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com

Nuclear Energy and Technology 3 (2017) 307–312

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Specific features of initial fuel load of the innovative power unit under
AES-2006 project
A.N. Prytkov, A.B. Tereshchenko, E.I. Golubev, I.A. Boev∗
Branch of JSC “Concern Rosenergoatom” “Novovoronezh Nuclear Power Plant”, 1 Promyshlennaya zona Yuzhnaya, Novovoronezh, Voronezh Region
396072, Russia
Available online 29 November 2017

Abstract
Experience of initial fuel loading of VVER-type reactors was analyzed prior to initiation of the “first criticality” phase of Novovoronezh
NPP-II unit no. 1 commissioning. The analysis demonstrated a number of negative factors which may develop during the commissioning
phase under discussion, for instance those associated with fuel assembly stability. Special measures were undertaken to ensure safe initial
fuel loading with simultaneous use of loaded and dummy assemblies. Monitoring of deformation, flushing and verification of dummy
fuel assemblies were applied for ensuring safe first fuel loading with simultaneous loading of fuel and dummy assemblies in the reactor.
Conventional method of nuclear fuel loading ensuring resistance of partially loaded reactor core against internal and external disturbances
of natural and man-inflicted character (in particular, against seismic effects) was refined taking into account the revealed issues and the
experience of start-up of new power units by the use in the implementation of initial loading of regular nuclear reactor core with fuel
assembly imitators. Simultaneous loading of charged FAs and dummy FAs in the reactor core was used as applied to VVER reactors for the
first time. A set of measures was suggested allowing formulating the conclusion about applicability of dummy FAs for joint use with regular
FAs. Control of deformations, flushing and inspection of FA imitators for ensuring safe initial core load in the case of joint loading of FAs
and dummy FAs in the reactor core were implemented. Additional equipment was implemented for controlling coolant level in the reactor
core and concentration of boric acid in the process of initial loading of VVER-1200 reactor core, because low level and absence of coolant
circulation in the core do not allow using standard control systems. Effects of calculation parameters and high sensitivity of detectors on the
control of neutron flux in the course of implementation of nuclear fuel loading were investigated.
Copyright © 2017, National Research Nuclear University MEPhI (Moscow Engineering Physics Institute). Production and hosting by
Elsevier B.V. This is an open access article under the CC BY-NC-ND license. (http://creativecommons.org/licenses/by-nc-nd/4.0/)

Keywords: AES-2006; VVER-1200; First criticality; Reactor core; Nuclear fuel; Dummy fuel assembly.

Introduction equipped with pressurized water power reactors (VVER)

Power unit no. 1, Novovoronezh NPP-2 is the standard de-
sign of Russian NPP of new “3+” generation with improved
technical and financial performance parameters. Semi centen-
nial experience of safe and accident-free operation of NPPs
∗ Corresponding author.
E-mail addresses: PrytkovAN@nvnpp1.rosenergoatom.ru
(A.N. Prytkov), TereschenkoAB@nvnpp1.rosenergoatom.ru
(A.B. Tereshchenko), GolubevEI@nvnpp1.rosenergoatom.ru
(E.I. Golubev), BoevIA@nvnpp1.rosenergoatom.ru (I.A. Boev).
Peer-review under responsibility of National Research Nuclear University
MEPhI (Moscow Engineering Physics Institute).
Russian text published: Izvestiya vuzov. Yadernaya Energetika (ISSN
0204–3327), 2017, n.3, pp. 121–130.
[1–4] served as the basis of the project. This power unit
is equipped with VVER-1200 reactor designed under “AES-
2006” project. Power unit of the Novovoronezh NPP became
the leading power unit in the project and was the first to go
through the process of commissioning before the beginning of
electricity output to the consumers. This process included the
“First criticality” phase commenced in March 2016. Loading
nuclear fuel in the standard reactor core (RC) constitutes the
most important part of this start-up phase.
