1VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
NPP Power Uprate and Modernization
French-Slovak summer schoolKocovce, 13.9 – 17.9 2010
Ing. Branislav Hatala, PhD.
2VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Historical development of nuclear power
3VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Content
Background on Power Uprates
Types of Power Uprates
Mochovce NPP Unit 1&2 Power Uprate
Safety Aspects of Power Uprate
Bohunice NPP Unit 3&4 Modernization + Power Uprate
Discussion
4VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Background on Power Uprates
To increase the power output of a reactor, typically more highly enriched
uranium fuel. This enables the reactor to produce more thermal energy and
therefore more steam, driving a turbine generator to produce electricity.
In order to accomplish this, components such as pipes, valves, pumps, heat
exchangers, electrical transformers and generators, must be able to accommodate the conditions that would exist at the higher power level.
Depending on the desired increase in power level and original equipment
design, this can involve major and costly modifications to the plant such as
the replacement of main turbines.
All of these factors must be analyzed by the licensee as part of a request for a
power uprate, which is accomplished by amending the plant's operating license.
5VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Background on Power Uprates
Power Uprate
Thermal reactor power increase Increase thermal efficiency of Unitupgrade
Secondary Circuit
Electricity part
6VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Types of Power Uprates
Measurement uncertainty recapture power uprates
are less than 2% and are achieved by implementing enhanced techniques for calculating reactor power.
This involves the use of state-of-the-art feedwater flow measurement devices to
more precisely measure feedwater flow, which is used to calculate reactor power.
More precise measurements reduce the degree of uncertainty in the power level, which is used by analysts to predict the ability of the reactor to be safely
shutdown under postulated accident conditions.
7VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Types of Power Uprates
Stretch power uprates
are typically up to 7% and are within the design capacity of the plant
without major plant modifications.
Instrumentation set-points are adjusted to achieve the higher power.
The actual value for percentage increase in power a plant can achieve and stay within the stretch power uprate category is plant-specific and depends on the
operating margins included in the design of a particular plant.
8VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Types of Power Uprates
Extended power uprates
These are characterized by power increases of up to 20% , and involve significant investment into the balance of plant equipment. Large items, such
as turbines, generators and transformers are usually involved in the task.
9VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 Power Uprate
10VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 Power Uprate
Power uprate up to 7%
Reactor thermal power
1375 MW 1471.25 MW
Electric power
440 MW 470 MW
- without hardware changes
- without change of plant design
11VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 - Power Uprate
Power uprate up to 7%
Reactor thermal power 1375 MW 1471.25 MW
Electric power440 MW 470 MW
12VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 - Power Uprate
new type of fuel assemblies (Gd-II) (4.25% / 3.84%)
central tube
4.4% U235
4.0% U235
3.6% U235
4.0% + 3.35% Gd2O3
Enrichment
13VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 - Power Uprate
Thermohydraulics and electrical measurement
Evaluation of mass and energy balance scheme
Evaluation of the report for Ministry of Environmen t
Update of database for safety analysis calculations
Performance of safety analysis calculations
Update of Safety Report
Update of operation procedures
Steps
14VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 - Power Uprate
- performed with the aim to verify turbine margins
- performed for each turbine and generator separately
- maximal required generator gross electrical power 235 MW
- maximum steam flowrate to the turbine
- electrical devices monitoringtemperature of disconnectors coolant temperature of generator coolant temperature of exciter transformer temperature vibration of generator
Thermohydraulics and electrical measurement
15VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 - Power Uprate
- no problem for electric power increase originating from the hardware characteristics.
- limitation is only coolant circulation temperature, which depends on weather conditions such as outside temperature, humidity, wind speed ...
