Experience of fuel operation at Russian NPPs

Experience of fuel operation at Russian NPPs

N.M. Sorokin, Yu.V. Kopyov, V.E. Khlentsevich, А.К. Egorov

N.M. Sorokin, Yu.V. Kopyov, V.E. Khlentsevich, А.К. Egorov

2

Russian NPPsRussian NPPs1010 NPPs, 3131 units, N installed.=2324223242 MW

Beloyarsk NPP

Balakovo NPP

Novovoronezh NPP

Kursk NPP

Kalinin NPP

Kola NPPLeningrad NPP

Smolensk NPP

Bilibino NPP

VVER-1000

VVER-440

BN-600

EGP-6

RBMK-1000

Rostov NPP

3

Output of Russian NPPs in 1992-2015

(considering the activities aimed at output improvement, without grid restrictions for Kola NPP from 01.01.2009,

and both taking into account commissioning of new units and without it)

Output of Russian NPPs in 1992-2015

(considering the activities aimed at output improvement, without grid restrictions for Kola NPP from 01.01.2009,

and both taking into account commissioning of new units and without it)

4

Load factor at Russian NPPs in Load factor at Russian NPPs in 1992-1992-2015 2015

(according to the output forecast)

Load factor at Russian NPPs in Load factor at Russian NPPs in 1992-1992-2015 2015

(according to the output forecast)

5

Total capacity of different type NPP units - 23242 МW

Total capacity of different type NPP units - 23242 МW

9000 МW

2640 МW

11000 МW

600 МW 2 МW

VVER-1000 VVER-440 RBMK-1000 BN-600

6

Annual consumption of fuel assemblies - 4196 pieces

Annual consumption of fuel assemblies - 4196 pieces

411 445

2950

246 144

VVER-1000 VVER-440 RBMK BN-600

7

Annual consumption of the enriched uranium - 605 tons

Annual consumption of the enriched uranium - 605 tons

204,087

54,649332,17

10,003 3,7

VVER-1000 VVER-440 RBMK-1000 BN-600 EGP-6

8

Annual consumption of the natural uranium - 3711 tons

Annual consumption of the natural uranium - 3711 tons

1497,7

367,4

1605,6

214,2 19,7

VVER-1000 VVER-440 RBMK-1000 BN-600 EGP-6

9

Main targets of Rosenergoatom in the area of fuel use

Main targets of Rosenergoatom in the area of fuel use

Enhancement of the fuel operation

reliability and safety

Improvement of the fuel operation

efficiency

Increase of the electricity

generation

Enhancement of the fuel operation

reliability and safety

Improvement of the fuel operation

efficiency

Increase of the electricity

generation

10

Data on the fuel operationData on the fuel operation

1. Monitoring of the operational parameters:Fuel burn-up;Operational life;Integrity of the fuel elements;Deformations of the fuel assemblies;Load cycles.2. Post-reactor studies:Study of the fuel damage causes;Justification of the fuel burn-up

improvement;Justification of the implementation of the

new generation fuel assemblies.

11

Operational life up to 6 years; Average fuel burn-up to 68 MW – day/kg

U; Improved bending rigidity; Operational reliability value ~ 10-6 1/year;

Portable design; Decrease in the number of the distance

lattice; Improvement of the uranium content; Application of the anti-debris filters; Application of the mixing lattice

intensifiers.

Main areas in the fuel improvement for VVER-1000

Main areas in the fuel improvement for VVER-1000

12

Main stages in implementation of new fuel types at VVER-1000Main stages in implementation of new fuel types at VVER-1000

1994 SFA (UGT)1994 SFA (UGT)

1993 Zirconium distance lattices and inserts1993 Zirconium distance lattices and inserts

1998 AFA1998 AFA

2003 FA-22003 FA-2

2006 FA-2М and AFA-ALPHA2006 FA-2М and AFA-ALPHA

13

Modification of main design fuel features for VVER-1000

Modification of main design fuel features for VVER-1000

Design

SFA AFA FA-2 AFА-ALPH

A

FA-2М

Maximum burn-up,

МW·day/kg U49 49 55 55 68 68

Maximum operation life, effective hours

30000 30000 31500 30000 40000 40000

Number of the load cycles 70 70 115 115 115 118

14

Average burn-up of the unloaded fuel at VVER-1000, МW*day/kg UAverage burn-up of the unloaded fuel at VVER-1000, МW*day/kg U

30

32

34

36

38

40

42

44

1990-1991

1992-1993

1994-1995

1996-1997

1998-1999

2000-2001

2002-2003

2004-2005

2006

Growth for 38 %

15

Specific consumption of the natural uranium at VVER-1000, kg

U/МW*day

Specific consumption of the natural uranium at VVER-1000, kg

U/МW*day

0,15

0,16

0,17

0,18

0,19

0,2

0,21

1990-1991

1992-1993

1994-1995

1996-1997

1998-1999

2000-2001

2002-2003

2004-2005

2006

Decrease for 17 %

16

Maximum burn-up of the unloaded fuel at VVER-1000 NPP units, МW*day/kg U

Maximum burn-up of the unloaded fuel at VVER-1000 NPP units, МW*day/kg U

NPP Unit 2004 2005 2006Balakovo NPP

SFA, FA-2

1 44,7 43,9 45,4

2 45,9 49,0 44,4

3 45,0 42,8 45,1

4 45,6 48,6 45,8

Kalinin NPP

AFA

1 55,7 58,6 62,2

2 47,0 47,1 48,1

Rostov NPP

SFA

1 39,9 42,9 44,7

Novovoronezh NPP

«Casing»

