PWR Description Jacopo Buongiorno Associate Professor of Nuclear Science and Engineering
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1 PWR Description Jacopo Buongiorno Associate Professor of Nuclear Science and Engineering 22.06: Engineering of Nuclear Systems
2 Pressurized Water Reactor (PWR) Public domain image from wikipedia.
3 SCHEMATIC OF A PWR POWER PLANT Major PWR vendors include Westinghouse, Areva and Mitsubishi source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
4 PWR Coolant Circuits INDIRECT CYCLE: Primary and Secondary Coolant Loops Single Phase (Liquid) Reactor Coolant [T in =287.7 C, T out =324 C, P=15.2 MPa, T sat = C] Two-Phase (Steam-Water) Power Conversion Cycle Loop [T SG,in =227 C, T SG,out =285 C, P=6.9 MPa, T sat =285 C] [ ] [T Condenser = 37.8 C, P=6.6 kpa] Condenser
5 Phase Diagram of Water Pressure [MPa] Saturation line PWR primary system PWR secondary system Liquid Condenser Vapor Temperature [ C]
6 PWR Vessel, Core and Primary System
7 ARRANGEMENT OF THE PRIMARY SYSTEM FOR A WESTINGHOUSE 4-LOOP PWR A.V. Nero, Jr., A Guidebook to Nuclear Reactors, 1979 University of CA press. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
8 FLOW PATH WITHIN REACTOR VESSEL CR guide tubes Upper support plate Barrel flange Water in at 288 C Hot nozzle Water out at 324 C Cold nozzle Top of active fuel Core Bottom of active fuel Lower core plate
9 REACTOR VESSEL AND INTERNALS Pictures from: M. Kanda, Improvement in US-APWR design from lessons learned in Japanese PWRs.ICAPP-07. May 2007 (top), and EPR brochure available at (bottom two) Public domain image from Wikipedia. source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
10 TYPICAL 4-LOOP REACTOR VESSEL PARAMETERS Overall length of assembled vessel, closure head, and nozzles Inside diameter of shell Radius from center of vessel to nozzle face Inlet Outlet Nominal cladding thickness Minimum cladding thickness m 439m m 3.12 m 5.56 mm 3.18 mm Coolant volume with core and internals in place m 3 Operating pressure Design pressure Design temperature Vessel material Cladding material Sta Number of vessel material surveillance capsules, total MPa MPa C Carbon steel inless steel
11 TYPICAL 4-LOOP CORE Image by MIT OpenCourseWare. Masche, G., Systems Summary: W PWR NPP, 1971
12 Geometry of the fuel Image by MIT OpenCourseWare. source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see Image by MIT OpenCourseWare. Cross Section of a Representative Fuel Pin (not drawn to scale) mm (in.) BWR PWR 2r o (0.409) 8.20 (0.323) 2r co (0.483) 9.50 (0.374) t (0.032) 0.57 (0.023)
13 Why the fuel/clad gap? Provides clearance for fuel pellet insertion during fabrication Accommodates fuel swelling without breaking the clad Filled with helium gas Example of a Cracked Fuel Cross Section Source: Todreas & Kazimi, Vol. I, p Taylor & Francis. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
14 TYPICAL FUEL ROD PARAMETERS Outside diameter Cladding thickness Diametral gap Pellet diameter Pitch Rods array in assembly Fuel rods per assembly 9.50 mm 0.57 mm mm 8.19 mm 12.6 cm 17x Total number of fuel rods in core 50,952
15 CUTAWAY OF TYPICAL ROD CLUSTER CONTROL ASSEMBLY (RCCA) Masche, G., Systems Summary: W PWR NPP, 1971 From: EPR brochure. Available at source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
16 PWR Control Rod ( Westinghouse RCCA) Made of ( black rods for scram) or Inconel ( gray rods for fine tuning) Public domain image from wikipedia. Control rod guide tube (24) Instrument thimble source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
17 Other means to control reactivity in PWRs Boron (boric acid, H 3 BO 3 ) dissolved in coolant. Compensates for loss of reactivity due to fuel burnup. High concentration at BOC (beginning of cycle), progressively decreased to zero at EOC (end of cycle) Pros: uniform absorption throughout core, concentration is easily controlled Cons: makes coolant slightly acidic (requires addition of other chemicals to reequilibrate ph), can deposit (come out of solution) as crud on fuel rods, can make moderator reactivity feedback positive at high concentration 8000 Core critical boron concentration (ppm) Exposure (GWD/MTU) Enrichment = 5 W / 0 U235 Enrichment = 6 W / 0 U235 Enrichment = 7 W / 0 U235 Image by MIT OpenCourseWare.