- mass and energy balance scheme was calculated, resulting in the new nominal thermal reactor power
The results of measurements
16VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 - Power Uprate
mass and energy balance scheme 100%T-H PARAMETRE V TEPELNEJ SCHEME I.O BLOKU ***************************************** MIESTO V POPIS MIESTA TEPLOTA TLAK PRIETOK ENTALPIA TEPELNEJ (ST. C) (MPA) (KG/S) (KJ/KG) SCHEME (*M3/H) ====================================================================== /2/ VSTUP DO REAKTORA 267.32 12.641 9245.1 1170.0 *42552. ---------------------------------------------------------------------- /3/ VYSTUP Z REAKTORA 297.88 12.360 9245.1 1329.0 *45908. ---------------------------------------------------------------------- /51/-/56/ VSTUP DO PG 297.88 12.335 1540.9 1329.0 /61/-/66/ VYSTUP Z PG 267.27 12.245 1540.9 1169.7 ---------------------------------------------------------------------- /8/ CELKOM NV DO PG 216.21 4.690 799.66 927.0 /9/ CELKOM PARA Z PG 259.92 4.690 787.66 2792.3 ====================================================================== GLOBALNE PARAMETRE: ******************* TEP.VYKON AZ (MW) 1471.25 * ROZ.TEPLOT V R (ST.C) 30.56 ---------------------------------------------------------------------- PRIKON HCC (MW) 7.48 * ROZ.TLAKOV V R (KPA) 281.4 STRATY I.O ODV.TEPLA (MW) 6.03 * ROZ.TEPLOT V PG (ST.C) 30.61 ---------------------------------------------------------------------- STRATY I.O VYM.CHL. (MW) 0.95 * PRIEM.PRIETOK HCC (M3/H) 7100.2 TEP.VYKON DO II.O (MW) 1471.75 * ROZ.TLAKOV V HCC (KPA) 436.8 ---------------------------------------------------------------------- TEP.VYK. DO ODLUHOV (MW) 2.49 * KONC.ROZ.TEPL.PG (ST.C) 7.35 TEP.VYK. DO PARY (MW) 1469.26 * ROZ.TLAKOV PG-HPK (KPA) 170.3 ----------------------------------------------------------------------
mass and energy balance scheme 107%T-H PARAMETRE V TEPELNEJ SCHEME I.O BLOKU
***************************************** MIESTO V POPIS MIESTA TEPLOTA TLAK PRIETOK ENTALPIA TEPELNEJ (ST. C) (MPA) (KG/S) (KJ/KG) SCHEME (*M3/H) ====================================================================== /2/ VSTUP DO REAKTORA 266.67 12.644 9259.3 1166.7 *42558. ---------------------------------------------------------------------- /3/ VYSTUP Z REAKTORA 295.36 12.360 9259.3 1315.2 *45642. ---------------------------------------------------------------------- /51/-/56/ VSTUP DO PG 295.35 12.335 1543.2 1315.1 /61/-/66/ VYSTUP Z PG 266.61 12.248 1543.2 1166.5 ---------------------------------------------------------------------- /8/ CELKOM NV DO PG 214.53 4.668 737.62 919.3 /9/ CELKOM PARA Z PG 259.62 4.668 733.93 2792.5 ====================================================================== GLOBALNE PARAMETRE: ******************* TEP.VYKON AZ (MW) 1375.00 * ROZ.TEPLOT V R (ST.C) 28.69 ---------------------------------------------------------------------- PRIKON HCC (MW) 7.48 * ROZ.TLAKOV V R (KPA) 283.8 STRATY I.O ODV.TEPLA (MW) 6.04 * ROZ.TEPLOT V PG (ST.C) 28.74 ---------------------------------------------------------------------- STRATY I.O VYM.CHL. (MW) 0.95 * PRIEM.PRIETOK HCC (M3/H) 7101.3 TEP.VYKON DO II.O (MW) 1375.50 * ROZ.TLAKOV V HCC (KPA) 436.5 ---------------------------------------------------------------------- TEP.VYK. DO ODLUHOV (MW) 0.79 * KONC.ROZ.TEPL.PG (ST.C) 6.99 TEP.VYK. DO PARY (MW) 1374.71 * ROZ.TLAKOV PG-HPK (KPA) 147.7 ----------------------------------------------------------------------
17VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 - Power Uprate
