Part - I (General) : Rajasthan Atomic Power Station
Part - I (General) : Rajasthan Atomic Power Station
Part - I (General) : Rajasthan Atomic Power Station
INTRODUCTION:
The land selected is in between Rana Pratap Sagar Dam &Gandhi Sagar
Dam at the right bank of Chambal River. The water from the reservoir of the
Rana Pratap Sagar Dam serves the requirements of the Nuclear Power
Plants.
There are four PHWR units of 100X1,200X1,220X2 MWe and two units of
235 MW newly constructed which feed the Northern Grid as abase load
station. There is lush greenery around the site. For employees various
colonies are constructed with all the domestic facilities.
Sr90
1 U235 U236
n
γ - Ray
In the above equation, (1) the total mass before fission, is the sum of the masses
n 1 of U235 and the
neutrons. Mass after fission is the sum of fission fragmentsXe and14neutrons.
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Since loss of mass of 1 a.m.u is equivalent to an energy release of 931 MeV. Therefore energy
release in the above RELEASE
ENERGY reaction could beDURING
calculated asFISSION:
follows. Since
In the above equation, the total mass before fission is the sum of the
masses of U235 and the neutrons. Mass after fission is the sum of fission
fragments and neutrons.
2
Since loss of mass of 1 a.m.u is equivalent to an energy release of 931
MeV. Therefore energy release in the above reaction could be calculated
as follows. Since
PHWRs have established over the years a record for dependability, with
load factors in excess of 90% over extended periods. In the PHWR, the
heavy water moderator is contained in a large stainless steel tank
(calandria) through which runs several hundred horizontal zircalloy
calandria tubes. The D2O moderator is maintained at atmospheric
pressure and a temperature of about 70°C. Concentric with the calandria
tube, but separated by a carbon dioxide filled annulus which minimizes
heat transfer from fuel to the moderator, is the zircaloy pressure tube
containing the natural UO2 fuel assemblies and the heavy water coolant
at a pressure of about 80 kg/cm² and a temperature of about 300°C.
The term pressurized refers to the pressurized D2O coolant which flows in
opposite directions in adjacent tubes and passes its heat to the
secondary coolant via the steam generators. System pressure is
maintained by a pressurizing one of the legs of a steam generator.
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REACTOR BUILDING
Following are the parts of reactor building:
1. Calandria 8. Dump Tank
REACTOR:
Reactor is the place where actual nuclear fission takes place. The
building that houses reactor and other accessories is called Reactor
Building. Following are the ingredients of Reactor Building:-
CALANDRIA:
It is a huge cylindrical structure which houses bundles. The specifications
regarding 200 MWe reactors calandria are:-
Weight - 22tons
Length - 4645 mm
Main Shield I.D - 5996 mm
Small Shell I.D. - 4928 mm
Thickness of Shell - 25 mm
CONTROL RODS:
The control rods contain material that regulates the rate of the chain
reaction. If they are pulled out of the core, the reaction speeds up. If they
are inserted, the reaction slows down.
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purposes such as cobalt therapy etc.
FUELLING MACHINE:
Reactor fuel is moved into and out of reactor by a pair of fuelling
machines that is clamped to channels on north and south ends of the
reactor. It consists of Head, which contains positioning the mechanisms
for manipulating the fuel, a carriage for Head in line with any desired fuel
channel, and numerous houses and cables, which supplies fluid and
electrical services. A ram and associated mechanism is provided for
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pushing reactor fuel and handling plugs in the reactor channels. The ram
is operated by the hydraulic pressure of Heavy water. The fuelling
machine is left in the vault when not in the use, unless maintenance
operations are required on it.
The various plugs and fuel handled by the fueling machines are stored in
the various chambers of the rotary magazine. The magazine has twelve
chambers. Refuelling can be done in a number of channels during one
refuelling session.
HEAT EXCHANGER:
Tube-and-shell type heat exchangers are suitable in this type of system.
The U type heat exchanger, shown in Fig simplifies expansion problems
and reduces the number of tube sheet joints. Heavy water hold-up is
reduced by passing the heavy water through the tubes and the cooling
water on the shell side.
