1/9/2012 - tom blair's electrical engineering reference...
TRANSCRIPT
1/9/2012
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Welcome to
Energy
Production
Systems
Engineering Thomas Blair, P.E. USF Polytechnic – Engineering
Session 3:
Steam Plant
Fundamentals
& Nuclear Energy
Spring 2012 Energy Production Engineering
Thomas Blair, P.E. ([email protected])
Session 3: Steam Plant Fundamentals Steam Plant Fundamentals
Nuclear Energy
Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals
Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals First law of thermodynamics – energy is neither created
nor destroyed, only altered in form. Second law of thermodynamics – all thermodynamic
processes are irreversible
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Isothermal – constant temperature Isobaric – constant pressure Isometric – constant volume Isentropic – constant entropy Adiabatic – no heat transfer Throttling – constant enthalpy
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Thermodynamic cycle:
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Carnot Cycle (ideal) – eff = 1-(Tl/Th)
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Rankine Cycle –
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Steam Plant Fundamentals Rankine Cycle –
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Regenerative Design – Feedwater Heaters
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Superheat
Design
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Reheat Design
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Steam Plant Fundamentals Condensate Depression (Subcooling) – Process of lowering condensate Temperature below Tsat
thereby reducing risk of cavitation but reducing efficiency
Increasing “Subcooling” lowers condensate temp and
lowers efficiency. Decreasing “Subcooling” raises condensate temp and
increases efficiency.
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Compression/Expansion not really Isentropic
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Combined cycle – Brayton/Rankine = topping/bottoming
cycle
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Energy Production Engineering Thomas Blair, P.E.
Basic Power plant Design Purpose: electricity / process steam Power plant Heating Plant Cogeneration Combined Cycle Combined Cycle - Cogeneration
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Energy Production Engineering Thomas Blair, P.E.
Basic Power plant Design Cycle Choice – ST vs. GT Steam vs. hot water Fuel Auxiliaries – duct heater I&C Development - DBC vs. owners engineer Site requirements
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Fire Tube / Water Tube designs
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Steam Generators Water Tubes hanging
from roof of boiler.
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Boiler Access
Door
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Major Components Furnace Steam superheater (primary & secondary) Steam Reheater Boiler Bank Economizer Steam Drum Attemperator (temp control)
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Energy Production Engineering Thomas Blair, P.E.
Water Steam Path
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Steam Drum
& Water Wall Design
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Combustion Air System Natural Draft Forced Draft Induced Draft Booster Fan overcome pressure drop Air preheater Sootblowers
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Water
Wall
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Steam Drum
construction & operation
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Steam
Separator
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Steam Generators A-type packaged
boilers
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Steam Generators D-type packaged
boilers
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Steam Generators O-type packaged
boilers
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Field Erected units –
Stoker unit Possible to use Limestone in bed to
limit SO2
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators HRSG – Heat Recovery Steam Generator Exhaust gas to generate steam
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Pinch Point &
Approach Point
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Energy Production Engineering Thomas Blair, P.E.
Steam Generators Fire Tube / Water Tube designs
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Steam Plant Fundamentals Burners – Oxygen control – stoichiometric Minimize Aux energy for ignition Minimize NOx & SOx formation Collection of non combustible Uniform combustion Wide / stable firing range Fast response High availability / low maintenance
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Horizontally
fired burner
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Steam Plant Fundamentals
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Steam Plant Fundamentals Air Dampers
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Steam Plant Fundamentals Tangentially fired burner
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Steam Plant Fundamentals Vertically
fired burner
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Steam Plant Fundamentals Cyclone
burners
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Steam Plant Fundamentals Low NOx burners- NOx development dependent on Temperature when
combustion takes place Primary and secondary combustion zones – more later.
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Igniters – Provide ignition energy 3 types of Igniters Class1 - > 10% main burner Class2 – 4% – 10% main burner Class3 < 4% main burner
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Combustion Process – - Adequate oxygen - Thorough mixing of fuel & oxygen - Temperature maintained above ignition temp - Volume residence time adequate for complete
combustion
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Stoichiometric ratio – Fuel to Oxygen
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Incomplete combustion – 2 C + O2 2 CO CO is combustible with value of 4347 BTU/lbm
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Steam Plant Fundamentals Stoichiometric air – just enough oxygen to combust fuel
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Heat Rate – plant NPHR = QB/NPO Where; NPHR = Net Plant Heat Rate (BTU/kWh) QB = Heat into boiler (BTU/h) NPO = Net plant output (kW) LOWER NPHR IS BETTER!