During more than 30 years the so-called “dry” methods of
initial loading were used for starting up VVER power units
including power units commissioned already in the XXI cen-
tury (Kalinin NPP, Rostov NPP, Tianwan NPP in China, Ku-

https://doi.org/10.1016/j.nucet.2017.11.006
2452-3038/Copyright © 2017, National Research Nuclear University MEPhI (Moscow Engineering Physics Institute). Production and hosting by Elsevier
B.V. This is an open access article under the CC BY-NC-ND license. (http://creativecommons.org/licenses/by-nc-nd/4.0/)
308 A.N. Prytkov et al. / Nuclear Energy and Technology 3 (2017) 307–312
dankulam NPP in India). This method implies implementation
of the following two phases of nuclear fuel loading:
- Loading of part of fuel assemblies (FA) in the reactor filled
with solution of boric acid to the level of upper surface of
support pipe grid in the in-vessel reactor shaft.
- Adding fuel to reach full load set inside the RC filled with
boric acid solution.
The term “dry loading” is the professional slang. The term
“dry loading” was accepted according to the initial phase of
fuel loading. Advantage of dry loading is the possibility of
visual control of the loading process.
Analysis of the planned first nuclear fuel loading
Novovoronezh NPP-2 Unit 1 the reactor core fuel load-
ing includes 163 FA [5]. Subcriticality during loading VVER
reactors is ensured by the selection of configuration of the
loading and by maintaining concentration of boric acid dis-
solved in the primary loop coolant. In accordance with safety
requirements [6,7] the required subcriticality must be sub-
stantiated with taking into account the reactor control rods
extracted from the core.
Nuclear safety analysis was performed both for the par-
tially and for the completely loaded RC. The analysis included
analysis of criticality for the following cases:
- Different levels of filling with boric acid with different
concentrations of solution.
- Different coolant densities.
- Local replacement of coolant with pure condensation wa-
ter.
- Occasional violations of the first fuel loading map.
Results of analysis implemented for Power Unit 2,
Novovoronezh NPP are presented in the report [8].
Calculated values of effective neutron multiplication factor
(Keff ) for the first phase with complete filling of the reactor
with coolant are as follows:
- 0.881 without boric acid.
- 0.591 for boric acid concentration equal to 16 g/kg H2 O.
Criticality was determined for different coolant densities
for the first phase of fuel loading. Keff < 0.95 for concen-
tration of boric acid in the coolant not less than 4 g/kg H2 O
within the whole range of coolant densities for RC loaded
in accordance with partial fuel loading map. However, in the
presence of boric acid in the coolant Keff > 0.95 for coolant
densities from 80 kg/m3 to 400 kg/m3 . Maximum value of
Keff = 1.062 for coolant density equal to 180 kg/m3 .
For reactor core loaded with 61 FAs Keff < 0.95 is en-
sured for any occasional violation of the first fuel loading map
for boric acid concentration in the coolant exceeding 4 g/kg
H2 O. However, in the absence of boric acid in the coolant
Keff > 0.95 for a number of options of occasional violations
of the first fuel loading phase (from 0.953 to 1.01).
Based on the above and taking into account the analysis of
“dry” method of first loading the following several negative
factors were revealed which must be taken into consideration:
- For coolant densities from 80 kg/m3 to 400 kg/m3
Keff > 0.95.
- Calculations demonstrated that in separate cases of poten-
tial occasional violations of the first fuel loading map (vi-
olation of coordinates or the type of loaded FA) excess of
the value of Keff = 0.95 is possible when RC is filled with
coolant without addition of boric acid.
- FA installed in the reactor which will be surrounded with
empty cells or FA having only one adjacent FA may, in
case of small deviations from vertical position, hinder in-
stallation of adjacent FAs during the second phase of fuel
loading.
- Interruption is possible of fuel loading caused by the prob-
lems which may emerge on the NPP power unit in the pro-
cess of commissioning, for instance, interruption of fresh
nuclear fuel loading for investigating the cause of trigger-
ing the “STOP” signal on the excursion signalization unit
of the neutron flux control system during fuel re-loading
(refueling monitoring system - SKP) when certain number
of FAs not having adjacent FAs or being in contact with
them with only one plane during indefinite period of time,
which may negatively affect their stability.
- In pursuance with [9] FAs loaded in the reactor during
the “dry” loading must be resistive against external im-
pacts caused by processes, events or factors of natural and
man-inflicted origin, in particular, against seismic impacts
characterizing the NPP site.
- Conditions of the reactor during loading (low coolant level
or absence of its circulation) do not allow using standard
systems for controlling coolant level and boric acid con-
centration.
