B257.OL3 - 004 - HT - Primary - Secondary Circuit - Rev01

Heat Transfer between
Primary and Secondary

Circuit
OL3 EPRTM Advanced Course
TD: B257.OL3.004
Date: 10/2011
Confidential as defined in the Olkiluoto 3 Plant Contract. The reproduction, transmission or use of this document or its
contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including
rights created by patent grant or registration of a utility model or design, are reserved by AREVA.
Learning Objectives
Explain the heat transfer mechanisms and their application in

a Nuclear Power Plant with PWR
Describe design and special features of EPRTM Steam Generator
Explain the function and the benefits of the Axial Economizer
Explain the normal operation of the Steam Generators
Describe the steam drying process and why it is of importance
Recall the main associated systems to the Steam Generators
and survey their functions
Exemplify the Steam Generator Tube Rupture scenarios
and how they are mitigated within the EPRTM concept
2 Training Center AREVA NP GmbH Proprietary - CONFIDENTIAL

EPRTM Advanced Course – Heat Transfer between Primary and Secondary Side 01/2010 © AREVA NP - All rights are reserved, see liability notice
Contents
Chapter 1: Introduction
Chapter 2: Heat Transfer in the PWR
Chapter 3: Power Interface Steam Generator
Chapter 4: Operation of the Steam Generators
Chapter 5: Main Associated Systems
Chapter 6: Steam Generator Tube Rupture

Chapter 1
Introduction
Overall Plant Functionality
Primary System Secondary System
4
1 2 3
3 2
3
2
Main
Main Steam
Steam-- related
related
Systems
Systems
1 Steam Generators 3 Main Feedwater System

2 Main Steam System 4 Steam Turbine
Exchange of
638.1 kg/s 293.0 °C
Thermal Power
Primary Secondary
System System
Core Thermal Power 644.5 kg/s

4500 MW 230.0 °C
∆T = 34.4 K ∆T = 63.0 K
Reactor Coolant Feedwater / Steam
Blowdow 6.40 kg/s
5533.75 kg/s 5533.75 kg/s All values for

329.8 °C 295.4 °C 100 % power FA3
Main Steam-Related Systems
Main Steam System
MSS
M
NI TI
PZR Safety Valves

SG
Relief Main Feedwater System MFWS

PZR Tank
Reactor Start-up and Shutdown

PRZ Connected
with Loop 3 Feedwater System SSS
Loop 1 Loop 2 SG Blowdown System

SGBS
Flash
Tank
Emergency Feedwater
Reactor Coolant System System EFWS
(Loop 3 and 4 not shown)
EFW
Tank

Chapter 2
Heat Transfer in the PWR

Kinetic Definition of Heat
Heat is the average statistical state of disordered motion
of a (large) quantity of microscopic particles*.
*Kinetic Theory of Gases
Heat is the total kinetic energy
of a substance‘s
Molecules or
Atoms
Molecules have various internal
vibrational and rotational
degrees of freedom due to the
complexity of their structure.
Thermally agitated molecule:

Thermal motion of a segment of
a protein alpha helix
Heat and Internal Energy
Q Heat is related to changes in
through the First Law of Thermodynamics:

UInternal
Energy
∆U = Q – W [J] W: Work
In thermodynamic terms Heat is defined (like work) as

Energy in Transit,
i.e. a spontaneous flow of energy without exchange of work
from a high temperature object
to a lower temperature object.

Heat Transfer Mechanisms
Heat transfer is the passage of thermal energy from
a hot body to a cold body until a thermal equilibrium is reached
as a result of the Second Law of Thermodynamics:
“ The entropy of an isolated system not in equilibrium will tend to
increase over time, approaching a maximum value at equilibrium*. ”
Rudolf Clausius* 1865

∆Q J dS Q: Heat
(German Physicist,
∆S =   ≥ 0 T: Temperature
originator of the
∆T K  dt
S: Entropy
concept of entropy) t: Time
1. Heat Conduction through contact surfaces

2. Heat Convection within flowing media
3. Heat Radiation electromagnetic waves
Heat transfer can never be stopped, it can only be slowed down.
Heat Conduction
Heat conduction is the spontaneous transfer of thermal energy
through matter, from a region of higher temperature to a region of
lower temperature transmitted by the rapidly moving particles of matter.
Thot ∆T Tcold Q Amount of heat transferred [J]
.
Q Heat flow rate [W]
Q
λH . dQ ∆T
Q Q = = - λH A
A Q dt ∆x
Q λH Heat conductivity [W/mK]
Q A Surface normal to heat flow [m2]
∆T Temperature difference [K]
x x Thickness of the body [m]
Kind of Matter Gases and Liquids Metals Insulators
Transmitting Particles Atoms or Molecules Free Electrons Phonons
Energy Transfer Elastic impact Diffusion Vibrations
Heat Transfer by Convection
Heat Convection is a combination of conduction and transfer of thermal energy
by fluid circulation or bulk movement of the hot material portions to cooler areas
in a fluid medium.
Convection = Heat Conduction + Mass Flow
The strongest convective flow

ever, takes place in the sun.
m
ρ =
V
Hot water in a heated pot rises,

cools, and falls down due to
density changes ∆ρ.
NASA image of sun from SOHO satellite 2007
Heat Exchangers
A Heat Exchanger is a device built for efficient heat transfer from one fluid
to another, whether the fluids are separated by a solid wall so that they
never mix, or the fluids are in direct contact.
Heat Exchanger Design: Determination Criteria of
Maximize surface area of wall Heat Transfer:
between the two fluids Tasks of heat exchangers
Minimize resistance to fluid flow Phase change or not
through the exchanger Heat Transfer Type
All three types of heat transfer Admixing fluids or surface HT
Radiation fraction is very small Design
in the range 0 ≤ T ≤ 300oC Flow arrangement
An example of forced convection are fluids

being pumped through a heat exchanger.
Heat Exchanger Types
Classified by Task
One- Phase Heat Exchangers
Heat transfer without changing state of aggregation
Pre-Heater: Heating a medium by cooling a hot medium
Cooler: Cool down a medium
Super-Heater: Adds heat to saturated steam for super-heating
Phase-Change Heat Exchangers
Heat transfer with change of state of aggregation
Pre-Heater: Transfer of heat by condensation of extraction steam
Boiler: Steam Generator
> heat a liquid to evaporate (or boil) it by setting free the latent heat
Condenser:
> cool a vapor and condense it to a liquid by extraction of latent heat
> maintain Condensate temperature at wet steam conditions
Classified by Heat Transfer
Mixing- Pre-Heater
Heat transfer by admixing two fluid flows
Medium providing heat is mixed with medium absorbing the heat
Most effective heat transfer convective process
In the Feedwater Storage Tank, the bled steam enters the tank
underneath the water surface
Surface Heat Exchanger

