Primary circuit of PWR reactors

Reactor technology
Lecture 3

Ildikó Boros
Assistant lecturer
Budapest University of Technology and Economics
Institute of Nuclear Techniques (BME NTI)
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 Primary circuit
• Main components:
– Reactor; Tasks:
• Heat transfer to the SG
– Steam generator (SG); • Fuel cooling (also moderating and reflecting at the
– Main coolant pump (MCP) same time)
• Maintaining the primary pressure (with the
– (Main closing valve - MCV) pressurizer)
– Pressurizer • Pressure boundary

– Main circulation loop (pipes)

• Connecting systems:
– Emergency cooling systems
– Chemical and Volume
Control System - CVCS
– (Makeup water system)
• Other important
primary systems
– Intermediate cooling loops
– Oil systems
– Drainage system
– Spent fuel pool and
refueling machine
– Boron injection system
2
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 Primary circuit

Primary circuit 3
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 Primary circuit - EPR
Primary coolant
H2O
Operational pressure
155 bar
Core inlet temperature
295.5 °C
Core outlet temperature
328.1 °C
Number of MCPs
4
Mass flow rate
78 000 t/h
Number of loops
4

Source: Areva
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 Primary circuit - VVER-440
Primary coolant
H2O
Mass of primary coolant
165 t
Pressure
125 kg/cm²
Core inlet temperature
267 °C
Core outlet temperature
297 °C
Number of MCPs
6
Coolant mass flow rate
39750 t/h
Number of loops
6
Source: Paks
5
NPP
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 The reactor

• Includes:
– Reactor pressure vessel
(RPV)
– RPV internal structural
elements
– Core (incl. the fuel)
– Safety and control rods
• Design considerations:
– Reactivity control
– Monitoring & surveillance
• Keeping operational limits
and conditions
– Designed to withstand
thermal, mechanical,
radiation loads

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Source: IAEA
6
 Fuel
Fuel assembly
Szinterelő kemence
UO2-pasztilláknak

Spacer grid
Height: 40 mm UO2 - pellets
Thickness: 0.4 mm (D = L = 10 mm)

Control rod Fuel rod

guide tubes (L = 4.2 m, D = 12 mm,
s = 1 mm)

Compression spring
Header

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 Fuel
EPR VVER-440

Core height 4.2 m 2.42 m

Core diameter 3.767 m 2.88 m

Number of fuel 241 349

assemblies

FA outer 21.4 cm 14.7 cm

diameter
Average power 89.3 kWt/l 85.2 kWt/l
density

Number of fuel 265 126

rods per FA
VVER-
FA geometry 17x17 Hexagonal 440

Cladding M5 Zr-1 %Nb

Average burnout 60000 37000 MWd/tU
MWd/tU

8
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 Fuel

Source: TVEL

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 Fuel - EPR

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 Fuel – VVER-440

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 Fuel – VVER-1200

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 Control rods - EPR
• For quick reactivity control
• EPR (similar system in other PWRs)
– 89 RCCA (rod cluster control assemblies), each with 24 control rods
– Cd-alloy at the lower part, B4C at the upper part
– Absorbent pellets are arranged in SS (stainless steel) clad in He gas
– 37 RCCA for power control, 52 for safety purposes (SCRAM)
– Control rod drive mechanism

Fuel of EPR
EPR core
Source: Areva

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 Control rods – VVER-440
• Structure:
– Fuel assembly
– Absorbing part
– Connecting element
• Its upper part is connected to the CRDM,
its lower part to the follower fuel
assembly
VVER-440 core
• 7 control, 30 safety control assembly Moderator
Fast neutron
• Follower fuel is the same as other FAs
• Absorbent: boron steel
• Special RPV because of the follower
FA structure

Boron steel

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 Fuel

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 Core monitoring systems
• Design requirements – following should be
considered at least (also in accident
conditions, recently also in severe accident
conditions):
– Core power (distribution and time
dependence)
• In-core or ex-core detectors
– conditions and physical properties of the
coolant and moderator (flow rate,
temperature)
– efficiency of the means of shutdown
– Water level
– Pressure
– Activity of coolant
– Control rod position
– Boron concentration
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 Reactor - EPR

