adjusted in such a way that it will
release pressure. Heater is set at 230ºC.