Development of redesigned concept of first nuclear fuel
loading
Conventional method of nuclear fuel loading was re-
configured taking into consideration the above discussed prob-
lems and the experience of reaching first criticality on newly
commissioned power units for implementation of first fuel
loading of standard RC of the innovative power unit under
the “AES-2006 project.
Configuration consisting of 54 FAs was selected for the
first phase of nuclear fuel loading ensuring Keff < 0.95 within
the whole range of densities of pure condensation water for
eliminating the first negative factor. Results of calculations
are presented in the technical information bulletin [10]. Fuel
loading maps after completion of the first and second phases
of the re-designed fuel loading procedure are presented in
Fig. 1 for power unit 1, Novovoronezh NPP-2.
 A.N. Prytkov et al. / Nuclear Energy and Technology 3 (2017) 307–312
Fig. 1. Fuel loading maps after completion of the first and second phases of the re-designed fuel loading procedure for power unit 1, Novovoronezh NPP-2.
Preliminary loading of 109 dummy FAs prior to the begin-
ning of nuclear fuel loading was used for eliminating other
negative factors.
Typically, a set of FA dummies (DFAs) and dummies of
neutron absorbing pins of the reactor control and protection
system (AP CPS) is loaded in the reactor core during start-
up of the power unit for verification of reactor assemblability
and control of parameters during the “cold-hot test run of
the reactor unit” sub-phase of phase A “Pre-commissioning
adjustment operations”. Design on DFAs for power unit 1,
Novovoronezh NPP-2 was developed on the basis of design
of VVER-1200 FAs. Geometry, weight, structural materials
of the DFAs and FAs are absolutely similar. The material
substituting fuel pellets in the FAs is lead.
After loading 109 DFAs in the reactor during the first
phase of fuel loading, installation of FAs in cells devoid of
DFAs is implemented. Sequential replacement of DFAs with
FAs is implemented during the second fuel loading phase.
This fuel loading procedure ensures guaranteed FA fixation
309
in the support barrels and strict maintenance of FA vertical
positioning.
In case of forced interruption during any moment of fuel
loading FAs are rigidly fixed. In the case of impossibility
to continue RC loading operations without delay, reactor is
covered by technological head excluding penetration of for-
eign objects. Such measures ensure resistance of the partially
loaded core against internal and external impacts. The main
advantage of the “dry fuel loading”, i.e. the possibility of
visual control of the process, is retained.
Distinguishing feature of the reactor loading pattern in
question is the fact that combined use of DFAs and FAs was
never applied before during start-up of power units equipped
with VVER reactors. It is obvious in the conditions of lack of
experience that undertaking additional measures for ensuring
safe fuel loading is needed in the case of combined load-
ing of FAs and DFAs in the reactor. This refers to excluding
the possibility of confusion of FAs and DFAs, as well as to
ensuring stringent control of conditions of the DFAs.
310 A.N. Prytkov et al. / Nuclear Energy and Technology 3 (2017) 307–312
Exclusion of the possibility of confusion of FAs with DFAs
is ensured by the system of control and accounting of nuclear
materials and by step-by-step control of schedules of fuel
loading.
Maximum achievable approximation of conditions of reac-
tor core first loading to the conditions of standard re-fueling
is implemented by the filling of reactor with boric solution af-
ter loading 109 DFAs. Filling is conducted to the level 40 cm
below the upper edge of DFA heads. This excludes dry fric-
tion between the surfaces of the loaded FA and adjacent FAs,
DFAs or with the partition of the in-vessel reactor shaft. The
value equal to 40 cm was selected based on the fact that after
completion of loading 54 FAs during the first loading phase
the level in the reactor should not exceed the top of DFA and
FA heads. Increase of the level occurs due to the displacement
of boric acid solution by the loaded FAs.
Control of conditions of DFAs used during the first
reactor core loading
A set of measures was developed for controlling DFA con-
ditions allowing formulating the conclusion about applicabil-
ity of DFAs for their combined use with FAs.
• Control of deformation of DFAs.
Due to the absence in the design of the Novovoronezh
NPP-2 of a special structure for controlling linearity of DFAs
control of deformation of DFAs was implemented during un-
loading the DFAs from the reactor core in the fuel cooling
pool (FCP). The following prohibition criteria were estab-
lished for the use of DFAs in the fuel loading:
- Increase of weight by more than 75 kg-f during unloading
DFAs from the reactor core.