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Source: Areva
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 Reaktor - EPR

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 Reactor Pressure Vessel (RPV)

• Material: 15-25 cm thick carbon steel (+Ni,

Mo, Cr, Mn), with an austenitic steel cladding
of 3-10 mm thickness (preventing corrosion)
• Fast neutron effluent during lifetime: about
1024 n/m2
• Design requirements
– Maintaining integrity in DBA conditions (now:
even in core melting cases – planned outer
cooling)
– Reducing the number of welded joints
(mainly at the core height)
– The break of the RPV is not a DBA event, this
event should be excluded
– The failure of the RPV upper head is a LOCA
event, below the nozzles it leads to SA

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 RPV
• Material embrittlement due to the neutron radiation Typical aging
– Dislocation of atoms in atomic lattice process of the
– PWRs are more exposed to neutron radiation (at BWRs the RPV!
effluent is lower by two order)
– Mainly at the height of the core, welded joints are more
sensitive in this region
– The Cu and Ni content of the alloy furthers the embrittlement
• At PWRs: PTS (pressurized thermal shock) Embrittlement:
– Larger amount of cold water enters into the RPV at large (near
lower (thermal)
operational) pressure
stresses can cause
– Significant heat stresses (+embrittlement)
failure of the
– Cracks could be induced
material
• At BWRs the most significant process is the over- (crackings)
pressurization at low temperatures
• Other considerable failure processes:
– Stress corrosion at CRDM penetrations (Davis-Besse)
– Stress corrosion at vessel bottom penetrations (STP1)

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 RPV - EPR
Material
MnMoNi steel
Wall thickness
250 mm
Clad thickness
7.5 mm
Height
12.7 m
Inner diameter
4.87 m

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 RPV - EPR
• No penetrations at RPV bottom
• Nozzle region manufactured
from one block
• Co-content of cladding is low
• Tcrit under 30oC even after 60
years operation
• Elevated nozzles (larger water
volumes under the nozzles)
• Heavy reflector (steel with lower
water content)
Source: Areva
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 RPV – VVER-440
Material
12H2MFA (Cr–Mo–V carbon steel)
Wall thickness
140 mm
Clad thickness
9 mm
Height
11.8 m
Inner diameter
4.27 m
Operational / design / testing
pressure:
123 / 137 / 172 bar

No axial welding
Thinner RPV wall, smaller water
volumes -> requirements for materials

Source: IAEA
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 RPV internal structures
• Tasks:
– Positioning and fastening of FAs and monitoring
systems
– Guiding the control rods
– Coolant flow directing and smoothening
• Typical internal elements:
– Core barrel
– Core shroud
– Coolant directing plates EPR internals
– Upper internals (guide tubes)
– EPR: heavy reflector

Source: Areva
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 Main coolant pump (MCP)
• Task: to provide adequate coolant flow
• Requirements
– Maintaining the proper mass flow rate to avoid
exceeding fuel limits (DNBR criteria)
– adequate flow coastdown characteristics in the
event of a pump trip (fly-wheel)
– Monitoring during operation: vibrations, leaks,
temperature
– Preventing high energy missiles in case of MCP
failure
– Example: EPR:
• 1 s electricity outage without MCP trip
• MCP does not receive a stopping signal after
reactor SCRAM
• Planned lifetime of housing: 60 years
• The coastdown time of MCP is enough for loss of
electricity + design earthquake

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 MCP - EPR
• Plus sealing stage for SBO

REACTOR COOLANT PUMP ASSEMBLY

− Design pressure (bar) 176
− Design temperature (°C) 351
PUMP
− Thermo-hydraulic flow rate (m3/h) 27,195
− Suction temperature (°C) 295.9
− Mass without water (including motor support) (kg) 50,520
MOTOR
− Type Air cooled squirrel cage induction motor
− Power rating (kW) 9,000
− Design input power, RCP [RCS] under normal conditions
(kW) 8,000
− Voltage (volts) 10,000
− Phase 3
− Frequency (Hz) 50
− Insulation class Class F thermoelastic epoxy insulation
− Mass (without water or oil) (kg) 60,700
− Total inertia (pump and motor) of the rotor (kg.m²) 5210