440
445
450
455
460
465
470
475
14 16 18 20 22 24 26 28 30 32
Cooling Water Temperature [°C]
Gro
ss E
lect
ric P
ower
[M
W]
94.8
96.8
98.8
100.8
102.8
104.8
106.8
108.8
The
rmal
Rea
ctor
Pow
er [
%]
Gross Electric Power Thermal Reactor Power
Prediction of gross electric power
18VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Mochovce NPP Unit 1&2 - Power UprateMonthly Temperatures of Cooling Water form Cooling Towers
0
5
10
15
20
25
30
January February March April May Jun July August September October November December
Tem
pera
ture
[°C
]
Year 2004 Year 2005 Year 2006
21.8 °C
19VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Nuclear Safety Aspects of Power Uprate
Licensing documentations
Update of Safety Analysis Report
Update of operation procedures
Definition of setpoints of safety and control systems
Documentation for Ministry of environment
20VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Nuclear Safety Aspects of Power Uprate
21VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Nuclear Safety Aspects of Power Uprate
In order to protect the public in case of an accident, we need to:
1. Shut down the reactor and keep it shut down
2. Keep the reactor cool after it's shut down
3. Contain the reactor coolant
Barriers
1. Fuel matrix
2. Fuel cladding
3. Primary circuit
4. Confinement
22VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Nuclear Safety Aspects of Power Uprate
Reactor core power distribution
1
4. SKUPINA (1,4 ; MAX>
3. SKUPINA (1,2 ; 1,4>
2. SKUPINA (1,0 ; 1,2>
1. SKUPINA (1,0 ; 1,0>
Relatívny výkon prútikov
Fuel assembly power distribution
1
Relatívny výkon prútikov
23VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Nuclear Safety Aspects of Power Uprate
Thermal power 1375 MW 1471 MW
Uncertainty 4% 2%
Fuel type Gd-2 Gd-2
Pellet power limit 325 W/cm 325 W/cm
Rod power limit 56.6 kW 56.6 kW
Average rod power 31.6 kW 33.45 kW
Average assembly power 3.9 MW 4.2 MW
Reactor overflow 42300m3/h 42300m3/h
Hot channel output 321 °C 321 °C
Assemblies output 312 °C 314 °C
∆T on reactor 28.9 °C 30.8 °C
24VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Nuclear Safety Aspects of Power Uprate
Schema of NPP VVER-440Break location and ECCS availability
25VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Calculation result of LOCA Max. Cladding Temperature
0
200
400
600
800
1000
1200
-50 0 50 100 150 200 250 300 350 400 450
Time [s]
Tem
pera
ture
[°C
]
VUJE, a.s. RELAP5x
•997 °C -Power uprate 107 % (1471 MW)
•989 °C -Power 100 % (1375 MW)
26VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Calculation result of LOCA Max. Cladding Temperature
900
920
940
960
980
1000
1020
200 210 220 230 240 250 260 270 280 290 300
Time [s]
Tem
pera
ture
[°C
]
VUJE, a.s. RELAP5x
•997 °C -Power uprate 107 % (1471 MW)
•989 °C -Power 100 % (1375 MW)
27VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Calculation result of LOCA Max. Cladding Temperature
•1200 °C Safety Limit - Regulatory acceptance cri teria
•997 °C Power uprate 107 % (1471 MW)
•989 °C Power 100 % (1375 MW)
•203 °C
•211 °C
•Safety margin
28VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Bohunice NPP Unit 3&4
Modernization
Power Uprate
29VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Bohunice NPP Unit 3&4 – Modernization + Power Uprate
Bohunice NPP unit 3&4 – Modernization
Thermal reactor power increase 107%
Increase thermal efficiency of Unit.