- Decrease of weight by more than 75 kg-f during placement
of the DFAs in the FCP stack.
This is a more conservative requirement compared with
that established by the Guidance on operation of FAs per-
mitting repeated attempt of loading (extraction) of FAs with
weight changing by ±735 N (±75 kf-s) and raising the block-
ing to ±1470 N (±150 kf-s). The raise of blocking up to
±2205 N (±225 kg-f) is implemented under the permission
of Chief Engineer of the NPP.
• Flushing DFAs.
Flushing of each DFA with chemically desalinated water
using flushing machine is implemented for removing possible
depositions and foreign objects.
• Technical inspection of DFAs.
Technical inspection of DFAs with participation of supplier
of FAs and DFAs is implemented for controlling outward ap-
pearances, outside dimensions, absence of foreign objects in
the guiding and instrument channels, coupling of the DFA
with fuel loading devices, marking, as well as visual control
of deformation of DFAs.
DFAs guiding channels of which have installed dummies
of AR CPS were selected from the set of FA dummies.
This significantly reduces the probability of presence of non-
detected foreign objects in the DFAs.
Non-standard equipment for controlling first nuclear fuel
load
Additional equipment including depth sampling devices,
level signaling devices and pumps for emergency coolant
pump-out is applied for controlling the level of coolant and
concentration of boric acid in the reactor.
Presence of non-standard equipment in the RC is associ-
ated with danger of hooking its cables by the fuel handling
machine [11]. Besides the above, cables of the equipment
cause impediments during installation of technological head
in the case of emergence of unwanted interruptions during
fuel loading.
The following new additional non-standard equipment con-
stituting unified system was developed for power unit no.1,
Novovoronezh NPP-2:
- Two devices for signaling level of boric acid in the reactor.
- Device for sampling boric acid solution in the reactor.
- Device for controlling signaling and sampling devices.
Coolant level signaling device represents vertical string
consisting of seven sensors arranged sequentially along the
height at the distance of seven centimeters form each other (0,
5, 10, 15, 20, 25, 30 cm) installed inside the hollow cylinder
made of stainless steel. Signaling device allows to sequen-
tially obtain with increasing level signals from each of the
seven sensors in the case of direct contact with boric acid so-
lution. Triggering of audio and light signalization takes place
in case of every contact of the sensor with solution.
Device for sampling boric acid solution in the reactor is
equipped with electric pump and hose ensuring taking sample
of boric acid from the elevation mark of the central control
room (supply of the solution to the height up to 25 m).
By the moment of beginning of loading the first FA in
the reactor core filled with boric acid solution with loaded
109 DFAs additional non-standard equipment is mounted and
arranged in the technological openings made in the in-vessel
shaft of the reactor. Thus, any contact between the equipment
and loaded FAs is excluded, movement of equipment is mini-
malized and arrangement of cables and hoses of equipment is
minimalized in order to exclude the danger of their hooking
by the equipment of fuel handling machine.
Submersible pump for pumping chemically non-aggressive
fluids was intended for emergency pumping out the coolant.
Extraction of two DFAs was anticipated in case of necessity
with installation in their place of pump-out pumps.
Special sealings ensure access inside the reactor of cables
and hoses of additional non-standard equipment, as well as
 A.N. Prytkov et al. / Nuclear Energy and Technology 3 (2017) 307–312
Table 1
Characterization of neutron flux control channels during loading nuclear fuel.
Functionality Type of Number of IC
ionization channels
chambers (IC)
In-vessel reactor neutron KNK-15 in 6 (in pipes in
flux control system pulsed mode the partition)
during fuel re-loading
(SKP)
Fig. 2. Layout of arrangement of neutron flux control channels for Unit 1,
Novovoronezh NPP-2.
shielded SKP hoses are used in the installation of the tech-
nological head on the reactor vessel.
Control of neutron flux during first nuclear fuel loading
Characteristics of channels for neutron flux control dur-
ing loading nuclear fuel are presented in Table 1. Layout of
arrangement of control channels is presented in Fig. 2.