5 49,0 - 49,5

17

Maximum operation life of the unloaded fuel, effective hoursMaximum operation life of the unloaded fuel, effective hours

NPP Unit 2004 2005 2006

Balakovo NPP

SFA, FA-2

1 23736 24072 24600

2 29928 29544 24000

3 23232 30528 23592

4 29640 29736 23880

Kalinin NPP

AFA

1 40536 43056 49752

2 28488 29880 30168

Rostov NPP

SFA

1 21762 28752 28344

Novovoronezh NPP

«Casing»

5 25344 - 26808

18

Relative number of the damaged fuel elements unloaded at VVER-1000 NPP

units, 10-5

Relative number of the damaged fuel elements unloaded at VVER-1000 NPP

units, 10-5

3,44,4

12

7,9

10,7

8,5

4

14,5

10,7

7,3

26

6,15,3

2,3

5,4

2,8

0

5

10

15

20

25

Damaged

19

Main areas in the fuel improvement at VVER-440

Main areas in the fuel improvement at VVER-440

Operational life up to 6 years;

Average fuel burn-up to 53 МW·day/kg U;

Improved operational reliability (vibration

resistance bundle, anti-debris lattices, upgraded

conjunction facility);

Portable design;

Application of the zirconium coating with

decrease concentration of hafnium ;

Improvement of water-uranium relation;

Elongation of the pellet active part.

20

Main stages of implementation of the new fuel types at VVER-

440

Main stages of implementation of the new fuel types at VVER-

440

1998 pellets with uranium-hafnium pellets1998 pellets with uranium-hafnium pellets

1995 pellets with enrichment 3,82%1995 pellets with enrichment 3,82%

2000 vibration resistance pellets2000 vibration resistance pellets

2002 pellets of the 2-nd generation2002 pellets of the 2-nd generation

21

Modification of the main fuel design features at VVER-440

Modification of the main fuel design features at VVER-440

Design 4.4% non-

standard

3.82% 4.4% standard with

uranium-

hafnium fuel

Vibration resistance pellets

2-nd generati

on pellets

Maximum burn-up (designed),

МW·day/kg U

28,9 45,4 42,1 48,1 57 57

Maximum burn-up (achieved),

МW·day/kg U

31,5 49,0 45,9 53,4 57 (design) 57(design)

Maximum operation life

3 years 5 years 4 years 5 years 9 years (7 if EP)

44430 effective

hours if EP

Number of the load cycles

30 start-ups,

60 EP

actuations

30 start-ups,

60 EP

actuations

30 start-ups,

60 EP

actuations

30 start-ups,

60 EP

actuations

30 start-ups,

60 EP

actuations

50 start-ups,

100 EP

actuations

22

Average burn-up of the unloaded fuel at VVER-440 (2-nd generation),

МW*day/kg U

Average burn-up of the unloaded fuel at VVER-440 (2-nd generation),

МW*day/kg U

30

32

34

36

38

40

42

44

46

48

1990-1991

1992-1993

1994-1995

1996-1997

1998-1999

2000-2001

2002-2003

2004-2005

2006

Growth for 36 %

23

Specific consumption of the natural uranium at VVER-440 (2-nd generation), kg U

/МW*day

Specific consumption of the natural uranium at VVER-440 (2-nd generation), kg U

/МW*day

0,15

0,16

0,17

0,18

0,19

0,2

1990-1991

1992-1993

1994-1995

1996-1997

1998-1999

2000-2001

2002-2003

2004-2005

2006

Decrease for 17 %

24

Relative number of the damaged fuel elements unloaded at VVER-440,

1-st stage, 10-5

Relative number of the damaged fuel elements unloaded at VVER-440,

1-st stage, 10-5

25

Relative number of the damaged fuel elements unloaded at VVER-440 units, 2-nd

stage, 10-5

Relative number of the damaged fuel elements unloaded at VVER-440 units, 2-nd

stage, 10-5

0 0 0

4,4

8,8

0

17,6

0

15,3

10

16,5

25,1

5,51

36,1

24,1

12

0

5

10

15

20

25

30

35

Damaged

26

Characteristic of fuel reliability by WANO indicator

Characteristic of fuel reliability by WANO indicator

VVER-1000World average

VVER-440 of the 2-nd generation

27

Post-reactor studies of fuel assembliesPost-reactor studies of fuel assembliesType of the fuel

assemblyReactor

typeNumber of

the fuel assemblies

Maximum burn-up,

МWday/kg U

Maximum operation life, effective days

Serial VVER-1000 15 55,55 1268,60

SFA VVER-1000 7 48,50 1212,90

Casing VVER-1000 5 46,80 882,00

AFA VVER-1000 4 55,30 1082,00

RK VVER-440 8 56,50 1872,00

RК with distance lattice

VVER-440 5 38,10 1110,00

ARK with distance lattice

VVER-440 1 50,50 1514,00

Vibropacked FA BN-600 3 10,60 560,00

Serial 2,4 %, 2,6% RBMK-1000 12 31,00 11,6 лет

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CONCLUSIONCONCLUSION

1. Implementation of new fuel designs and fuel cycles improved the efficiency of fuel use at NPPs and allowed to improve load factor.