new Low Pressure Turbine Rotors
new High Pressure Turbine Rotors
new Steam Condenser
innovation of Steam flow Measuring Orifices, other minor changes
30VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Bohunice NPP Unit 3&4 Modernization + Power Uprate
Reactor thermal power 107%
1375 MW 1471.25 MW
Electric power 113%
440 MW 500 MW
- hardware changes on secondary circuit
31VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Bohunice NPP Unit 3&4 Modernization
Objectives
Safety
Requirements of regulatory bodies IAEA recommendationsNew knowledge and experience of the plant operatorReplacement of the obsolete part by the up to date technique
Reliability
To eliminate unplanned losses in power generation and electricity supply by equipment modernization (replacement obsolete equipment by state of the art technique)
Economy
To establish prerequisites for life extension and power upratingTo include units into the mode of secondary grid control
32VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Bohunice NPP Unit 3&4 Modernization
Scope of technical activities in the project V2 Mod ernization
I&C part –the most important part of Modernization
Modernization of the Reactor Protection System (RPS)
Modernization of the Reactor Limitation System (RLS)
Installation of the Post-Accident Monitoring System(PAMS)
Modernization of information systems
Neutron flux measurement
Reactor power control system
33VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Bohunice NPP Unit 3&4 Modernization
Scope of technical activities in the project V2 Mod ernization
Electric part
Modernization of the essential power supply, category II (DG start and excitation, 0.4 kV buses, 6 kV buses)
Replacement of 400 kV switches, electrical penetrations
Stand by power supply from Madunice hydro power plant
34VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Bohunice NPP Unit 3&4 Modernization
Scope of technical activities in the project V2 Mod ernization
Machinery part
Emergency core cooling and residual heat removal system
Pressurizer-B&F mode, qualification of safety valves
Essential service water system modification
Steam dump relief valves (PSA)
Ventilation and air conditioning systems
Emergency feedwater system
35VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Conclusion
Types of Power Uprates
Mochovce NPP Unit 1&2 Power Uprate
Safety Aspects of Power Uprate
Bohunice NPP Unit 3&4 Modernization + Power Uprate
36
Approved (126 NPPs)
Pending (16 NPPs)
VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
USA Uprate Programme
TYPE NPPs Uprate [%] MWtMU 44 0.4-1.7 13-65
S 65 0.9-7.0 24-239
E 20 6.3-20.0 105-579
TYPE NPP’s Uprate [%] MWtMU 8 1.6 27-57
E 8 11.9-17.0 229-521
17 179 MWt5 796 MWe
3 436 MWt1 145 MWe
Expected in 2010 – 2014 (40 NPPs)
TYPE NPP’sMU 22S 1E 17
7 198 MWt2 399 MWe
37VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Russian Uprate Programme
Russia's nuclear plants are nowadays operating with 31 reactors generating totally 21,743 MWe. An initial proposal for a rapid expansion of nuclear capacity was based on the cost effectiveness of completing the 9 GWe of then partially
built plant. Most reactors are being uprated.
During 2010 the uprating program is expected to be completed for all VVER units except Novovoronezh 5: 4% for VVER-1000, 5% for VVER-440. Mass and
energy balance scheme was calculated, resulting in the new nominal thermal reactor power.
All RBMKs will be uprated 5% by 2013, except Leningrad 1. A major contract for upgrading Leningrad unit 4 over 2008-11 is under way, as is that for Kursk 4.
Kursk 2 & 3 with Smolensk 3 will soon follow. Kursk 1 was the first RBMK unit to be licensed for pilot operation with 5% uprate. The R&D Institute of Power
Engineering was preparing plans for 5% uprating of the later Leningrad, Kursk and Smolensk units.
Rosenergoatom is investigating further uprates of VVER-1000 units to 107 or 110% of original capacity, using Balakovo 4 as a pilot plant by 2014. This could
then be extended to other Balakovo units, then Rostov and Kalinin.
38VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Finnish Uprate Programme
Olkiluoto 1&2 (BWR)
- Started up 1978 – 1980.
- Designed electrical power – 658 MWe (net).
- First power uprated after 30y – 860 MWe (net).
- Proposes to uprate to ~ 1000 MWe.