HEAT EXCHANGER
MODERATOR SYSTEM:
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The following are the parts of moderator system-
MODERATOR SYSTEM
NUCLEAR FUEL:
The fuel used in a PHWR type reactor is sintered natural uranium di-
oxide in the form of small pellets. These pellets are kept in the zircalloy
tubes and are 24 per tube. The tubes are known as pencils and 19
pencils make a complete fuel bundle. The pencils are held between end
plates and zircalloy provide spacing between the tubes and zircalloy pads
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provide bearing action. This help mixing of the coolant flow with the sub
channels between the elements.
FUEL BUNDLE
COOLING TOWERS:
Mainly there are two types of cooling towers:-
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STEAM TURBINE:
It is a rotating machine in which heat energy of steam is converted into
mechanical energy. The steam is caused to fall in pressure in a passage
or nozzle; due to this fall in pressure a certain amount of heat energy is
converted into mechanical kinetic energy, and the steam is set moving
with a greater velocity. The rapidly moving particles of steam enter the
moving part of the turbine and here suffer a change in direction of motion
which gives rise to a change in momentum and thus to a force. This
constitutes the driving force of the machine.
ZONE CLASSIFICATION:
Depending on contamination level the entire plant is divided into four
zones. This classification is as follows:
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RADIOACTIVE WASTE MANAGEMENT:
SAFETY:
INDUSTRIAL SAFETY:
We mean that the measures adopted as a whole in industry to reduce
accidents to bare minimum.
CAUSES OF ACCIDENTS:
Hazards are the risks and perils or dangers that
contribute to accidents and injuries.
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KINDS OF HAZARDS:
• Fire
• Heat
• Material Handling
• Floors
• Ladders
• Tools
• Machinery
• Walking and Working surfaces
• Process
• Chemicals
• Electricity
• Unsafe Act
• Unsafe Condition
RADIATION SAFETY:
Radiation in Nuclear reactor is produced in following ways :
• Directly in fission reaction
• By decay of fission products
The following reaction shows the emissions of Alpha, Beta, Gamma and
Neutron.
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U238 → 2He4 → 92U234 +
92 (alpha)
It has very low penetrating power and can be stopped by simple paper.
It also does not have good penetrating power and in human skin it can
penetrate up to about half mm. It can be very easily shielded
COBALT-60 DATA
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§Radiation field at 1 mtr from 1 Ci : 1.35 R/hr
PART- II (PROJECT)
INTRODUCTION TO PLC
Many PLC configurations are available even from a single vendor. But, in
each of these, there are common components and concepts. The most
essential components are: power supply – this can be built into the PLC
or be an external unit. Common voltage levels required by the PLC (with
and without the power supply) are 24 Vdc, 120Vac, 220Vac, CPU (central
processing unit)- this is a computer where ladder logic is stored and
processed. I/O (input/output) – a number of input / output terminals must
be provided so that the PLC can monitor the process and initiate actions .
Indicator lights – these indicate the status of the PLC including power on ,
program running , and a fault . These are essential during diagnosing
problems. The configurations of the PLC refers to the packaging of the
components typical configurations are listed below from largest to
smallest as shown in figure 3.1. Rack – a rack is often large (up to 18’’by
10’’) and can hold multiple cards .When necessary, multiple racks can be
connected together . These tend to be of the highest cost , but also the
most flexible and easy to maintain . Mini – these are similar in functions to
PLC racks , but about half the size shoebox – a compact , all –in-one unit
(about the size of a shoebox) that has limited expansion capabilities.
Lower cost and compactness make these ideal for small applications.
Macro – these units can be as small as a deck of cards. They tend to
have fixed quantities of I/O and limited abilities, but cost will be the
lowest. Software – software based PLC requires a computer with an
interface card, but allows the PLC to be connected to sensors and other
PLCs across a network.