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 Pressurizer
• Function: to ensure that variations in
the reactor coolant inventory or in
thermodynamic conditions would not
affect the RCS boundary
• Operation:
– Steam-water equilibrium
– Pressure control by electric heaters and
cold water injection (from cold leg of
RCS)
– At primary overpressure: power operated
relief valves, and safety valves (into relief
tank)
• Requirements:
– An adequate steam space is maintained to
bear pressure transients in the RCS;
– Spray systems or heaters and overpressure
protection devices should maintain the
pressure within acceptable limits in all Source: NRC
operational cases up to DBA
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 Pressurizer – VVER-440
• Vertical arranged, insulated
carbon steel vessel with 9 mm
cladding (austenitic steel)
• 300 mm diameter nozzle at
bottom, connected to loop 6 1. Head
2. Air removal
hot leg by two-branch surge 3. Injection system
4. Vessel wall
line 5. Maintenance tools
7. Electric heaters
• 108 electric heater (15 kW 9. Supporting device
11. Inlet of injection
each) 12. Connection to PORV and SV

• 44 m3 volume
• Operational parameters:
Tsat = 325 °C p = 123 bar
• PORV, safety valves, relief tank
with rupture disks

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 Pressurizer - EPR

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Chemical and volume control system (CVCS)

26/04/2019 ReactorSource:
technology
NRC
30
 Chemical and volume control system (CVCS)
• Functions:
– Chemical control of the reactor coolant;
– Inventory control for the reactor coolant;
– Cleanup and purification for the reactor coolant;
– Reactivity control for the reactor;
– Supply seal water for the reactor coolant pump;
– Supply water for the auxiliary pressurizer spray Ion exchange resin
• Operates mainly in normal operational states
• Operates continuously as a part-flow cleaning
system
• Letdown to the liquid radioactive
waste management system

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 Steam generator Primary side (in the HE tubes):
Large flow rate
High operational pressure
• Heat exchanger between the primary and Radioactive coolant
secondary side Secondary side (shell):
Intensive boiling
• Functions: Accumulation of contamination

– heat transfer from primary to secondary

side
– Separation of the radioactive primary and
the secondary coolant
– Part of both circuits!
• Requirements
– Boundary between primary and secondary
side!
– Design of flow pattern
• No stagnating region is allowed (to prevent
impurities deposition)
• To prevent flow induced vibrations
– Leak detection
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 Source: IAEA
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 Source: Korea Atomic Energy Reseach Institute

PWR vertical SG Nuclear Training Center

http://www.kntc.re.kr/openlec/nuc/NPRT/

SG vane separator

SG centrifugal steam separator

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 EPR SG
• weight: 550 t,
• height: 25 m
• diameter: 5.2 m
• 6000 U-tubes,
representing an area of
8000 m2 and a length of
140 km of tubes.
• 99,75% steam content
• Axial feedwater preheater

• Feedwater temperature: 230°C

• Feedwater mass flow 2.443 kg/s
• Fresh steam temperature: 293°C Installation of SG
• Fresh steam pressure: 78 bar at Olkiluoto-3
Source: AREVA

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 Steam generator – VVER-440
Moisture
separator
Hot-side collector HE tubes
Cold-side collector
Steam collector

Shroud

Feedwater
inlet

Hot-side collector

Continuous and
Source: Paks
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periodic Annular
Reactor technology Feedwater inlet
NPP letdown letdown 36
 Steam generator – VVER-440
• Features:
– Mixing feedwater pre-heater zone
– Low steam outlet velocity (NPP Paks:
0.1-0.5 m/s),
– One-stage vane separator
– Low water level above the upper tube
bundle
– No HE tubes in the bottom region
(where the corrosion product sludge
settles)
– Primary collectors could be open from Source: Paks
the top NPP
• NPP Paks:
– L ≈ 12 m
– D≈3m
– HE tubes number: 5536
– HE tubes: ∅16 x 1.4 mm U steel tube
– Produced steam: 450 t/h, 46 bar, 260 °C
– Moisture content: 0,25 %
– Steam volume: 30 m3
– Water volume: 40 m3