Special program on the verification of effects of weld-
ing operations and operation of the polar crane and fuel-
handing machine on the functionality of SKP channels was
implemented prior to the beginning of fuel loading in the
reactor. No effects of operation of the polar crane and the
fuel-handling machine on the functionality of the SKP were
revealed. Welding operations performed inside the steam-
generator rooms within the internal containment of the re-
actor building demonstrated strong influence on the operation
of SKP channels in the form of pronounced outbursts of read-
ings of pulse frequency, period and triggering of “STOP” and
“REVERSE” signals on the SKP runaway signaling device. In
connection with the above welding operations inside the inter-
nal containment of the reactor building are prohibited during
the period of fuel loading and special regime for implemen-
311
Number of Range of thermal Neutron radiator,
detection units neutron flux density, sensitivity to thermal
in the channel s–1 /cm neutrons, 1/(n/cm2 )
1 до 1.0106 235 U, 0.5 ± 0,1
tation of these operations is established to be implemented in
special cases.
No triggering of signaling devices of the runaway signal-
ing unit was observed during FA loading in the internal ar-
eas of the reactor core. Pulse frequencies for the SKP chan-
nels were at zero level, neutrons from these areas along the
path to detectors are absorbed (mainly, in the boric acid so-
lution). However, triggered “STOP” and “REVERSE” signals
appeared after installation of the FA in the cell 14–23 located
near the SKP channel no. 1 and in cell 14–35 located near
the channel no. 6. Triggering occurred in the SKP equipment
after reaching the setting for the reactor period equal to 40 s
specifically for those channels in the vicinity of which loading
of FAs was taking place. Triggering generated the signal for
blocking the fuel-handling machine. Loading operations were
suspended for analyzing the registered data in these states,
for revealing and eliminating the causes.
Analysis of the situation demonstrated that when FAs are
loaded in the cell directly adjacent to the SKP chambers neu-
tron flux on the detector appears which is generated in the
FA by primary neutrons from the neutron source (from spon-
taneous fission of 238 U, 234 U nuclei and (α, n)-reactions on
oxygen isotopes) multiplied by fission chain reaction on nu-
clei of 235 U and 238 U. Spontaneous fission, decay of nuclei
and generation of neutrons in the fission reaction are the sta-
tistically distributed processes leading at low level of neutron
flux density to fluctuation of the number of neutrons penetrat-
ing the detector per unit time and to fluctuations of pulse fre-
quency at its output (including interference of noises). Fluc-
tuations of pulse frequency (n) on the output of the detectors
cause surges of reactor period (Т) which in accordance with
[12] is expressed by the following relation:
Т = n/(dn/dt ) (1)
Period is calculated in the neutron flux control equipment
(NFCE) through the inverse period (1/Т) equal based on (1)
as follows:
1/Т = (N (Dt, t2 ) − N (Dt, t1 ))/(N (Dt, t1 ) × (t2 − t1 ) ), (2)
where N(t, t1 ), N(t, t2 ) are the number of pulses registered
during the time period t at the time moments t1 and t2 ,
respectively.
It was discovered that initially established parameters for
calculation of frequency in combination with high sensitiv-
ity of detectors result in the calculation of the period within
short time interval (t2 –t1 ) which incurs spontaneous stepwise
increase of (1/Т) and, correspondingly, decrease of Т reading.
312 A.N. Prytkov et al. / Nuclear Energy and Technology 3 (2017) 307–312
Number of pulses counted during time interval t and the
length of the time interval (t2 –t1 ) were increased for ensuring
calculation of reactor period taking into account low levels of
neutron flux and pulse repetition rates per channel.
Conclusions
First criticality of power unit 1, Novovoronezh NPP-2
was achieved with application of the modified fuel loading
method. The configuration for the first phase of nuclear fuel
loading ensures Keff < 0.95 under filling the reactor core with
pure condensation water within the whole range of coolant
densities which secures additional guarantees of nuclear safety
during the shaping of the initial reactor core. Safety was
confirmed and combined use during the first loading of FAs
together with DFAs intended for verification operations and
control of parameters during the phase A “Pre-commissioning
adjustment operations” was implemented for the first time for
VVER power units. Special attention was paid to ensuring re-
sistance of partially loaded RC against internal and external
impacts. Specific features of neutron flux control during the
first loading of VVER-1200 reactor were revealed.
Experience gained during the first loading of the stan-
dard RC of the innovative power unit under the “AES-2006”
project can be used in the future during commissioning power
units equipped with VVER-1200 reactors, as well as power
units of the next generation.
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