EVOLUTION OF PLC:
In the late 1960’s the need to design more reliable and more flexible
control system became apparent e.g the automotive industry was
spending millions of dollars for rewiring control panels in order to make
relatively minor chamges at the time of yearly model changeover. In 1968
a team of automotive engineers wrote a specification for what they called
a ‘Programmable Logic Controller’. What they specifies was a solid steate
replacement for the relay logic. Istead of wires there would be bits,instead
of the wiring of the circuit the logic was dictated by the memory circuit.The
machines would use solid state outputs and n inputs instead of control
relays to control the motor starters and sense push buttons and limit
switches. The first commercially successful programmable controller was
introduced in 1969 by a firm called Bedford Associates (Modicon) and
delivered to the General Motors Hydromantic Division. By today standard
it was a massive machine containing thousand of electronic parts. It
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should be stressed that this machine was designed at a time long before
the availability of microprocessors. In the late 1970 the microprocessor
became the reality and greatly enhanced the role of the programmable
controllers permitting it to evolve from simply replacing relys to the
sophisticated control system component that it has become today.
ADVANTAGES OF PLC:
• Enhanced reliability
• On-line fault diagnostic capabilities
• Interactive operative interface
• Flexibility while setting and changing the logic during
commissioning and operation
• Online repair facility
• I/O forcing through software
Plc (Programmable Logic controller) DL-06
LADDER LOGIC:
Ladder logic is the main programming method used for PLSs. As
mentioned before, ladder logic has been developed to mimic relay logic.
By selecting ladder logic as the main programming method, the amount of
retraining needed for engineers and trades people was greatly reduced.
Modern control systems steel includes relays, but these are rarely used
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for logic. A relay is a simple device that uses a magnetic field to control a
switch as pictured in figure given below. When a voltage is applied to
input coil, the resulting current creates a magnetic field. The magnetic
field pulls a metal switch (or reed) towards it and contacts touch, closing
the switch. The contact that closes when the coil is energized is called
normally open. The normally closed contact touches when the input coil is
not energized. Relays are normally drawn in schematic form using a circle
to represent the input coil. The output contacts are represented with two
parallel lines. Normally open contacts are shown as two lines and will be
open (non – conducting) when the input is not energized. Normally closed
contacts are shown with two lines with a diagonal line through them.
When the input coil is not energized the normally closed contacts will
remain closed (conducting)
Normally open; an active input X will close the contact and allow the
power to flow.
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Normally closed: power flows when the input X is not open.
Immediate inputs will take current values, not those from the previous
inputs scan.(Note: this instruction is actually an output that will update the
input the input table with the current input values. Other output contacts
can now be used to examine the new values.)
3. One shot relay (OSR): When initially energized the OSR instruction
will turn ON for one scan but then be turned OFF for all the later
scans.
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4. Latch and Unlatch: These instructions can be used to lock the ON
outputs. When a L output is energized, the output will turn ON
indefinitely even when output coil is de-energized. The output can
only be turned OFF using a U output. This like a flip-flop and stays
set even when the PLC is turned off.
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• As only plug-in cards are used, easy and fast maintenance is
possible.
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110/220 V AC
Power (+10%, -15%), 50- 12/24V DC
60 Hz
Input Voltage Range 95-240 V AC 12-24V DC
Maximum Power 30VA (DL05) 40VA 20W
(DL06)
Maximum Inrush Current 13 A, 1 ms 10A, < 1ms
(240V AC)
Storage Temperature -4Deg.F to 158
Deg.F (-20Deg. to
70Deg. C)
Ambient Operating Temp. 32Deg.F to
131Deg.F(0Deg. to
55Deg.C)
Ambient Humidity 5% - 95% Relative
Humidity(Non-
condensing)
Vibration Resistance MIL STD 810C,
Method 514.2
Shock Resistance MIL STD 810C,
Method 516.2
Noise Immunity NEMA(ICS3-304)
Atmosphere No corrosive gases
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DV-1000 Data Access Unit, EZ Touch, EZ Text, Direct
Touch, DS Data.
INTRODUCTION:
Heat generated in nuclear reactor due to fission of natural uranium is
carried away by Primary Heat Transport System (PHT) fluid to steam
generators. PHT fluid transfers its heat to feed water to process saturated
steam in SGs. This steam is expanded in turbine to produce shaft work to
drive generator. Steam after expansion in turbine is condensed in
condenser at constant pressure. This condensed steam is transferred to
steam generators through various heaters by Condensate Extraction
Pumps (CEPs) and Boiler Feed Pumps (BFPs). This system describing
the transfer of condensed steam in condenser to SG is called condensate
and feed water cycle.