Heat transfer by conduction, both media separated by a wall if:
Higher temperature difference between heat deliverer and absorber
Pressure difference between heat deliverer and absorber
Different materials (oil cooler)
Different water quality (demineralized water to river water)
Activity barriers
> Primary Circuit to Secondary Circuit
> Primary side to intermediate (component) cooling cycles
Classified by Construction
Shell and Tube Heat Exchanger Plate Heat Exchanger
Computer simulation
of fluid flow Arrangement
in shell of many
plates
forming
channels of
hot and cold
Turbulences liquid
alternately
high low
Flow velocity u
Tube Bundle in Pressure Shell Set of thin Metal Plates transfers
guiding two high-pressure fluids heat between 2 low-pressure liquids
Heat transfer through tube walls Extremely large surface area
Fluids can be liquids or gases High speed of temperature change
On either shell or the tube side Corrugations in plate turbulences
Straight-Tube Heat Exchanger Tube-side Tube-Bundle
fluid in
Shell-side Heat Exchangers
Deflection fluid in
Tube
chamber
sheet Most of the heat exchangers
in Power Plants are
Tube-Bundle Heat Exchangers
Shell-side
Shell Tube Many variations in design
Baffles sheet Tube-side
fluid out fluid out Tubes connected through
holes in tubesheets to plenum
U-Tube Heat Exchanger
Shell-side
fluid in
Baffles directing the shell flow
Tube sheet Outlet
Baffle Shell plenum more effective flow path
Straight Tube Bundle
out > higher flow velocity
in > Single pass type for Condenser
Tube-side U-Tube Bundle
fluid
Shell side Baffle
> larger transfer surface
Tube bundle Shell-side Inlet
with U-tubes fluid out plenum > higher pressure loss

Phase-Change
T[K]
Vaporization Heat Exchangers
T1in
∆vH (OL3) = + 2758 kJ/kg
Steam
Water
Generator
T1out
Steam T=const.
T2in T2out
+∆vH = Enthalpy
Heat is absorbed by boiling water of Vaporization
Inlet Heat Transfer Area [m2] Outlet

Latent Heat
T[K]
Condensation
Heat is released by condensing vapor The Steam Generator can basically
be seen contrary to the Condenser.
T1in T1out
Water T=const. Condenser
T2in
Steam –∆vH = Enthalpy

∆vH (OL3) = – 2466 kJ/kg T2out
of Condensation
Inlet Heat Transfer Area [m2] Outlet
Chapter 3
Power Interface Steam Generator

Steam Generator Tasks
The Steam Generator (SG) is the power interface between
the Primary Circuit (Reactor Cooling Circuit)
and the Secondary Circuit (Water-Steam Cycle).
Tasks of the Steam Generators:
Heat sink function
> Transmission of nuclear thermal power
to the Water-Steam Cycle
> Removal of nuclear decay heat during plant shutdown (partly)
> Reserve for mitigation of transients during abnormal situations
Generation of saturated steam of required steam quality X
to drive the Turbine X = 0.9975 at main steam outlet
Key component of PWR regarding the Plant Efficiency
U-tube bundle heat exchanger
with phase change of the working medium (Feedwater)
The EPRTM Steam Generator
The EPRTM Steam Generator features distinctively

larger volumes than previous designs as compared
to the relative increase in Thermal Power.
GV 79 / 19 TE Heat transfer area [100 m2]
Tube diameter [mm]
T: Triangular pitch
RCP1
E: Axial Economizer
EPRTM Steam Generator Main Characteristics:
Vertical U-Tube bundle & shell
heat exchanger with natural circulation
Heat transfer when RCPs stopped
Supplied with an innovative preheater
the Axial Economizer
Advanced version of N4 Steam Generator
16 SG in Civaux 1+2 and Chooz B1+B2
EPRTM Steam Generator
Main Sub-Assemblies
Steam SG Main Sub-Assemblies:
Steam Drum
(Dry Steam) Pressure Shell

Upper Channel Head (CH)
Internals Primary Coolant
(Wet Steam) Tube Sheet (TS)
U-tube ends welded
Secondary Lower Internals
Medium > U-Tube Bundle
(Feedwater > Bundle Wrapper
and Steam)
Evaporator
> Tube Bundle Support Sys.

Lower Upper Internals
Internals > FW Distribution System
> Emergency FW System
TS > Primary Separators
Reactor Coolant
CH
(Primary Water)
> Secondary Separators
Components
Level Measurement Nozzle
Main Steam Outlet Nozzle
(Narrow and Wide Ranges)
Dryer Frame
Secondary Manway
Drain Pipes
Sampling Tap Swirl Vane Separator
Emergency Feedwater Nozzle Emergency Feedwater Ring

Level Measurement Nozzle Main Feedwater Ring
(Narrow Range) Main Feedwater Nozzle
Upper Support Brackets Double Wrapper
Anti-Vibration Bars
Tie Rod
Bundle Wrapper
Secondary Partition Plate Tube Support Plates (9x)
Level Measurement Nozzle U-Tube Bundle
(Wide Range)
Flow Distribution Baffle
Secondary Drain Tap (2x)
Tube Sheet Blowdown Tap (3x)
Primary Partition Plate Channel Head
Primary Manway Primary Coolant Outlet Nozzle
30985
28700 Main Data
1505
Characteristics FA3 Unit
1400
26200 Design Life Time 60 y
4900
Number of SGs 4
2028 23750
Overall height 24.621 m
128
Lower shell thickness
110 mm
(net)
19750 Cladding thickness 6 mm
Secondary fluid volume 238 m3
24621
Overall mass (empty) 500 t

