Technology Enhancement for Indigenous PWR

Development

Rajit Kumar, Vivek Shrivastav, Arun Kumar, P.K.Mishra, A.B.Mukherjee & K.N.Vyas

Bhabha Atomic Research Centre, Mumbai, India

Technical Meeting on

Technology Assessment for New Nuclear Power Programmes

Sept 1st – 3rd , 2015 IAEA Headquarters

Vienna, Austria

Lecture outline

1.0 Introduction: India’s Electricity Scene

2.0 India’s Nuclear Power Programme

3.0 Nuclear Power Capacity

4.0 Indian PHWR

5.0 LWR programme in India

6.0 Indian PWR

7.0 Strength of Indian Industries

8.0 Development of RPV Forgings for IPWR

9.0 Conclusions 2

The installed capacity in India is 272,688 MW as on 30.04.2015.

At current levels India is 5th in the world in installed capacity and generation.

Despite growth in capacity, there are shortages - 12% at peak time There is an urgent need to considerably augment energy and electricity

supply in India.

India’s Electricity Scene

165236

1200

23062

41632

5780

35778 Coal

Diesel

Gas

Hydro

Nuclear

Renewable

Source: Central Electricity Authority, Minister of Power, Government of India

3

• Indian nuclear program is based on the known reserves

of Uranium and abundant reserves of thorium.

• To make best of the resources, Closed fuel cycle

adopted as the national policy. Indian Nuclear Program

is aimed at following 3 stages wise

• Stage 1: Use Natural uranium in PHWR

• Stage 2: Fast Breeder reactors using reprocessed Pu

from Thermal Reactors and Th. Blankets.

• Stage 3: Thorium-Uranium 233 reactors

Indian Nuclear Power Program

4

India’s Three Stage Nuclear Power Program

5

NPPs in Operation & under Construction

Kundankulam

1000 MW 1000 MW

Under Operation = 5780 MWe Under construction = 4300 MWe

6

Kudankulam, T.N .

2 X 1000 MW

Jaitapur, Maharashtra

2 X 1650 MW

Mithi Virdi, Gujarat

2 X 1100 MW

Kovvada, AP

2 X 1500 MW

Gorakhpur, Haryana

2 X 700 MW

Chutka, MP

2 X 700 MW

Mahi-Banswara,Rajasthan

2 X 700 MW

Kaiga, Karnataka

2 X 700 MW

Kalpakkam, TN

2 X 500 MW

PHWR Site

LWR Site

FBR Site

NPPs under Planning

Under Planning 17100 MWe

7

Indian PHWR

8

Indian

PHWRs

High

availability factor

and capacity factor

Experience of

~350 reactor years.

Indian industries

fully capable of

Manufacturing of large

size components

Complies fully

With regulatory

requirements

Most recent

technologies

incorporated

High Level of

Performance,

Efficiency,

Operability Economics

sound and proven

technology.

Integrate the results

of decades of Indian

research and

development

Experience of construction, operation & maintenance and adoption of state of the art technology

for engineering and analysis has contributed in development of a robust, safe and reliable model of

the Indian PHWR 9

Operating LWRs based on foreign technical cooperation GE- BWR (TAPS-1&2) VVER (KK-1 )

Planned LWRs based on foreign technical cooperation VVER AP1000 EPR

Indigenous design and development of PWR Indian PWR (IPWR), a joint project of BARC &

NPCIL

LWR Programme in India

10

INDIAN PRESSURIZED WATER REACTOR (IPWR)

Development of IPWR is culmination of --- • Expertise available for design, construction and operation of

PHWRs. • Experience gained in commissioning, operating and

maintenance of LWRs. • Qualified man-power to design, construct and operate nuclear

power plant. • Expertise available for development/ making of Materials in

Indian plants. • Fuel fabrication technology is available at NFC. • Control and instrumentation can be made at ECIL. • Indian industries are since poised to make heavy and critical

equipment like Reactor Pressure Vessel (RPV), steam generators (SG), PHT Pumps, etc.