REQUIREMENT OF CONDENSOR:
• To reduce the steam exhaust pressure from last stage of Turbine
so as to increase specific output of turbine (i.e. work produced
from turbine with one unit heat addition to feed water in SG). If the
circulating cooling water temperature in condenser is low enough
(as per design) it creates a low back pressure (vacuum) for the
turbine. This back pressure is equal to saturation pressure
corresponding to condensing steam temperature which is a
function of the cooling water temperature. As back pressure is
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further lowered, higher is the cycle efficiency and output of the
turbine.
• To recover high quality feed water in the form of condensate and
feed it back to the system generator with the minimal
treatment/chemistry control during normal operation.
• Condenser
• Gland steam condenser
• LP heaters
• Deaerators
• Condensate transfer pumps
• Condensate extraction pumps
• Boiler feed pumps
• Auxiliary boiler feed pumps
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2. DEAERATOR:
PRINCIPLE OF DEAERATOR:
• Deaerating Column
• Feed Storage Tank or Deaerator Tank
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In the event of Station Black Out (SBO) when auxiliary boiler feed pump
will also be not available, there is a provision to feed fire water directly
into SG. Fire water line is connected at down stream of check valve near
SG 10% feed nozzle.
# SPEACIAL POINT:
In ‘ON & OFF’ position of HS, the corresponding during pump will start
and stop respectively.
(b) In AUTO #2 position, the pump will start after 20 sec when
• Pump trip
• Differential pressure across suction strain is high (0.3kg/cm2)
• HS error.
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LEGENDS USED IN THE CONNECTIONS OF INPUT
& OUTPUT OF PLC:
The legends are divided in two groups viz. Non-safety and safety. The
connections used in safety region are not available all the time for
monitoring as their failures are not affordable. The Non-safety region is
being monitored at regular intervals for its long use.
Various terminals are used in Safety and Non-safety region and some
panels are used in between both of these regions. Those terminals are as
follows:
In the wire diagram of CTP’s connection of input and output of PLC, these
terminals are as per there safety and non-safety requirements. Non-
safety terminals such as CDFT and BFCT are accompanied with Main
Control Panel Terminal and used in controlling Hand Switches. Various
relay contacts are checked by using NC & NO condition.
Basically in connections of PLC’s inputs and outputs two loads are used
viz. Normal Load (380 mA) & Maximum overload (400 mA). A +ve 48V
D.C supply is given to the BUS which is connected to the inputs of PLC.
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• 4321-P-1008 pump from class-III is started by MCC No P2 and
starter ‘J’. It is rated as 15 KW.
• 4321-P-1008 is Non-safety related group ‘A’ LOAD and redundant
to 4321-P-1009.
• Hand Switch being in Auto-1 position, pump 4321-P-1008 starts
when Deaerator level is low & both CEPs have tripped after a time
delay of 10 seconds.
• Hand Switch being in Auto-2 position, pump 4321-P-1008 starts
when the pump 4321-P-1009 not starting in 20 seconds on Auto-1
condition.
• Running pump will trip, when Main Condensate Storage Tank level
is low or Deaerator level is high.
• In one DG condition, the pump will not be allowed to run,
irrespective of HS position.
• 64321-SV-742 energises when both CEPs are not running &
closes the CEP recirculation valve 4321-CV-1228.
There are 23 inputs and 16 outputs on DL06 kit with four communication
ports. 3 slots can be used as optional slots on the kit.
For developing a RUNG on the kit various input are renamed as per the
kit. The input specifications are as follows:
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The Interface relay specifications are as follows:
TIMERS: Basically timers are used for the delays between the systems
for setting up an automised time.
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This basically finds out the redundancy of two loads, means the left CPU
mode address and the right CPU mode address. Two mediums are
available, one is permanent and other is standby.
In Tinyterm4.1 PLC, the kit contains 352 inputs, 160 outputs, 512
interface relays, 60 timers and number of multiplying relays which are
used for further operations such as hand switch, level switch, thermal
switch etc. it provides around 4 additional ports. The Kit also contains a
WATCH DOG TIMER which is used for self-diagnosis.
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