13315
Pressure shell material 18 MND 5

11720
Cladding material Ni-Cr-Fe

12675
15515
3600
13551
13800
Steam Generators are
110 located at Rooms:
SG1: HRA15-003
9380 SG2: HRA15-004
SG3: HRA15-007
7455
150 SG4: HRA15-008
5150
2000 Floor Level + 5.15 m
0
Steam Generator
Shell Manufacturing
OL3
Tubesheet welded to the Lower Shell

SG Pressure Shell:
Consists of 9 heavy forgings
Manufacturing takes 3 years
Upper Evaporator Shell Forging: Japan Steel Work (J)
and Transition Shell
welded together (2005) Assembly: Châlon Factory (F)
Conical Transition Shell
134 mm OL3
Bundle
Wrapper
Tube
Bundle
Working Platform
AREVA´s Saint Marcel plant near Châlon, France
Completion of the manufacturing and hydraulic testing of the

first EPRTM Steam Generator was performed in winter 2008
Steam Generator
Supports
Advanced EPRTM SG Supports:
Below the primary channel head
> 4 vertical columns (a)
> support the total mass of SG
b
Near level of the center of gravity
c > 2 snubbers (b)
> 2 struts (c)
> limit the consequences of
earthquake and LOCA
d
In the bottom part (lowest shell)
> 3 stops (d)
a
> parallel to U-Leg and Hot Leg
> limit the size of potential breaks
> limitation of axial opening
Functional Advances
of EPRTM Steam Generator
EPRTM Evolution: Resulting Benefits:
Larger volumes Smoothing over of transients
Increased mass of secondary Dryout-time of 30 minutes in
water case of total feedwater loss
Augmented volume of
steam drum Delay SG filling up with
coolant in case of SGTR
Main FW Distribution System:
> Deflector System Eliminate overflow phenom.
> FW nozzle in conical shell Minimize thermal stratification
Emergency FW System:
> New design of I-tubes Avoid thermal shock on Shell
Upper Internals simplification Minimize corrosion risk
Advanced SG supports Limit seismic consequences
Chapter 4
Operation of the Steam

Generators
Steady State Steam
Generator Operation
h: Enthalpy •
m
• steam
m: Mass flow x steam
P: Power Steam
p: Pressure
Generator
T: Temperature
•
m feed
Tfeed
A
Reactor α
Thot
•
m
Tavg blowdown
Tcold
RCP *neglecting
blowdown rate
Primary •
Heat Balance
P=m • (h(155 bar, Thot) - h(155 bar, Tcold))
Secondary* •
Heat Balance P = msteam • (hsteam(psat) - hliquid(psat , Tfeed))
Heat Transfer from
Primary to Secondary Side
Primary Secondary Heat Resistance Partition:
Side Side Primary Side 25 % convection
SG Tube 50 % conduction
TPrimary Tsat Secondary Side 25 % convective
boiling
Tube
wall
Heat Transfer depends on: Power P = A • α • LMTD
Heat Transfer Area A [m2 ]

Heat Transfer Coefficient α [W/m2 oC]
Heat Transfer Resistance α
R = 1/α [m2 oC/ W]
Logarithmic Mean Thot - Tcold

Temperature Difference LMTD =
ln {(Thot - Tsat) / (Tcold - Tsat)}
Steam Generator
Primary Side
FA3 Steam Generator
U-bent tubes made in
Nickel-alloy 690 TT
by “Valinox Nucléaire“
(delivered June 2008)
Primary Side Primary Shell Tube Bundle Data

11720
Bundle
Bundle Wrapper
Wrapper Primary design
176 bar
pressure
Tube
Tube Bundle
Bundle
Tube bundle height 11.720 m
Tube
Tube Sheet
Sheet Tube number 5980
Partition
Partition Plate
Plate
Heat exchange area 7960 m2
Coolant volume 43 m3
Coolant
Coolant Nozzle
Nozzle U-Tube outer ∅ 19.05 mm
*New tubes U-Tube Wall thickness 1.09* mm
Hot Leg Cold Leg Tube array pitch 27.43 mm
U-Bend with the
Upper Tube Support Plate
OL3 Tube Support

Plate with
Trefoil holes
Vertical
Tie Rods
Bundle
Wrapper
Each Steam Generator contains 5980 tubes,

resulting in 140 km of tubing and 11960 tube-ends
Tube Support Plate
Operational Function of
Trefoil the Tube Support Plates:
Tube
Support
Support the tube bundle
Plates Define tube bundle position
Assure secondary flow path
Preclude unacceptable
vibration coolant flow
Isthmuses in contact with tubes

are flat (minimum area)
to avoid risk of drying out
and hide-out
High permeability to increase the

recirculation ratio and to obtain
additional margins with respect to
Trefoil broached holes the risk of clogging
Primary Operating
Conditions at Full Load
Primary Shell Operational Data
Characteristics FA3* Unit
Thermal power per SG 1131.5 MW
Flowrate per loop 27185 m3/h
Mass flowrate per loop 5558 kg/s
Temperature at SG inlet 329.8 °C
Temperature at SG outlet 295.4 °C
Steady State Average SG temperature 312.6 °C
Primary Side *PSAR
(sizing Primary operating pressure 155 bar
Operation power) Primary side pressure loss 3.50 bar
.
m = V • ρ (155 bar, Tcold) / t
ARCL = 0.4778 m2 (∅ ∅in = 780 mm)