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Heat Rate – Turbine NTHR = QT/NTO Where; NTHR = Net Turbine Heat Rate (BTU/kWh) QT = heat into turbine (BTU/h) NTO = Net turbine output (kW) LOWER NTHR IS BETTER!
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals NPO = NTO – AP Where NPO = net plant output (kW) NTO = net turbine output (kW) AP = auxiliary power (kW) hB = QT / QB
Where QT = heat into turbine (BTU/h) QB = heat into boiler (BTU/h)
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals NPHR = net plant heat rate (BTU/kWh)
NTHR = net turbine heat rate (BTU/kWh)
AP = auxiliary power (kW)
NTO = net turbine output (kW) hB = efficiency of boiler
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals To keep NPHR as small as possible -> NTHR = small as possible AP = as small as possible NTO = as large as possible hB = as large as possible
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Steam Plant Fundamentals Note hB and NPHR are inverse of each other A higher boiler efficiency results in lower heat rate (this is good – less BTU for a kWh generated) A lower boiler efficiency results in a higher heat rate (this is not so good – more BTU for a kWh generated)
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Power plant Fans – FD, ID, PA, Gas Recirculation, Booster
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Fan operation: Air HP = (k*V * H) / (6356*eff) where; K = compressibility factor V is flow (CFM) H is head (“H2O) eff = mechanical efficiency
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Compressibility
Factor, Kc
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Steam Plant Fundamentals Centrifugal fan design
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Steam Plant Fundamentals Centrifugal fan design
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Steam Plant Fundamentals Blade Type – Efficiency – Erosive Tolerance Straight 70 High Forward curved 80 Medium Backward curved 85 Medium Airfoil 90 Low
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Typical fan curve
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Flow Control – Damper control changes
system resistance Speed control changes fan
pressure / power curve
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Steam Plant Fundamentals Axial Flow Fan
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Steam Plant Fundamentals Axial Fan Air
Foil Blading
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Steam Plant Fundamentals Speed ctrl – Erosion reduction Startup shock Flow ctrl Noise reduction Power draw at startup Fluid drive, two speed motor, VSD, ST drive
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Fan fundamental law; Power = flow * head
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Steam Plant Fundamentals Fan Laws 1.For given size, R-sys, and density;
1.When speed varies 1.Flow varies directly with speed 2.Pressure varies to square of speed 3.Power varies to cube of speed
2.When pressure varies 1.Flow & speed vary as sqrt 2.Power varies by 1.5
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Fan Laws – density changes 2.For constant pressure
1.Speed, flow, power vary as sqrt of density (directly for pressure, inverse for temperature)
3.For constant flow & speed 1.HP and pressure vary directly to density (directly for pressure, inverse for temperature)
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Fan Laws – density changes 4.For constant flow
1.Capacity, speed, pressure vary inversely to density 2.Power varies inversely as square of density
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Air Preheater
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Steam Plant Fundamentals Crusher
Dryer
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Steam Plant Fundamentals Ball
Tube Mill
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Steam Plant Fundamentals Classifier
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Steam Plant Fundamentals Ball & Race
Mill
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Steam Plant Fundamentals Roll Ring
Mill
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Steam Plant Fundamentals Roll Ring Mill
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Steam Plant Fundamentals Stokers Underfeed
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Steam Plant Fundamentals Stokers Overfeed
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Cooling Towers / Air Cooled Condensers
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Cooling Towers / Air Cooled Condensers
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Energy Production Engineering Thomas Blair, P.E.
Cooling Towers / Air Cooled Condensers
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Energy Production Engineering Thomas Blair, P.E.
Steam Plant Fundamentals Heat Balance – Heat gained by air = Heat lost by water + heat loss by evaporation. G = Mass flow air, h = enthalpy L = Mass flow water, T = temp H = Humidity ratio
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Steam Plant Fundamentals Natural draft vs. mechanical draft Induced draft vs. Forced Draft Cross flow verses counterflow Splash type fill vs. film type fill
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Steam Plant Fundamentals Natural Draft Tower
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Steam Plant Fundamentals Splash type fill
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Steam Plant Fundamentals Film Type Fill
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Steam Plant Fundamentals Regulate cold side
(water out) temp by air flow control
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Steam Plant Fundamentals Air Cooled condenser – Dry cooled (direct / indirect) Fin cooler
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Steam Plant Fundamentals Air Cooled
condenser – Wet surface cooled
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Water Treatment Impurities – deposit and erode Turbidity – insoluble matter Hardness – calcium & magnesium deposit out Soluble gases – accelerate corrosion Biological - fowling
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Energy Production Engineering Thomas Blair, P.E.