- As a part of this, 25 MWe PU has already been done (unit 1).
Loviisa 1&2 (PWR)
- Started up 1977 – 1980.
- Designed electrical power – 445 MWe (net).
- Already uprated to 488 MWe (net).
39VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Swedish Uprate Programme
From 2004 – ongoing:
-Ringhals 1–4: more than 400 MWe (further uprate envisaged).
-Forsmark 1–3: ~ 370 MWe (about 190 MWe further assumption).
-Oskarshamn 1–3: ~ 320 MWe (500 MWe completely in 2013).
Spain Uprate Programme
Notable for power plants uprates – a programme to add 810 MWe (11%) to its nuclear capacity through upgrading its reactors by up to 13%.
For instance: Almaraz NPP – +5%.
Cofrentes NPP – uprated 4x to today’s 112%, final 120% expected.
40VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
NPP Paks Uprate Programme
- Four type VVER–440/213 units, installed between 1984–1987.
- Total safety evaluation of the units (Project AGNES) –accomplished in 1994.
- Over 1996–2002 – a Programme of Safety Measurements.
- Reconstruction of the secondary loop and replacements of the turbines increased electric power to 470 MWe gross.
- By increasing the heat power of the reactor (2009) – 500 MWegross output (1485 MWt).
Technical conditions, modifications needed:
New fuel introduction
Primary loop pressure controller reconstruction
Core Control Systemreconstruction
Reactor Defence System modification
Modification of the parameters of the
hydro-accumulators
Main circulator pumps (Unit 2) modification
Modification of turbines
Increasing the concentration of boric
acid in the failure systems
41VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
France Uprate Programme
In the light of operating experience, EdF uprated its four Chooz and Civaux N4 reactors from 1455 to 1500 MWe each in 2003. Over 2008-10 EdF plans to
uprate five of its 900 MWe reactors by 3%. Then in 2007 EdF announced that the twenty 1300 MWe reactors would be uprated some 7% from 2015, within
existing licence limits, and adding about 15 TWh/yr to output.
Czech Uprate Programme
- Program to boost Dukovany's gross output by 240 MWe by 2012.
- Four Dukovany units were uprated from 440 to 456 MWe gross 2005-2008 by replacing low-pressure turbines, two of them have been running at 462 MWe.
- A 38 MWe uprate of unit 3 was announced in May 2009 – bringing its total gross capacity to 500 MWe – from improved fuel, replacing the high-pressure turbine, refurbishing the generator, and I&C changes.
- Temelin 1 & 2, each performing at 994 MWe, Skoda Power modified the high pressure turbines (2004-2007) to achieve 1013 MWe gross, 963 MWe net. A further upgrade since is expected to result in 1050 MWe gross.
42VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
Belgian Uprate Programme
STATION NAME
TYPEDESIGNED
POWER (MWt )UPRATED POWER
(MWe ) netUPRATE TYPE &
POWER INCREASEDoel 2 PWR 1 192 1 311 E 10%Doel 3 PWR 2 785 3 064 E 10%
Tihange 1 PWR 2 665 2 875 E 8%Tihange 2 PWR 2 785 2 905->3 064 S/E 4.3%/10%
* till 2007
German Uprate Programme
* till 2007
STATION NAME
TYPEDESIGNED
POWER (MWt )UPRATED POWER
(MWe ) netUPRATE TYPE &
POWER INCREASEEmsland PWR 3 765 3 850 S 2.3% Grohnde PWR 3 765 3 850 S 2.3%
Isar 2 PWR 3 765 3 850->3 950 S/S 2.3%/4.9% Neckar 2 PWR 3 765 3 850->3 965 S/S 2.3%/5.3%
Phillipsburg 2 PWR 3 765 3 803->3 850->3 950 MU/S/S 1%/2.3%/4.9% Unterwesier PWR 3 733 3 900 S 4.5%
43VÚJE, Inc., Okružná 5, 918 64 Trnava, Slovak Republic
43
• Thank you for your attention.