phot = 154.7 bar pcold = 151.2 bar Inner sectional area of coolant nozzle
Thot = 329.8 °C Tcold = 295.4 °C ATubes = 1.3367 m2 (5980 ends)
TRPV = 329.9 °C TRPV = 295.7 °C Overall inner sectional area of U-tubes
Steam Generator
Secondary Side
Secondary Downcomer Annulus:
Side Recirculated Water
Evaporator Feedwater
Feedwater
Feedwater Halfring
Halfring
36 00
Feedwater
Feedwater Nozzle
Nozzle
Double
Double Wrapper
Wrapper
Water Layer
Secondary Medium
Bundle
Bundle Wrapper
Wrapper Secondary Lower Shell Data
Divider
Divider Plate
Plate
Secondary design
100 bar
pressure
Main Steam nozzle ∅(in) 738 mm
Feedwater nozzle ∅(in) 442.9 mm
Lower Support Plane (LSPL)
FW elevation from LSPL 15515 mm
Secondary Side
Lower Internals
Top Top
Double
Double Wrapper
Wrapper View
Bundle
Bundle Wrapper
Wrapper
supported by the
pressure shell
channeling of FW
inside SG
Holes
Holes in
in the
the
Bundle
Bundle Wrapper
Wrapper for
for
anti-seismic
anti-seismic blocks
blocks
Divider
Divider Plate
Plate
Distance
Distance Rods
Rods
(for manufacturing)
Bottom Bottom View
Natural Circulation
of Steam Generator
Economizer SG Due to the void inside the Bundle Wrapper,
a pressure difference exists at the wrapper bottom:
p(downcomer) > p(bundle)
This induces 1 (Boiler) or 2 (Economizer)

Natural Circulation Loops with:
Downflow in the downcomer
Upflow inside the wrapper
along the tube bundle
. .
CR = m(Total bundle) / m(Steam)
RT: Recirculation
Threshold
.
m: Mass flow rate Circulation Ratio (CR) at full power: 2 < CR* < 5
*for Boiler SG Recirculation begins RT ≈ 3 % (RP) at 300 °C
Axial Economizer of EPRTM
The Axial Economizer causes an enhanced overall heat transfer efficiency
by directing the cold feedwater in total to the Cold Leg
and 90 % of hot recirculated water to the Hot Leg
SECTION A-A
of the primary U-tube bundle.
Pressure Double Wrapper
Shell Advantages of the
Bundle Divider Plate Axial Economizer:
Wrapper
90 % Recirculated
Steam Pressure increase
10 % Recirculated Water
Water by about 3 bar
100 % Feedwater
Feedwater distribution by
Pressure 180° double wrapper
Shell Double Wrapper
No impact on tube
bundle vibrations
Bundle
Divider Wrapper
Plate EPRTM Improved Feature:
*Depending substantial contribution to
Hot Leg Cold Leg on site EPR-Plant Efficiency (37 %)*
Main Feedwater Distribution System
The EPRTM Steam Generator is supplied with a new improved
Main Feedwater Distribution System in order to preclude the
overflow phenomenon at the
double wrapper inlet.
Lateral
Support Conical Shell
Conical shell
Main
Main Feedwater
Feedwater Ring
Ring
Deflector
Deflector Plates
Plates
Bundle
Wrapper
Double Wrapper
with
a welded
Oblong
Oblong Holes
Holes Main
Main FW
FW Nozzle
Nozzle thermal sleeve
Emergency Feedwater Supply System
ASG1
z
I-Tubes y
50 I-Tube
x
EFW Nozzle
Emergency Feedwater Ring (EFWR)
The EPRTM Emergency Feedwater Supply is only used
during start-up and shutdown, faulted conditions and routine tests
The EFWR is installed at higher level than in previous designs
The advanced EFW Ring is equipped on its upper circumference
with a set of upright I-Tubes, angled towards the interior of the SG
This allows preheating of the emergency feedwater before it gets
in contact with SG shell or internals to avoid cold thermal shocks
Steam Quality
The dynamic Steam Quality x is the proportion of the mass flow
.
rates m of saturated steam in a saturated water-steam mixture.
.
m (steam) x = 0 100% Water
x = . .
m (steam) + m (liquid) x = 1 100% Steam
p = 1.013 bar To produce 100 % dry steam in a boiler,

Tsat = 100 °C Two-Phase and keep the steam dry throughout a
x ≈ 0.9 Steam piping system, is in general not possible.
Water droplets are produced through:

Turbulences and splashing when
bubbles escape from water surface
Condensation by heat loss at
pipe wall or internal structures
Steam Generator Upper Internals
Main
Main Steam
Steam Nozzle
Nozzle Larger Steam Drum volume
Flow
Flow Restrictor
Restrictor + Safety injection pressure
< secondary safety valves: p
8340
Dryer
Dryer Frame
Frame
Prevent SGs from filling up
Swirl
Swirl Vane
Vane Separat.
Separat. with coolant in case of SGTR
Emergency
Emergency FW
FW Ring
Ring
At Tube Bundle exit:
Steam Quality x = 0.27 (OL3)
Emergency
Emergency FW
FW Noz.
Noz. (at full power)
forced convection
Secondary
11720
Secondary Shell Steam Drum Data

Side
Steam Drum Steam Drum volume 67 m3
Steam Drum height 8340 mm
Steam Drum inner ∅ 4900* mm
Steam Drum wall
128* mm
*net (wo. cladding) thickness
Swirl Vane Separators Assembly
EPRTM
Support
Frame
Swirl Vane
Separators
(SVS)
Steam/Liquid
Distribution Tubes
Ladder N4
Access
Hatch
Swirl Vane Separator Assembly:
Reduced separator number
Tube Bundle Roof Steam/Liquid > 53 instead of 130 (N4)
Mixture
> margins against corrosion risk
Application of: mechanical, > Upper Internals simplification
static Steam Drying Devices Enlarged separator diameter
Swirl Vane
Separator Function
x < 0.85
Two-stage Moisture
Separator S335-2 Helix
1.5 times larger
than the N4
Second stage
Water droplets are

splashed against walls
2028
335 by centrifugal force

45°
First stage
2 stages account for

void fraction difference at
the tube bundle outlet in
Steam cold and hot leg region
Mixture
x = 0.27 Water
Steam Dryer Unit
x ≈ 0.9994
1015
1505
A A
Drain Grid
Pipe Drip Pan
x < 0.85
Section A-A
The Dryer Unit consists of 12 frames Double Pocket
in a single stage star arrangement Vanes
equipped with:
Double pocket vanes Droplet
scoops
Front face metal grid Steam
horizontal steam flow Water Grid
Instrumentation and
Level Measurement
The SG Water Level is measured by means of 4 static pressure taps.
The differential pressure ∆P between 2 taps
Steam
is converted into Water Level taking only into
account pressure variations due to gravity g.
Zup Zup
NR
∆P − (Z −Z
up down ).ρvsat
LEVEL
Level = Z + g
Zdown
WR down (ρ −ρvsat )
lDC
Water
ρνsat : Steam Density at saturation conditions
Zdown Water level depends on water density ρlDC :