Water Treatment Pretreatment – sedimentation clarification filtration softening oxidation degasification Demineralization – evaporation ion exchange RO
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Energy Production Engineering Thomas Blair, P.E.
Water Treatment Oxidation – chemical addition or aeration Convert soluble gas to solids Sedimentation – settle out suspended matter Clarification – add coagulants to settle out smaller suspended matter
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Water Treatment Flocculation – after clarification slowly stir to further increase particle size and remove suspended matter Softening – removed dissolved impurities by chemical reaction to convert to a removable form.
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Water Treatment Filtration – process of passing fluid through medium perpendicular to medium to remove solids. Follows clarification/flocculation.
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Water Treatment Demineralization – Ion Exchange Evaporation RO
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Water Treatment Evaporation – flash distillation
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Water Treatment Reverse Osmosis (RO) – Uses semipermeable membrane and pressure to separate. Results in concentrate & permeate. Ultra filters (UF) & Micro filters (MF) alternate to RO RO pores are smallest, MF pores are largest
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Energy Production Engineering Thomas Blair, P.E.
Water Treatment Ion Exchange – Uses resin beds to replace unwanted ions with less objectionable ions
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End of
Steam Plant Fundamentals
Energy Production Engineering Thomas Blair, P.E.
Nuclear Energy
Energy Production Engineering Thomas Blair, P.E.
Nuclear Energy 235U most common fuel Neutron fission of U to other decay particles Moderator – reduce neutron energy to increase fission Coolant – remove heat from Fuel rods Half-life – avg time for one half of population to decay
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Nuclear Energy Fissile material generates neutron and non fissile material Fertile material generates neutron and fissile material Breeder – generates more fuel than it consumes Converter – generates less fuel than it consumes
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Nuclear Energy
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Nuclear Energy
K = neutron multiplication factor P = reactivity K = 1, p = 0 ; System is critical K < 1, p < 0 ; System is subcritical K > 1, p > 0 ; System is supercritical
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p = accumulation/production
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Energy Production Engineering Thomas Blair, P.E.
Nuclear Energy Method to control nuclear reactor – Adjust production, leakage, absorption of neutrons Soluble neutron poisons Control rods Fixed burnable poisons Scram – insertion of control rods by gravity / gas pressure Negative temperature feedback – increased temperature > less neutrons moderated.
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Energy Production Engineering Thomas Blair, P.E.
Nuclear Energy A Fuel bundle being transferred under water Cerenkov Radiation (That blue glow). Water used for shielding and cooling.
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Nuclear Energy Fuel Rod Storage
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Nuclear Energy Six types of nuclear steam system (80s design) BWR = Boiling Water Reactor PWR = Pressurized Water Reactor PHWR = Pressurized Heavy Water Reactor PTGR = Pressurized Tube Graphite Reactor HTGR = High Temperature Gas Cooled Reactor LMFBR = Liquid Metal Fast Breeder Reactor
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Nuclear Energy Boiling water reactor
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Nuclear Energy BWR – Steam generated in pressure vessel Light water – coolant and moderator Wet steam turbines employed Reactivity control – Control rods & coolant flow Bottom mounted control rods inserted via gas pressure
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Nuclear Energy ABWR
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Energy Production Engineering Thomas Blair, P.E.
Nuclear Energy ABWR – Use of internal recirc pumps to eliminate external jet pumps Finer control rod adjustment Operation action to LOCA 3 days ESBWR- Natural circ. – no recirc or jet pumps Condenser / hx to remove heat Large Pool to flood vessel in LOCA
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Energy Production Engineering Thomas Blair, P.E.
Nuclear Energy
To be continued …
Energy
Production
Systems
Engineering
Thomas Blair, P.E. USF Polytechnic – Engineering
End of Session 3:
Steam Plant
Fundamentals
& Nuclear Energy
Spring 2012