18 Other means to control reactivity in PWRs (2) Burnable absorbers ( poisons ) loaded in fuel. Gd (Gd 2 O 3 )has higher a than 235 U, thus it burns faster than fuel, which tends to increase k eff over time. Pros: no impact on coolant corrosion or moderator reactivity feedback Cons: lowers melting point and thermal conductivity of UO 2, cannot burn out completely by EOC k Assembly exposure (GWD/MTU) No Poison 24 BA Pins 32 BA Pins 36 BA Pins 40 BA Pins 44 BA Pins Image by MIT OpenCourseWare.
19 PWR GRID SPACERS From: Mitsubishi US-APWR Fuel and core design. DOE Technical session UAP-HF June 29, Masche, G., Systems Summary: W PWR NPP, 1971 Hold fuel rods in place prevent excessive vibrations Have mixing vanes enhance coolant mixing and heat transfer source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
20 Connection of PWR Core Design to Neutronics Why is Zr used as structural material in fuel assemblies? What functions does water perform? What determines the fuel rod spacing? Why are the fuel rods so small? Why are the control rods arranged in clusters? Why is boron dissolved in the coolant? What is Gd used for?
21 PWR Bundle Design Advances Extended burnup features Advanced cladding (ZIRLO, M5) Annular blankets Larger gas plena Improved mechanical performance Improved debris filters Low growth, wear-resistant materials Improved economic and operational performance Natural uranium blankets Flow mixing grids to enhance margin to DNB Reduced O&M costs Low cobalt steel alloys to reduce exposure Reduced inspection requirements source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
22 REPRESENTATIVE CHARACTERISTICS OF PWRs Parameter 4-loop PWR Parameter 4-loop PWR 1. Plant 5. Fuel Assembiles Number of primary loops 4 Number of assemblies 193 Reactor thermal power (MWth) 3411 Number of heated rods per assembly 264 Total plant thermal efficiency (%) Plant electrical output Power generated directly in coolant (%) Power generated in the fuel (%) 2. Core Core barrel inside diameter/outside diameter (m) Rated power density (kw/l) Core volume (m 3 ) Effective core flow area (m 2 ) Active heat transfer surface area (m 2 ) Average heat flux (kw/m 2 ) Design axial enthalpy rise peaking factor (F h ) Allowable core total peaking factor (F Q ) 3. Primary Coolant System pressure (MPa) / Fuel rod pitch (mm) Fuel assembly pitch (mm) Number of grids per assembly Fuel assembly effective flow area (m 2 ) Location of first spacer grid above beginning of heated length (m) Grid spacing (m) Grid type Number of control rod thimbles per assembly Number of instrument tubes Guide tube outer diameter (mm) 6. Rod Cluster Control Assemblies Neutron absorbing material Cladding material L-grid * Ag-In-Cd Type 304 SS Core inlet temperature ( o C) Cladding thickness (mm) 0.46 Average temperature rise in reactor ( o C) Total core flow rate (Mg/s) Effective core flow rate for heat removal (Mg/s) Average core inlet mass flux (kg/m 2 -s) ,729 Number of clusters Full/Part length Number of absorber rods per cluster *Employs mixing vanes 53/ Fuel Rods Total number Fuel density (% of theoretical) Fuel pellet diameter (mm) Fuel rod diameter (mm) Cladding thickness (mm) Cladding material Active fuel height (m) 50, Zircaloy Image by MIT OpenCourseWare. A.V. Nero, Jr., A Guidebook to Nuclear Reactors, 1979.