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 Steam generators
Differences between vertical and horizontal SGs
• Vertical SG
– 600-1000 mm thick tube sheet,
vertical U-tubes
– Convective counterflow preheating
zone
– Water surface is smaller
• More equal steam velocity
• Larger steam velocity -> carrying water
droplets into the steam phase
• Moisture separator with more stages
needed
– Higher heat transfer coefficient
[6,7 – 8,5 kW/(m2⋅K)],
– Material of heat exchange tubes: Cr-
Ni alloy
– Concentrated pollutants deposited
mainly on the tube sheet
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• Horizontal SG
– Horizontal U-tube heat exchangers, tubes
rolled-in and welded from primary side
– Collector has a wall thickness of 70 (130)-
200 mm
– Mixing preheating zone
– Water surface is larger
• Non-equal steam velocity at the surface,
• Smaller steam velocity -> water droplet
priming is not significant
• One-stage moisture separator,
– VVER-440 SG: lower heat transfer
coefficient [4,7 kW/(m2⋅K)],
– VVER-1000 SG: ∼6,1 kW/(m2⋅K),
– Tube material: stainless austenite steel
– Concentrated pollutants deposited mainly in
the bottom of the SG barrel (where no tubes
are placed)
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 SG replacement
• In case of vertical SGs: planned
replacement
• VVER: economically not feasible
• Typical failure processes (PWR):
SG replacement at TMI-1
– Stress-corrosion, friction corrosion
and pitting, other mechanical failures
• Possible solutions:
– Replacement of HE tubes (not applied because of the large exposure)
– Replacement of lower part of SG (example: Turkey Point)
– Replacement of whole SG
• USA: SG replacement in 57 of the 69 PWR (and planned in the
others)
• Time duration of replacement: 33 days – 1 year
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 SG replacement in St Lucie NPP (USA)
• USA, Florida
• PWR with twin units
(started: 1976, 1983),
2x1000 MW made by
Combustion Engineering
Source: Aszódi A., 2006
• 2003: lifetime extension
licence (until 2036 and 2042)
• SG replacements: 1997, 2007

New SGs at unit 2

(Forrás: FPL)
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 PWR secondary systems

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 Secondary circuit
• Main secondary systems

• Main steam system

• Steam generator
• Main steam line
• Turbine (HP and LP)
• Moisture separator and re-heater

• Condensate/ feedwater system

• Condenser
• Purification system
• Preheaters

• Other secondary systems

(depending on unit design):
– Emergency feedwater system
– Auxiliary emergency feedwater
systems
– Secondary residual heat removal
system
– House-service steam system
– Desalinated water system
– Condenser cooling system

Source: NRC
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 Main secondary systems – VVER-440

Source: Paks NPP Paks, VVER-440 43

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 Turbine
• Function:
– To convert the heat and kinetic energy of steam from SG to mechanical (rotational) movement
• Features of wet steam turbines
– Large unit power with low steam pressure and temperature
– Saturated fresh steam, low heat loss, large steam consumption
– Usually low (1500 rev/min) rotational speed

• Moisture reducing: moisture separator inside

or outside the turbine (bleeding / separator)
• Reducing the blade erosion: increasing the gap
between stator and rotor blades or with
material selection (corrosion standing steels,
titanium alloy)

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 Turbine Turbinaház
Steam
"Frissgőz" Fixed blades
Állólapát Moving blades
Futólapát Turbine
(állórész)
• Arrangement: inlet
belépés housing