11

General plant data Reactor thermal output : 2700 MWth

Design pressure :17.7 MPa

Design temperature : 350 °C

Service life : 60 calender years

Primary heat transport system data Primary coolant flow rate : 76,700 m3/h

Reactor operating pressure : 15.7 MPa

Average temperature of Coolant : 308 °C

No. of loops : 4 (one vertical SG and one PCP in each loop)

Reactor core Fuel material : UO2

Enrichment, % : 4.5 (avg.), 5 (max.)

Active core height : 3600 mm

Core diameter : 3306 mm

Average discharge burn-up of

fuel Approx : 46,200 MWd/t

Operating cycle length at full power

(fuel cycle length) : 410 days

Average linear heat rate : 160W/cm

IPWR : Plant Specification

12

• Features of modern LWRs

• 4 independent trains of Engineered Safety System (like

ECCS) with independent power source

• Passive heat removal under prolonged Station Black Out -

Plant Autonomy for 7 days

• Philosophy for Severe Management Accident

– Hydrogen mitigation

– Containment pressure management (Filtered Hard Vent)

– Prevention of corium-concrete reaction

• Air cooled DG set

• Design and safety Requirements of AERB and IAEA norms

will be met

IPWR - Salient Design Features

13

RPV : Reactor Pressure Vessel ECCS : Emergency Core Cooling System

RCP : Re-circulating Coolant Pump CVCS : Chemical and Volume Control System

SG : Steam Generator RHRS : Residual Heat Removal System

HPIS : High Pressure Injection System

Primary Coolant Circulating Loop of IPWR

14

Design features Target discharge burnup 46,200

MWd/t Reactor power is 900 MW(e) / 2700

MW(th) Enriched Uranium as fuel in a once

through in a three batch fuel cycle mode

235U enrichment 4.5 % ; UO2 Minimising the soluble boron

content Achieve a better local peaking factors

by way of using Gadolinium as IFBA (Integral Fuel Burnable Absorber) in the fuel

All reactivity feedbacks are negative Aim to achieve neutron

monitorability of the core at all stages

Core has been designed to provide 2700 MWt (900 MWe) over an equilibrium cycle length of 410 full power days.

Physics design of IPWR

Equilibrium Core Configuration

15

Core Layout (without TS)

• Material : SA 508 Gr.3 Cl.1, ID cladded with SS

• Main Nozzles: 4 Inlets, 4 Outlets in Two Separate Nozzle Rings

• Four auxiliary connection for ECCS • No weld in core belt region of shell • Surveillance coupon at mid-core plane • Provision for ISI • EOL fluence: 2 x 1019 n/cm2 (e > 1MeV) • Life : 60 Calendar years

Reactor Pressure Vessel

16

Strength of Indian Industries

Design (NPCIL, BARC & IGCAR):

Having strong R&D base

A long experience in nuclear power generation

Expertise in design capabilities for various nuclear power

generation technologies

Materials

Nuclear Fuel Complex (NFC) manufactures both natural

and enriched uranium fuel, zirconium alloy cladding,

incoloy seamless tubes and reactor core components from

the raw materials.

SG tubes of grade incoloy 800 for PHWR 700MWe is

indigenously developed.

Various special grades of carbon steel, low alloy steel &

stainless steel are also manufactured within the country by

different Indian industries meeting stringent requirements

for nuclear application. 17

Strength of Indian Industries.....cont.

Manufacturing Capability:

Infrastructure & capability to manufacture and supply heavy

equipment is available within country

Heavy equipment / components for PHWR (upto 700 Mwe PHWR)

e.g. calandria vessel, calandria tubes, end shields, pressure tubes,

pressurizer, steam generator, pumps, valves, turbo-generator,

transformer, etc. are indigenously manufactured.

Manufacturing capability conforming to stringent quality standards of

the nuclear power industry at par with international practice.