23 PWR PRESSURIZER Pressurizer (Saturated Liquid-Steam System: P=15.5 MPa, T=344.7 C) Controls pressure in the primary system Liquid Spray From cold leg Steam 2 m - Pressure can be raised by heating water (electrically) Electric heaters Liquid - Pressure can be lowered by condensing steam (on sprayed droplets) Surge Line Hot leg
24 PRESSURIZER TYPICAL DESIGN DATA Number and type Overall height Overall diameter Water volume Steam volume Design pressure Design temperature Type of heaters Number of heaters Installed heater power Number of relief valves Number of safety valves Spray rate Pressure transient Continuous Shell material Dry weight Normal operating weight Flooded weight (21.1 o C) 1 Two-phase water and steam pressurizer m 2.35 m cu m cu m 17.2 MPa 360 o C Electric immersion kw 2 Power-operated 3 Self-actuating 3028 L/m 3.79 L/m Mn-Mo steel, clad internally with stainless steel 106,594 kg 125, 191 kg 157,542 kg Image by MIT OpenCourseWare. Masche, G., Systems Summary: W PWR NPP, 1971
25 Reactor Coolant Pumps - Large centrifugal pumps - Utilize controlled leakage shaft seal - Have large flywheel to ensure slow coast-down upon loss of electric power to the motor
26 PWR Secondary System
27 PWR STEAM GENERATORS Primary side, Hot (T in = 324 C, T out = 288 C): High Pressure Liquid Secondary side, Cold (T sat = 285 C): Lower Pressure Steam and Liquid Water Boils on Shell Side of Heat E changer - Water Boils on Shell Side of Heat Exchanger - Steam Passes through Liquid Separators, Steam Dryers - Liquid Water Naturally Recirculates via Downcomer - Level Controlled via Steam and Feedwater Flowrates
28 U-TUBE STEAM GENERATOR source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see From: EPR bro chure. Available at
29 ONCE-THROUGH NUCLEAR STEAM GENERATOR Used only in old B&W plants B&W, Steam, Its Generation & Use, source unknown. All rights reserved. This content is excluded from our Creative Commons license. For more information, see Babcock & Wilcox. All rights reserved. This content is excluded from our Creative Commons license. For more information, see
30 TYPICAL DESIGN DATA FOR STEAM GENERATORS Number and type Height overall Upper shell OD Lower shell OD Operating pressure, tube side Design pressure, tube side Design temperature, tube side Full load pressure, shell side Maximum moisture at outlet (full load) Design pressure, shell side Reactor coolant flow rate Reactor coolant inlet temperature Reactor coolant outlet temperature Shell material Channel head material Tube sheet material Tube material Tube OD Average tube wall thickness Steam generator weights Dry weight, in place Normal operating weight, in place Flooded weight (cold) 4 Vertical, U-tube steam generators with integral steam-drum m 4.48 m 2.44 m 15.5 MPa 17.2 MPa o C 6.90 MPa 0.25% 8.27 MPa 4360 kg/s o C o C Mn-Mo steel Carbon steel clad internally with stainless steel Mo-Cr-Ni steel clad with Inconel on primary face Inconel 2.22 cm 1.27 mm 312,208 kg 376,028 kg 509,384 kg Image by MIT OpenCourseWare. Masche, G., Systems Summary: W PWR NPP, 1971
31 PWR power cycle (secondary s ystem) Reactor 5 3 W (1- f )m g T1 6 m p b a Steam Generator W P2 m s 2 High Pressure Turbine Boiler Feedwater Pump m s 11 Low Pressure Turbine 9 Moisture 4 Separator 10 m f 12 OFWH Turbine Low Steam Pressure Requires: Large turbine Lower rotational speed (1800 RPM) 13 Main Condensate Pump 1 W T2 Condenser fm g 8 Condenser Steam Side at Low Pressure Cooling water from sea, river or cooling tower W P1 7
32 PWR safety systems and containment to be discussed later in the course
33 MIT OpenCourseWare Engineering of Nuclear Systems Fall 2010 For information about citing these materials or our Terms of Use, visit:
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