– Turbine housing → stator

• Steam inlet lines and outlet lines
(bleeding points, outlet nozzle)
• Split horizontally at middle line
• Upper and lower housing
– Turbine shaft→ rotor.
– Fixed blades increase the steam
velocity and drives steam to the
moving blades in the proper angle Turbine
Turbina tengely
– Moving blades transform steam (forgórész)
shaft
kinetic energy into mechanical work
– Fixed and moving blade lines Megcsapolások
arranged alternately. Bleeding
Impulse
Impulzuserő Munkátvégzett
Steam gőz
points
– One fixed + one moving blade line is kilépés
outlet
a stage

Steam Gőz
inletbelépés Steam outlet
Gőz kilépés
a fokozatba
into the stage from the
a fokozatból
stage

45
26/04/2019 Reactor technology Fixed blades
Állólapátok Futólapátok
Moving blades
 Turbine – VVER-440
• Parameters:
– Steam consumption: 1350 t/h
– Rotational speed: 3000 rev/min
– Power: 230 MW
– Wet steam turbine
– HP: 6 stages
– LP: 2x5 stages

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 Turbine – VVER-440

HP turbine rotor

Source: Paks NPP

LP turbine rotor
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 Turbine - EPR

Gross electric output 1,720 MWe

Net electric output 1,600 MWe
Main steam pressure (HP turbine) 75.5 bar
Main steam temperature 290°C
Steam flow 2,443 kg/s
Rated speed 1,500 r.p.m.
HP turbine 1
LP turbine 3
Length of turbine-generator rotor train 68 m

Source: Areva

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 Moisture separator reheater
MSR

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 Moisture separator reheater
At Paks NPP:
• Function: Moisture content of steam from HP turbine 12 %
Steam temperature before the MSR 135 °C
– Remove moisture from the steam leaving
Moisture content after the MSR 0,0 %
the high pressure turbine before admitting
Steam temperature after the MSR 240 °C
the steam to the low pressure turbines
(at HP turbine outflow moisture content can reach 12-15%)
– Re-heat steam before LP turbine

• With mechanical moisture separators (at VVER: tube and elbow

pre-separators), series of vanes
• Reheater: heating with steam bleeding from the main steam line

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Source:technology
Areva
 Condensate-feedwater system – VVER-440

Condensate-feedwater system 51
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 Condenser
• Functions:
– Condense and recover the steam that
passes through the turbine
– Maintain a vacuum to optimize the
efficiency of the turbine.
• Features of nuclear condensers:
– The turbine has a large specific steam
consumption -> large condensers (50-70%
larger than in thermal power plants)
– Requirement: receive large amount of
steam (in accident conditions)
– In-service cleaning processes
– Vacuum maintained by mechanical
vacuum pump or steam driven air
ejectors that suck gases from the
condenser.
– On the steam side of the condenser, the
water collects at the bottom in a sump
(water source for condensate pumps)

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 Condenser – VVER-440
Steam
Gőz from turbina
a kisnyomású LP turbine
házból

• Features
– Two half condenser under the LP turbine
housing
– Coolant water (at Paks NPP: river Danube)
flows inside the tubes, the condensation of
the steam occurs at the outer surface of the Side view
tubes
– The condensed water is collected in a sump,
from here the main condensate pump
transfers it to the LP preheater Kondenzátor zsomp
Condenser sump
Condenser coolant
Kondenzátor hűtővíz

Top view

Coolant
Hűtővíz
HE Hőátadó
tubes csövek fordítókamra
reverse
Condenser pressure 30 mbar (abs)
Condensate temperature 25 °C
Pressure after main condensate pumps Be
In
22 bar
Hűtővíz
coolant
Condensate mass flow 1000 t/h
Condensate temperature after LP preheater out
Ki
148 °C

Source: Paks NPP 53

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 Condenser – VVER-440

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 Condenser - EPR

Condenser
Cooling surface: 110,000 m2
Cooling medium: sea water
Cooling water flow: 53 m3/s
Vacuum at full load: 24.7 mbar abs.
Sea water temperature rise: 12°C

Source: Areva
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Secondary system
– VVER-440

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