Control & Instrumentation Equipment Manufacturing

ECIL is equipped to meet the C&I requirements of the NPP of India.

C&I Systems of all operating NPP are supported / maintained by

ECIL. 18

Strength of Indian Industries.....cont. Capability Enhancement

Indian companies led by NPCIL plan to expand their

manufacturing base in the nuclear energy sector to supply

components for PWRs of 900 to 1,600 MWe capacity.

NPCIL, with joint venture, has constructed a state of the art plant

in country for making large size nuclear forgings.

Plant capacity with 300 ton ingots and 9000 ton forging

press.

Finished forgings for nuclear reactors, pressurizers, steam

generators and heavy equipment can be made.

Future expansion of capacity to 600 ton ingots & 17000

ton forging press 19

Development of Low Alloy Steel Forgings for

RPV of Indian PWR (IPWR)

Objective:

To Develop Technology for making special quality low alloy steel (grade SA 508 Gr.3 Cl.1) forgings for RPV application.

Establish process plans for Melting, Forging, HT &

Quality Control

Make prototype scale Forgings

Optimize process plans

Qualify material & technology by comprehensive

testing.

20

• Forgings for RPV is one of the critical item.

• Development has been initiated

• SA 508 Gr.3 Cl.1 (Mn-Mo-Ni) – RPV grade

High tensile Properties at RT and High temp

High impact properties

Long Term Properties (Fatigue &Fracture etc.)

Experience available for manufacturing

Irradiation embrittlement can be managed (through

chemistry control).

IPWR - RPV Material

21

Development of Low Alloy Steel Forgings ....cont.

Development of LAS forgings have been

planned in two stages:

1st stage : Small forgings

100 -120 T ingot size

100-200 mm thickness and up to

2500 mm diameter

2nd stage : Large & Heavy forging

Prototype forgings for IPWR

Technology development of forging 22

Development of Low Alloy Steel Forgings ....cont.

1st Stage of Forging Development is completed

high level of cleanliness

Uniform through thickness properties

Impurity Control in Low Alloy Steel Forgings for control on irradiation embrittlement and welding

Copper Phosphorus Sulphur Tin Arsenic Antimony Hydrogen

< 0.05% < 0.006% <0.004% < 0.003% < 0.005% < 0.005% < 1.5 ppm

0

0.002

0.004

0.006

0.008

0.01

0.012

P S Sn Al As Sb

Distribution of Impurity Elements in various different melts 23

Forging-1: OD 4830 x 340 thk.

Forging-2: OD 5300 X 750 thk.

Size of Forgings planned for Technology Development

24

Qualification for Higher thickness

Chemistry of core-belt region

• Manufacturing:

Primary Melting Sec. Refining Vacuum Degassing VIC (Vacuum ingot casting)

Forging

Prelim HT & Q&T

NDE

• Extensive testing for Qualification & Characterization of materials for RPV application

QT condition

QT+ Simulated PWHT Conditions

Scope of Work

25

high level of cleanliness

Through-thickness tests

Mechanical tests after QT & QT+ simulated

PWHT. Acceptance Shall meet the min

specified values

Low cycle fatigue

Fracture toughness

Weldability tests

Qualification of Forgings

26

India’s Nuclear Power Programme is playing important

role in building energy security of the country.

Indian PHWR programme has demonstrated the maturity

achieved in the research, design, development and

successful commercial deployment of nuclear technology

in the country.

Along with imported Light Water Reactors (LWRs) , India

has also initiated activities related to development of

indigenously designed PWRs to meet the country’s

immediate energy demand.

Indian industries have started gearing up to enhance their

capabilities so that heavy forgings and equipment

required for construction of PWRs can be indigenously

manufactured within the Country

CONCLUSIONS

27

The design and development of IPWR plant is a joint

work of a group of engineers and scientists working

in BARC and NPCIL. The authors acknowledge the

efforts put by design and review teams for valuables

contributions.

ACKNOWLEDGEMENT

28

Thank you for your Kind Attention