Narrow Range (NR): water at saturation
Wide Range (WR):
ρlDC: Water density
in the upper part > Hot downcomer water at saturation
of the downcomer > Cold downcomer subcooled water
Steam Generator
21.6
Water Level Surveillance
19 m 19 m
18.0 MAX2
Narrow 17.0 MAX1 Reactor Trip 69 % (NR)
Range 15.6 Nominal LEVEL 49 % (NR)
6.5 m 9
13.8 MIN1 Reactor Trip 20 % (NR)
12.5 Wide
m Range
18.6 m Actuation of Emergency
7.85 MIN2 Feedwater System (EFWS)
Reactor Trip Signals:

MAX1: Below SVS overflow point
Turbine trip (carry over)
0.4 Feedwater supply isolated
m 0
[m]
MIN1: Core cooling (water mass)
in case of total loss of FW
Steam Generator Cold Filling
19 m
At room temperature (20 °C) the
Emergency Feedwater System (EFWS)
15.69 is used to fill up the Steam Generator
m
EFWR with cold water.
Cold Filling Procedure:

Wide Wide The Reactor Core is not critical
Range Range
Level Level Demineralized water is injected
Hot Side Cold Side by the Emergency FW Ring
Steam Generator is filled up
to the nominal level 15.69 m
Water rising is controlled by
Wide range level on hot side
0.4
m Wide range level on cold side

Steam Generator
Hot Stand-By Operation
19 m
The Reactor Core is critical
Narrow Reactor Coolant Pumps running
Range
Level
No recirculation by the separators
SSS
.
FEEDWATE
Water level is the same in the
12.5 R downcomers and in separators
m
m = 32.2 Water level is controlled by the
kg/s Start-Up and Shutdown
Secondary
T = 230 °C Feedwater System (SSS)
SIDE
Water injected by SSS through
p = 90 bar
the Main Feedwater Half-Ring
T = 303.3
°C To reduce the effect of thermal
stratification in the feedwater
.
m = 5558 kg/s nozzle the SSS feedwater flow
303.3 °C T = 303.3 °C is continuous
Secondary Operating
. STEAM Conditions at Full Load
FA3
m = 638.1 kg/s
Secondary Shell Operational Data
Tsat = 293.2 °C
Water Level Steam saturation pressure 78 bar
15.69 m MAIN
Steam outlet pressure 77.1 bar
.
FEEDWATER
Steam flowrate 638.1 kg/s
m = 644.5 kg/s
Feedwater total pressure 78.7 bar
T = 230 °C
Feedwater temperature 230 °C
HOT
. SIDE COLD SIDE Overall circulation ratio 3.6
.
m = 1513 kg/s m = 748 kg/s Secondary water mass 77.2 t
T = 293.2 °C T = 239.4 °C Steam mass 5.5 t
CR = 2.4 CR = 1.2
Thermal Power = 4500 MW
Boiling Onset Two circulation loops are

Blowdown
+ 0.1 m fully developed
6.40 kg/s
. . Main Feedwater System (TI)
m= 5558 kg/s m = 5558 kg/s
T = 329.8 °C T = 295.4 °C supplies water to the SG
Chapter 5
Main Associated Systems

Division of Main Steam
and Main Feedwater Systems
The Main Steam Supply System (MSSS) and the
Main Feedwater System (MFWS) are divided in two parts.
Location of Main Steam System and Main Feedwater System:

From SG outlet / inlet (Reactor Building) [HRA] to a fixed point
outside the Safeguard Buildings Division 1 [HLF] and 4 [HLI]
This is the scope of the Nuclear Island (NI)
Beyond the fixed point outside the Safeguard Buildings
to the Turbine in the Turbine Building [HM]
This is the scope of the Turbine Island (TI)
From the Safeguard Buildings to the Turbine Building the pipes
are installed in the Outdoor Area in a Pipe Bridge [HMP]
This is the scope of the Turbine Island (TI)
Location of Main Steam
and Main Feedwater Systems
Reactor Building
Nuclear Island (NI) 1 Main Steam Line
+57.511 2 MS Valve Station
3 Main Feedwater Line
HRA
Safeguard Safeguard
Building Building
Division 1 Division 4
+29.30 2 +29.80
HLF HLI
+24.80
1 +24.80
+19.90 +19.90
+16.80 +16.80
+12.00 3 +12.00
+8.10 +5.10
+4.70 +4.70
+0.00 +0.00
-4.50 -4.50
-5.00
-8.60 -8.60
-9.60

Steam Generator Main Systems
Inside Nuclear Island
Main Steam System (MSS) [VDA]
Main Feedwater System (MFWS) [ARE]
∅ = 800 mm
Lines to
HLK Silencer
Check
Valve
Pipe
Reductions MS
Valves
Main Feedwater Feed
Lines Heads Main Steam
∅ = 500 mm Lines
∅ = 750 mm
Low Load Full Load
Line Line

Operational Functions of
Main Steam System
The Main Steam Piping System guides
the high pressure (77.1 bar*) saturated steam of 293 °C
from the Steam Generators to the Steam Turbines.
The steam is only driven by the thermodynamic expansion,

due to the high saturation pressure of 78 bar.
Main Operational Functions:

Power operation Supply steam to the Turbine Island
Plant shutdown Remove residual heat by steam relief
> to condenser or
> to atmosphere if condenser unavailable
until RHR connection (RCS Tav > 120 OC)
*Outlet pressure due to the flow restricter
Safety Functions
of Main Steam System
Main Safety Functions:
Isolation of the SG steam side in case of excessive increase
during steam flow events (Main Steam Line Break)
Retention of radioactivity by steam side isolation in case of SGTR
Protection of SG against overpressure by steam relief
to atmosphere through Main Steam Relief and Safety Valves
Removal of residual heat by steam relief to atmosphere for:
> RCS partial cool down to allow MHSI in case of SB/IB LOCA
or SGTR
> RCS fast cool down to allow LHSI following a DEC event*
(e.g. SB/IB LOCA with MHSI total failure)
LHSI: Low Head Safety Injection SB: Small Break *Beyond Design
MHSI: Medium Head Safety Injection IB: Intermediate Break Basis Events
in US EPR
Main Steam System
Inside NI
Silencer Outdoor Area
Pipe
MSSV MSSV Drain Line Bridge
Reactor MSRV
MSRIV
Building
to Turbine
MSIV Building
Main Steam Line
Safeguard WULIV WULCV

Building
Drain Line
MSIV Main Steam Isolation Valve

MSRIV Main Steam Relief Isolation Valve
MSRV Main Steam Relief Valve
MSSV Main Steam Safety Valve
WULCV Warm-up Line Control Valve
WULIV Warm-up Line Isolation Valve
Main Steam Valve Station
with Silencers
Two Main Steam Valve Stations for 2 Steam Generators respectively,
are located on top of the
safeguard buildings 1 and 4
Silencer
in spatial separation
against air plane crash.
Main Steam Relief Valve

50 % discharge capacity
HL RCP1 MS 1st Safety Valve
25 % discharge capacity
MS 2nd Safety Valve
2nd Safety Valve 25 % discharge capacity
1st Safety Valve
Main Steam Relief Valve
All devices together have a
discharge capacity of 100 %
of full load steam generation
of 1 train at design pressure.

Main Steam Overpressure
Protection System
95.5 bar 102 bar 105 bar Valve Setpoints
50 % 25 % 25 % Relief Capacity FA3
MSRT
1st 2nd to Atmosphere
MSRV MSSV MSSV
NI TI
MSRIV
Main Steam Line to Steam Turbine

MSRT Main Steam Relief Train or Main Steam
MSRIV Main Steam Relief Isolation Valve Bypass Station*
MSRV Main Steam Relief Valve [VDA]
MSSV Main Steam Safety Valve
Fluid-operated Valve (closed)
Motor-driven Control Valve (open) *In case of

condenser
Spring-loaded Valve (closed) steam dump
Secondary System
Overpressure Protection
Absolute Pressure [bar, psia]
129.7 130% DP
1885
120 120% DP 4 : MSIVs spurious closure (without
Scram) MSSV, atmospheric steam
1740
dump MSRT
3b 3b : MSIVs spurious closure (with Scram)

109.9 110% DP 1 MSSV, Reactor Trip
1595
4 3a : MSIVs spurious closure (with Scram)

105 MSSV Opening 3a
2 MSSV, 25% each (575 t/h)
1520
100 atmospheric steam dump
100% DP
1450 95.5 Reactor Trip 2b : Turbine Trip: Failed transfer to house
1380 load operation Condenser + 1 MSRT,
90 Condenser 2b 50% (1150 t/h) atmospheric steam dump
1305 steam
dump 2a : Turbine Trip: Successful transfer
2a to house load operation
78 Nominal Condenser steam dump, partial trip
1130 pressure
Set Points Measure of Mitigation

Functionality of
Main Feedwater System Inside NI
Outside the outer containment shell, the safety classified parts of
Main FW System consist of four strictly separated identical trains
Two valve stations each are located on top of Safeguard
Buildings 1 and 4 (spatial separation against air plane crash)
Each safety classified part of a Main FW Train consists of:
1 Full-load train (100 % capacity) with

1 control valve and 1 isolation valve
1 Low-load train (4% to 20 % capacity) with
1 control valve and 1 isolation valve
1 Common isolation valve downstream of the full-load and
low-load train to cope with the single failure
The full and the low-load train are both open
during full power operation

Main Feedwater System
Inside NI
FLCV Full Load Control Valve
FLIV Full Load Isolation Valve
Reactor Building Safeguard Building LLCV Low Load Control Valve
LLIV Low Load Isolation Valve
Very Low Load Line
MIV Main Isolation Valve
VLLCV VLLCV Very Low Load Control
Valve
NI
SG1 Pipe Duct Turbine Building
[RCP1] LLCV LLIV
[ARE] Low Load Line [ADA] Start-up and
Common Line Shutdown
• Pump
Check MIV FLCV FLIV Flow TI
Valve Full Load Line Common Meter
Line
FW
SG2 TI NI TI Header
(> 20% RP) T= const.
SG3
Main Feedwater
SG4 Pumps
Main Feedwater System
Arrangement Inside NI
to
HRA HL Outdoor
Area
Feed
Feed MFWS
Heads
Heads Valve
Compartment
Main FW
Line FLCV
Full Load Control Valve
FLIV
DN 500 Full Load Isolation Valve
LLCV
Low Load Control Valve
Check LLIV
Valve LLIV Low Load Isolation Valve
LLCV MIV
DN 500 FLIV Main Isolation Valve
DN 250
FLCV
MIV

Contamination of Secondary Water
Main contaminants of SG Secondary Water:
Total Secondary
1. Abrasion particles from SG tube surface
.Water Flow
m = 2276 kg/s 2. Minerals produced by phase separation
in the
Steam Generator Secondary Abrasion Rate of SG Tubes
Characteristic Data Unit
Nickel Alloy 690 TT (EPR) 1.5 mg / (dm2 month)
Micro
Nickel Alloy 690 (N4) 4.0 mg / (dm2 month)
Particles Total Abrasion (EPR) 60 years 860 kg
To avoid sludge deposition of metallic micro

particles at the top of the SG tube sheet
SGBS
The Steam Generator Blowdown System
(SGBS), [APG] is connected at the
6.40 kg/s lowest point of the secondary shell
to extract the corrosion products.
Steam Generator
Blowdown System
HRA BDFAV HL HM
10 bar
Flash Tank FW Tank
14 bar CI-V CI-V FTPCV