2. The task of the energy output growth at the existing NPP units will be resolved by reactor thermal power uprating, improvement of the turbine effectiveness and transition to operation with increased inter-outage intervals.

29

Main objective of the coming stage

Main objective of the coming stage

Growth of the electricity generation at the

operating NPP units

30

Organizational and statutory documents on the electricity

generation growth

Organizational and statutory documents on the electricity

generation growth1. Concept of the program on upgrading of the operating

NPPs for the period 2007-2012 approved by S.V. Kirienko, Head of Rosatom;

2. Program of the electricity generation growth at the operation NPPs of Rosenergoatom for 2007-2015 approved by V.V. Travin, Deputy Head of Rosatom;

3. Subprogram of thermal power increase at VVER-1000 units for 4 %;

4. Subprogram of thermal power increase at RBMK-1000 units for 5%.

5. Subprogram of thermal power increase at VVER-440 units for 7 %;

6. Subprogram of transition for 18-months fuel cycle at VVER-1000 units.

31

Main areas in electricity generation growth

Main areas in electricity generation growth

1. NPP power uprating;

2. Implementation of 18-months fuel cycles at VVER-1000 units;

3. Minimization of maintenance outage durations;

4. Increase of inter-maintenance cycles at RBMKs.

32

0,72

1,60

1,74

2,51

3,61

3,78

4,364,43

4,51

Transition to the 18-months fuel cycle at VVER-1000 NPPs

Increase of the thermal power for 5 % at RBMKs, 4 % at VVER-1000, and 7 % at VVER-440

Implementation of the ball cleaning system

SPDS upgrading

Replacement of the turbine diaphragms and blades

TOTAL

Equivalent NPP power uprating, GW

Activities aimed at the NPP power uprating

Activities aimed at the NPP power uprating

33

Schedule of the activities on rated power uprating to 104% at pilot NPP unit

(Balakovo NPP, unit 2)

Schedule of the activities on rated power uprating to 104% at pilot NPP unit

(Balakovo NPP, unit 2)

2009 Commercial operation at 104 %

2008 Pilot operation at 104% with testing performance

2008Upgrading of control, monitoring and protection

systems. Adjustments

2007

Design finalization. Development of the justification documents

(Feasibility study, ecological expertise, license amendments)

2006 Performance of the safety justification activities

2004-2005

Analysis of the possibilities and elaboration of the work program

100%

104%

- completed

34

2011 Transition to the fuel cycle of 480-510 effective days

2010Elongation of the campaign duration to 430-450

effective days

2008Commencement of transition to 18-months fuel cycle

(campaign duration 400 effective days)

2007Development of the safety justification for operation of the unit during 18-months fuel cycle. Elaboration of the

licensing documents

2006Commencement of FA-2M pilot operation

(with the elongated fuel column)

2005 Transition to the fuel cycle of 350-370 effective days

2003Commencement of FA-2 pilot operation

(with rigid frame)10-12 мес.

18 мес.

- completed

Transition to the 18-months fuel cycle of the pilot unit (Balakovo NPP unit 1)

Transition to the 18-months fuel cycle of the pilot unit (Balakovo NPP unit 1)

35

Generalized schedule of the activities on power uprating of VVER-440 to 107%

(Kola NPP unit 4)

Generalized schedule of the activities on power uprating of VVER-440 to 107%

(Kola NPP unit 4)

from 2010Commercial operation of the reactor unit at 107%

power

2009 Pilot operation of the reactor unit at 107% power

Outage-2007,

2008, 2009Upgrading of the unit equipment and systems

2008-2009Development of the justifying and permitting documents (safety case, ecological expertise,

license amendments)

2007-2008Design finalization and performance of the safety

justification activities

2006-2007Analysis of the possibilities and elaboration of the

work program 100%

107%

- completed

36

Generalized schedule of the activities on thermal power uprating of Kursk NPP unit 1

to 105%

Generalized schedule of the activities on thermal power uprating of Kursk NPP unit 1

to 105%

2009 Operation at 105%

2008 Pilot operation at uprated power

2008

Performance of the tests in accordance with the program of gradual unit thermal power uprating with completion of the measurements on justification of the forecast features of the systems and design characteristics of the reactor

installation

2007-2008Elaboration of the justification for licensing of the thermal

power uprating, performance of the technical activities

2005-2006Development of the programs and action plan on thermal

power uprating at RBMK-1000

2004-2005Assessment of possibilities for RBMK-1000 operation at

the uprated power 100%

105%

- completed