Check
M M M
APG
APG valve
•
M 195 °C 43 oC
M M M
Main
M M < 120 °C Condensate
MCAV
78 bar System
6.4 kg/s M M M Turbine

1st BDIVs 2nd BDIV
Condenser
BDIV Blowdown Isolation Valve

13 43 °C FTLCV
M
BDFAV BD Flowrate Adjusting Valve
MCAV Main Condensate Adj. Valve MW M
FTPCV FT Pressure Control Valve < 50 °C SGBS
FTLCV FT Water Level Contr. Valve Demin.
CI-V Containment Isolation Valve M HNX SYSTEM
Blowdown Cooler
Steam Generator Blowdown Operation
Main Operational Functions:
Maintain contaminants of SG Secondary Water within limits
by blowing down a part of SG secondary flow
Expand and cool the blowdown water such that it
can be returned to the Water-Steam Cycle
Process the cooled blowdown condensate in the
Steam Generator Blowdown Demineralizing System [APG2]
SG Blowdown System Normal Operation:

Plant load > 15 % SG are blown down only on the hot leg
Plant load < 15 % SG are blown down on hot leg and cold leg
Blowdown flowrate at full power 1 % of SG main steam flow
To achieve the design life of the SG, the blowdown
flow rate must be maintained as high as possible.
Chapter 6
Steam Generator Tube Rupture

Steam Generator
Tube Rupture Mechanism
The Steam Generator Tube Rupture (SGTR) accident is caused
mainly by 4 tube degradation mechanisms:
1. Wear by friction at the Anti-Vibration Bar (AVB) locations
2. Stress Corrosion Cracking (SCC) on primary or secondary side
3. Inter-Granular Attack (IGA) alloy degradation
4. Vibrations after clogging of Tube Support Plates fast flow
Endangered Regions for Steam Generator Tube Rupture
d = 1.09 mm ∆p = 77 bar
19.05 Safety
mm Analysis
Hot Cold Hot Cold Hot Cold

Leg Leg Leg Leg Leg Leg
Hot Side U-Bend Cold Side

Tube Degradation
Tubes affected Type of Degradation Preventive Treatment
U-bend Region
1 Large radius tubes Wear by friction at the - Gap reduction
AVBs locations - Replacement of AVBs
2 Small-radius U-bend SCC from the primary or Stress relief annealing
secondary side
Tube Sheet Region
3 All tubes in sludge zones Inter-Granular Attack (IGA) - Chemistry monitoring
and at tube sheet crevice - Chemical cleaning
- Lancing
4 Above tube sheet -Corrosion at tube ends AVT treatment
-Tube thinning by corrosion
5 Tube end hard roll Secondary SCC same as (3)
transition zones
6 Tube zones Primary SCC - Shot peening
at tube sheet outlet - Nickel electroplating
7 Loose parts Fretting Acoustic monitoring
Steam Generator
Tube Rupture Scenarios
A Primary-to-Secondary Circuit Leakage is due to:
Either a small continuous leak or „denting“ in a SG tube
or to the complete severance of one or several SG tubes
Tube Rupture Accident Probability of
in 1 SG Category Occurrence
Low
SGTR 1 Tube PCC 3 (10–2 to 10–3) / year radiological
SGTR 2 Tubes PCC 4* < 10–3 / year releases
SGTR 10 Tubes RCC-A* < 10–5 / year
SGTR + SLB RCC-A* < 10–5 / year No liquid
releases
Secure Mitigation of a SGTR event:
Consideration in plant design EPRTM strongly designed for SGTR
Early identification of any Reactor Coolant Leak in a SG
*Beyond Design Basis Event for US EPRTM
Potential Consequences of Steam Generator Tube
Rupture
SGTR ACCIDENT
Backflow*
PRIMARY SIDE SECONDARY SIDE
of unborated water
LOSS OF ACTIVITY
More or less contaminated
REACTOR COOLANT by: INCREASE
Corrosion products
Activation products
Fission products Via Main Steam Line
RCS Pressure Decrease
to the Turbine
Containment Bypass*
Need of SIS**
Risk
Risk of Steam Discharge
of
to Atmosphere
CORE
Fuel Rod Overheating by Main Steam Relief Train
MELT
**If leak not compensated by CVCS *Practically eliminated on EPRTM
SGTR Post-
Accident Mitigation
SGTR
=
Loss of 2nd BARRIER
+
Bypass of 3rd BARRIER
SIS cut-off only when

CORE COOLING KEEP INTEGRITY Core Uncovery excluded
1st Priority = of 1st BARRIER = Core covered,
RCS sub-cooled
LIMITATION OF
+
SGa Isolation
ACTIVITY Steam and Feed Lines
RELEASES = RECOVER INTEGRITY
of 3rd BARRIER
= +
2nd Priority SGTR leak-flow = 0
(SGa: Steam Generator affected)
Steam Generator
Tube Rupture Detection
A Steam Generator Tube Rupture is detected (OL3) by characteristic
Gamma-radiation of the Nitrogen isotope N-16 in the Main Steam Line.
Natural Oxygen Isotopes γ- energies (N-16)

O-16 99.759 2.750 MeV
O-17 0.374 6.130 MeV
O-18 0.2036 7.110 MeV
16 O+0 1n 17O* 0p
–1 16 N
8 8 7
16
7
N 16
8
O + β– + ν + γ
Halflife t1/2 (N-16) = 7.1 s
SGTR Mitigation Phases
The typical sequence of events in SGTR scenarios consists of 2 phases:
1. Short Term Phase: from Tube Rupture(s) to Controlled State
2. Long Term Phase: from Controlled State to safe Shutdown State*
Reactor Trip on:
Short Term Phase
> Low PZR Pressure
* Return to RHRS
> High SG Level
> Activity Signal (only for OL3)
Isolation of the Main Feedwater System full load line
Pressurizer Spray actuation: normal [RCP2] and auxiliary [RCV]
in order to reduce RCS pressure to reduce leak flow
Plant Heat Removal and control of secondary side pressure
by the Main Steam Bypass [GCT] or if not available
by the Main Steam Relief Trains [VDA]
Steam Generator Level: Reduction of level setpoint by 1m
in order to prevent overfilling of affected SG
[bar]
SGTR Typical Transient
Evolution
RCS Pressure
RT Equilibrium pressure SIS off

155 Signal SGTR flow = SIS flow PZR-SPRAY on MSB: Main Steam
(25 kg / s) Bypass
MSRT: Main Steam
130 Relief Train
120 RCS SGa: SG affected
SIS SGa Isolation SGu: SG unaffected
SG Pressure
Signal
MSRT/MSB SIS: Safety Injection
~95 System
78 SGa
SG nominal
SGu cooldown SGu
Automatic Manual max. cooling rate = SGTR flow Time
Protection Actions Operator – 56°C/h =0
Actions
(start)
SGa Level
SG level N4
control off
1 SGTR
EFWS SG blowdown
nominal on SGTR
+
SGTR SGTR SGTR cancelling Time [min]
0 PHASE A 20 PHASE B 40 PHASE C 70 80 PHASE C'
SGTR Short Term Mitigation Strategy
105 (OL3) Liquid release forbidden EPRTM
105 MSSV
1520 102 (OL3) 100 (99 OL3)
MSRT SGa
Pressure [bar – psia]
95.5 97 (prel. value) 1405
1380 1410
MHSI* RCS Pressure
Pa 4 SG
85
by
85
rtia
1230
1230
l C [250
oo
ld o ° C /h
wn ]
Tsat = 260 °C
60 MSRT SGu
870
Automatic Isolation
≈ of SGa
Time
Partial Cooldown Signal
SGTR Signal
Very low PZR pressure*
Very high SG level and Partial Cooldown finished
Very high SG level
Activity signal a. Partial Cooldown finished (OL3)
Activity signal (OL3)
SGTR Mitigation Concept of EPRTM
The EPRTM design is largely impacted by the SGTR concept.
Design
Design Features Compared to Values

current plants
MHSI pump injection pressure lower max.< 97 bar
Partial Cooldown* quicker p(SG) 95.5 to 60 bar
SG Safety Valves setpoint higher 102 / 105 bar
Shutdown Margin higher Core subcritical at
260 oC with N-1 Rods
SG design pressure higher 100 bar
*needed to contract RCS and allow safety injection
The Most Important Facts to Remember
The EPRTM
TM Steam Generator is a vertical U-Tube bundle & shell heat
exchanger with natural circulation (if RCPs stopped)

The Axial Economizer causes an enhanced heat transfer efficiency by
directing the cold feedwater in total to the Cold Leg and 90 % of hot
recirculated water to the Hot Leg
The very high steam saturation pressure of 78 bar of SG is a major
contributor to the high plant efficiency of the EPRTM
TM of up to 37 %.
The advanced Nickel-alloy 690 TT of SG tubes and a continuous SG

blowdown ensure SG 60-years lifetime and minimize SGTR risk
The increased steam volume and set pressure of the secondary safety
valves prevent any liquid release to environment in case of SGTR
EPRTM
TM design is strongly orientated to a secure mitigation of a Steam
Generator Tube Rupture Accident, possible in any case


B257.OL3 - 004 - HT - Primary - Secondary Circuit - Rev01

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Heat Transfer between

Primary and Secondary

Explain the heat transfer mechanisms and their application in

2 Training Center AREVA NP GmbH Proprietary - CONFIDENTIAL

3 Training Center AREVA NP GmbH Proprietary - CONFIDENTIAL

Primary System Secondary System

1 Steam Generators 3 Main Feedwater System

Core Thermal Power 644.5 kg/s

Reactor Coolant Feedwater / Steam

Blowdow 6.40 kg/s

5533.75 kg/s 5533.75 kg/s All values for

PZR Safety Valves

Relief Main Feedwater System MFWS

Reactor Start-up and Shutdown

Loop 1 Loop 2 SG Blowdown System

7 Training Center AREVA NP GmbH Proprietary - CONFIDENTIAL

Heat Transfer in the PWR

Thermally agitated molecule:

Q Heat is related to changes in

through the First Law of Thermodynamics:

In thermodynamic terms Heat is defined (like work) as

10 Training Center AREVA NP GmbH Proprietary - CONFIDENTIAL

Rudolf Clausius* 1865

1. Heat Conduction through contact surfaces

The strongest convective flow

Hot water in a heated pot rises,

An example of forced convection are fluids

Surface Heat Exchanger

18 Training Center AREVA NP GmbH Proprietary - CONFIDENTIAL

Inlet Heat Transfer Area [m2] Outlet

Steam –∆vH = Enthalpy

Power Interface Steam Generator

The EPRTM Steam Generator features distinctively

(Dry Steam) Pressure Shell

> Tube Bundle Support Sys.

Emergency Feedwater Nozzle Emergency Feedwater Ring

Overall mass (empty) 500 t

Pressure shell material 18 MND 5

Cladding material Ni-Cr-Fe

Tubesheet welded to the Lower Shell

AREVA´s Saint Marcel plant near Châlon, France

Completion of the manufacturing and hydraulic testing of the

Operation of the Steam

Heat Transfer depends on: Power P = A • α • LMTD

Heat Transfer Area A [m2 ]

Logarithmic Mean Thot - Tcold

Primary Side Primary Shell Tube Bundle Data

OL3 Tube Support

Each Steam Generator contains 5980 tubes,

Isthmuses in contact with tubes

High permeability to increase the

ARCL = 0.4778 m2 (∅ ∅in = 780 mm)

p(downcomer) > p(bundle)

This induces 1 (Boiler) or 2 (Economizer)

p = 1.013 bar To produce 100 % dry steam in a boiler,

Water droplets are produced through:

Secondary Shell Steam Drum Data

Water droplets are

335 by centrifugal force

2 stages account for

Zdown Water level depends on water density ρlDC :

Reactor Trip Signals:

Cold Filling Procedure: