SYSTEM NOTES PART – I

INDEX
Sr.
Topic Page No.
No.
1. Raw and Domestic Water System 04
2. Demineralizers 10
3. Regeneration Facility 14
4. Make-up Demineralizer System 17
5. Condensate Service and Make up Water System 21
6. Condensate and Feed Water System 25
7. Condensate Demineralizers 31
8. Steam Extraction and Feed Water Heating 34
9. Sea Water Intake 40
10. Circulating Water System 43
11. Chlorination System 46
12. Travelling Screen and Screen wash System 50
13. Plant Cooling Water System 53
14. Ventilation and Air Conditioning System 63
15. Compressed Air System 80
16. Turbine Generator 90
17. Turbine Lube Oil System 99
18. Turbine Shaft Sealing System 104
19. Generator Cooling System 108
20. Hydrogen Seal Oil System 114
21. Steam jet Air Ejector System 119
22. Reactor Vessel 123
23. Nuclear Steam Supply System 130
24. Reactor Recirculation System 137
25. Emergency Condenser System 143
26. CRD and CRD Hydraulic System 146
27. Liquid Poison system 159
 Raw and Domestic Water System

The raw water system is provided to meet the entire fresh water
requirements of the power station. The raw water from Sakhre Dam is received in
an underground raw water storage tank T-5 of 78 ft. dia and 20 ft. height. The
capacity of tank is 6,00,000 gallons (22,70,000 litters) which is enough to meet the
entire requirement for 5 days. The tank is located on East side of workshop
building. The initial treatment of water i.e. alum injection, settling, filtering and
chlorination is done at the site of Sakhre Dam from where water is supplied.

The inflow to tank T-5 is controlled by LS-832 and CV-832. The CV opens
when T-5 level falls to 18 feet and closes when T-5 level rises to 19 feet. T-5 high
level alarm is provided at 19 feet 6 inch and low level alarm is provided at 16 feet
6 inch level. A flow integrator is provided on raw water inlet line to measure the
water consumption. A pressure gauge and a wire mesh strainer is provided
upstream of CV-832 in the inlet pipe.

Two raw water booster pumps P-17A and B (10 HP, 455 lpm) are provided
for pumping water from T-5 to domestic water head tank T-6 and to supply all raw
water requirements. Two sand filters F-8A and B are provided on the discharge of
the pumps P-17A/B/C. The pumps P-17A/B/C, Filters F-8A/B are located near
Raw water tank (T-5) itself. Domestic water head Tank T-6 is located on the top of
service building at South Side. Each sand filter is a 7 feet dia. and 4 feet high
carbon steel tank containing 23 CFT of sand and gravel. Normally both the
filters are kept in service.

The filter is backwashed when ∆ P (Diff. Press) across filter reaches 5 psi
(0.35 Kg/cm2). An additional pump P-17C (10 HP, 455 lpm) is provided on the T-
5 Tank as a spare pump which can be used manually whenever required, no auto
controls are provided for this pump (P-17C). Normally One Pump out of P-17A/B
is kept on Auto and other one on Manual. P-17C is used when ever any of the P-
17A/B becomes unavailable.
 When on auto, the operation of raw water booster pump P-17A/B is
controlled by level in domestic water head tank T-6. The pump starts when T-6
level falls to 230 cms. and stops when T-6 level rises to 312 cms. The T-6 high
level alarm is provided at 335 cms. level and low level alarm is provided at
200cms. level. The raw water booster pump P-17A/B also trip automatically when,

i) The pump discharge pressure exceeds 65 psig.

ii) The T-5 level falls to 5 feet.

Whenever pump trips on discharge high pressure or T-5 low level, a reset
button on local panel must be pressed for restarting the pump. An alarm is
provided to know the tripping of P-17A/B on discharge high pressure or on T-5
low level.

The raw water for Cooling Tower Pump House (CTPH) is taken from the
upstream of the F-8A/B filters to avoid additional load on the raw water filters.
The raw water system supplies the following loads

1) Supply to Make up Demineralizer Plant.

2) Lube water supply to CW pumps bearings
3) Lube water supply to Jockey fire pump P-19.
4) Sealing water supply to water box vacuum pumps 1P-9 and 2P-
9.
5) Make up water to CTPH system.
6) Supply to hose stations in yard.
7) Supply to domestic water system.

When P17-A/B is not running, the above requirements are supplied by tank
Domestic head tank (T-6) except supply to CTPH. When P-17A/B is running, it
supplies requirements of 1 through 6 and also builds up level in the Domestic
water head tank T-6.
 Domestic Water System

The system consists of 60,000 gallons capacity Domestic water head tank T-
6 located at 148’ service building, booster pumps P-28A/B, hydro pneumatic tank
T-7, instrumentation and controls. Main purpose of system is to cater filtered
domestic water at essentially constant pressure to various utility points.

Pumps P-28A/B are 7.5 HP, 100 gpm flow, 60 psig TDH horizontal,
centrifugal pumps. The pumps take suction from T-6 tank and discharges in to
hydro pneumatic tank T-7. Pump is controlled by control switch having three
positions AUTO-OFF-RUN.

In Auto position pump is started automatically by level and pressure

switches on the hydro pneumatic tank. These pumps have an automatic alternator
which rotates the duty of the pump that is on automatic control. The hydro
pneumatic system maintains a nearly constant pressure in the system by means of a
cushion of compressed air rather than continuous operation of the pumps.

For a pump to automatically start, the level in the hydro-pneumatic tank

must be below the high level set point of LS-327H. Once the level goes down
below this point the pump can be started either by pressure switch PS-328B on
low pressure or LS-327L on low tank level. Once started the pump will continue to
run until the level rises above the high level set points of LS-327 H. When level
has been restored so that LS-327 is reset, low pressure in the hydro pneumatic tank
will be sensed by PS-328A, which will energize SV-327 to admit regulated service
air to the tank. This will pressurize the tank with air and reset the pressure switch.

When the control switch of the pump are in RUN position, the pumps will
start and run irrespective of any automatic start devices. The pump will be
automatically tripped by LS-327H on high level.
Domestic water system supplies to the following loads.
1) Evaporators of Chlorination system.
2) Lube water to SSW pumps.
3) Alternate cooling water to Screen Wash pumps.
4) Chemical addition tank in Radwaste.
5) Hot water tank T-9
6) Water coolers, showers, wash basins, lavatories in various areas.

DRG 05A
DRG 05B
DRG 05BC
 Demineralizers
Demineralizing is a process of purifying water by ion exchange process.
This is an excellent process of removing dissolved salts from water. The treated
water, obtained by this ion-exchange process is more than the equivalent of
distilled water and is free from all salts but for traces.

Natural water contains salts of Calcium, Sodium, Magnesium, usually

bicarbonates, sulphates and chlorides. These salts are present in water in ionic
form. The positive ions are known as cations and negative ions are known as
anions. In the ion-exchange process the cations are exchanged with hydrogen ions
of cation exchanger or cation resins and anions are exchanged with hydroxyl ions
of anion exchanger or anion resins. The purification process thus occurs in two
steps:

In the first step the positive metallic ions (Ca, Na, and Mg) are removed by
cation exchanger H2 Z as per typical reactions given below:

2NaCl + H2 Z = Na 2 Z + 2HCl.
MgSO4 + H2 Z = MgZ + H2 SO4

Na2Z or MgZ represent used or depleted cation exchanger. The other

product of reaction is an acid.

In the second step the remaining negative ions are removed by anion
exchanger R(OH)2 as per typical reactions given below:

2HCl + R(OH)2 = RCl2 + 2H2O

H2SO4 + R(OH) 2 = RSO4 + 2H2O

RCl2 or RS04 represent used or depleted anion exchanger. The other product
of reaction is pure water.

Thus the cation exchanger removes the cations to form acids and then the
anion exchanger removes acids to leave pure water.
 Normally after passing the water through cation exchanger (cation bed) and
anion exchanger (anion bed), it is passed through a mixed bed. The mixed bed
contains both cation and anion exchangers. As the water flows through closely
mixed cation and anion resins almost all the dissolved impurities are removed. The
resulting water is extremely pure.

The demineralizer plant thus normally consists of cation bed, anion bed and
mixed bed. In processes where the water to be processed is already of good
quality, only mixed beds are used for polishing the water and to improve the water
quality.

The demineralizer beds are contained in a carbon steel tanks which are
rubber lined. On inlet to the bed a water distributor is provided so that water is
uniformly spread over resins. At outlet of demineralizer a fine-mesh screen is
provided to prevent escape of resins.

The ion exchange reaction can continue only as long as the exchangeable
hydrogen or hydroxyl ions are available to replace cations and anions present in
water. Once the exchangeable ions are exhausted the exchanger resins must be
regenerated periodically to replenish exchangeable ions.

When cation resins are exhausted by capturing cations the resins are returned
to original state by regenerating them with dilute acid. The typical reactions during
regeneration are given below assuming that sulphuric acid is used for regeneration.

Na2Z + H2SO4 = H2Z + NaSO4

MgZ + H2SO4 = H2Z + MgSO4

H2Z represents regenerated cation resins. After completion of regeneration,

the bed is rinsed to wash out sulphates and excess acid left over.

Similarly anion resins are regenerated using dilute caustic. The typical
reaction during anion regeneration is given below:

RSO4 + 2NaOH = R(OH)2 + Na2SO4

RCl2 + 2NaOH = R(OH)2 + 2NaCl

R(OH)2 represents regenerated anion resins. After completion of

regeneration the bed is rinsed to wash out salts and excess caustic left over.
 For regeneration of mixed bed, the resins are first separated and then
regenerated. The regeneration can be done in same tank provided the care is taken
to prevent acid from depleting anion resins and caustic from depleting cation
resins. The other method of regeneration is to regenerate cation and anion resins
separately in different tanks.

The separation of resins is achieved by back washing the mixed bed with
controlled flow rate. The lighter anion resins separate from heavier cation resins
and rise to the top of bed. When the bed is allowed to settle there is a distinct line
of separation between resins with anions at the top and cations underneath.
Accurately placed distributors make it possible to regenerate the cation and anion
resins one by one without affecting each other. After the regeneration the bed is
rinsed, air mixed and rinsed again before returning to service.

The service run of demineralizer depends on quality of inlet water. In most

cases the capacity of anions will control the length of run between regenerations,
because excess of cations capacity is usually furnished. The status of bed is
monitored by measuring conductivity and silica in bed effluent. Increase in
conductivity is a sign of cation resins depletion and increase in silica is a sign of
depletion of anion resins. Based on experience in actual practice, the service run
of bed is given in terms of water quantity processed.

In TAPS, following demineralizers are provided:

1) Make up demineralizers
2) Condensate demineralizers.
3) Clean up demineralizer.
4) Radwaste demineralizer.

Make up demineralizers consist of a cation bed, anion bed and a mixed bed.
The regeneration of these beds is done in situ.

All other demineralizers in the plant are identical mixed beds. For
regeneration, the bed is transferred to common regeneration facility, where cations
and anions are separated and regenerated separately in separate tanks and then
mixed in storage tank and regeneration is completed by giving final rinse. Clean up
demineralizer resins pick up lot of reactor water activity and becomes highly
radioactive .Hence these resins are not regenerated and they are transferred to
Spent resin tank in Radwate 87’ elevation. The resins from Spent resin tanks are
disposed off separately.
 Regeneration Facility

Mixed bed demineralizers provided in condensate demineralizers, reactor

water clean up demineralizer and radwaste demineralizer are all identical. A
common regeneration facility is provided for regeneration of these demineralizers.
The depleted resins are transferred to regeneration facility and the regenerated bed
is transferred to the corresponding demineralizer. As all these demineralizers
process radioactive water, the depleted resins are radioactive. All operation at
regeneration facility are done remotely to minimize radiation exposure. The liquid
waste arising from regeneration is also radioactive and it is transferred to radwaste
for processing. The resins of cleanup demineralizer process reactor water and
become highly radioactive hence they are not regenerated but are transferred to
spent resin storage tank. The acid and caustic required for regeneration is stored in
respective acid and caustic storage tanks. It is pumped to regeneration facility
during regeneration.

The facility consists of cation regeneration tank T-17 or resin separation

tank, anion regeneration tank T-18, mixed bed storage tank T-19, hot water tank
T-72, air operated valves, piping, instrumentation, control panel etc. The tanks T-
17, T-18 and T-19 and the associated valves are located in shielded vault at turbine
building 133’ elevation.

T-17 is a rubber lined carbon steel tank of 4 ft. dia. and 12 ft. height. It can
receive full 84 cft of resins (56 cft cations and 28 cft anions). The tank has three
view ports. The resins are seen in the top port when the tank contains full resin
bed. From bottom port, it can be seen whether the tank is empty or not. Middle port
is used to see the proper separation of cation and anion resins. When the cation and
anion resins are separated the cation resins settle at bottom and anion resins settle
at top and a distinct line of separation is seen in the middle port.

The tank has three connections for resin transfer. The resins are received in
the tank from top line, the middle line is used for transfer of anion resins to anion
tank and bottom line is used for transfer of cation resins from T-17. Also, there is
provision for adding fresh resins in T-17 from the roof of the facility through a
hopper. A conductivity cell and sample point is provided on water outlet line.
 The depleted resins are received in T-17 for regeneration. The resins are
cleaned and separated in T-17, and the anion resins are then transferred to anion
tank for regeneration. The cation resins are regenerated in T-17 by injecting 120
liters of sulphuric acid of 4% to 5% concentration. The cation resins are then rinsed
to conductivity of less than 20 umho/cm to washout regeneration products and
excess left over acid.

T-18 is a rubber lined carbon steel tank of 3 ft. dia and 12 ft. height. It is
used for regeneration of anion resins. The tank has two view ports. Resins are seen
in the top port when the quantity of anion resins is correct. From bottom port it is
seen whether the tank is empty or not. The tank has two resin transfer connections.
The resins are received in the tank from top line and the bottom line is used for
transfer of resins from T-18. Also, there is provision for adding fresh resins in T-18
from the roof of the facility through a hopper. A conductivity cell is provided on
rinse water outlet line. The depleted anion resins are regenerated in T-18 by
injecting 240 liters of caustic of 4% to 5% concentration. The resins are then rinsed
to conductivity less than 100 umho/cm to washout regeneration products and
excess caustic left over.

The hot water tank is provided for supplying hot water for diluting the
caustic for regeneration of anion resins. Hot water helps in better silica removal.
An electric heater with thermostat control is provided to maintain hot water tank
temperature around 140oF–150oF. A three-way blending valve adjusts the hot
water supply such that temperature of caustic dilution water is 120oF.

The T-19 in a rubber lined carbon steel tank of 4ft. dia. and 12 ft. height and
it can receive full resin bed. The tank has two view ports. The resins are seen in top
port when the tank contains full resin bed. From bottom port, it can be seen
whether the tank is empty or not. The tank has two resin transfer connections. The
resins are received in tank from top line and bottom line is used to transfer resins
from T-19. A conductivity cell and sample point is provided on rinse water outlet
line.

After individual regeneration and rinsing the cation and anion resins from T-
17 and T-18 respectively are transferred to mixed bed storage tank T-19. The
resins are mixed in storage tank and final rinsing is done to conductivity less than 1
umho/cm. This completes the regeneration of bed.
 The valves used in regeneration facility are air operated CV’s and most of
the operations in regeneration facility are done remotely from local panel. A
conductivity recorder is provided on local panel for recording conductivity of rinse
outlet water from T-17, T-18 and T-19. The liquid waste arising from regeneration
goes to radwaste for processing. The high conductivity waste generated during acid
and caustic injection and individual rinsing is sent to waste neutralizer tanks T-
48A/B. The low conductivity waste (generally conductivity below 20 umho/cm)
generated during cleaning of resins, separation of resins and final rinsing is sent to
waste collector tank T-38.

DRG 12A
 Makeup Demineralizer System
The purpose of the system is to supply required quantity of highly pure
water required for the operation of boiling water reactors. The system mainly
supplies to make up the losses of primary coolant system. It also supplies to make
up losses in other auxiliary cooling water systems. The system consists of two
independent water processing units, a demin. Water storage tank, demin. water
transfer pumps, piping, valves and controls etc.

Each make up demineralizer unit consists of Make up inlet booster pump

(P86A/B), Cation bed (T21A/B), Degassifier (S-1A/B), Degassifier blower
(K2A/B), Makeup booster pump (P24A/B), Anion bed (T22A/B), Mixed bed
(T23A/B) and associated instruments and controls. Equipment numbers of Makeup
demin. Unit #1 has suffix A and those of Makeup demin, Unit #2 have suffix B.
The two make up demin. units are interconnected at the suction and discharge of
P24A/B, the interconnection provide flexibility in operation in case some
equipment is under maintenance.

Each inlet booster pump has 58 gpm capacity at 60’ TDH and is driven by 3
HP motor. The pump takes suction from raw water line going up to domestic water
head tank and delivers water to cation bed.

Cation bed is a rubber lined steel tank of 3½’ dia. and 7 feet height
containing 37 cft. of cation resins. The water enters into tank from top, flows
through the resin bed where cations are exchanged and flows out from bottom. The
cation bed is generally regenerated after it has processed 230 M3 of water. A flow
integrator is provided at cation bed inlet to measure quantity of water passing
through the cation bed.

Sulphuric acid is used for regeneration. An acid dilution tank is provided in

which the dilute acid is prepared by taking first predetermined quantity of water
and then strong acid. The dilute acid is then injected through cation bed by water
eductor. Acid injection is done in two stages. In the first stage acid of 2%
concentration is injected and in the second stage acid of 5% concentration is
injected.
 Injection of very dilute acid (2%) during first stage prevents the formation of
CaSO4 as a precipitate which would clog the resin bed. The Dilute acid tank has
the capacity of 300 liters. Out of which 100 liters of 2% and 200 liters of 5% dilute
acid is injected during regeneration. 37 liters of 98% sulphuric acid is taken in the
Dilute acid tank out of which 13 liters is used for 2% injection and 24 liters is used
for 5% injection.

After cation bed, the water passes through a degassifier where CO2 is
removed by breaking the water stream and passing a counter flow of air through
the water. The removal of CO2 by degassifier reduces load on anion bed.

The degassifier is a rubber lined steel tank of 2½ feet dia. and 9 feet height,
filled with rasching rings of 2 inch dia. and 2 inch length, through which water
passes from top towards bottom. A centrifugal blower of 300 CFM capacity and
driven by 1 HP Motor is provided to blow a counter current of air through the
down coming water. The effluent water collects into a degassifier sump. The level
in degassifier sump is controlled by a level controller which adjusts the inlet CV to
degassifier.

From degassifier sump, the water is delivered to anion bed by Make up

booster pump of 120 gpm capacity at 45 psig and driven by 7.8 H.P. Motor. This
pump is necessary to deliver water through anion bed and mixed bed up to the
demin. water storage tank.

Anion bed is a rubber lined steel tank of 3 feet dia. and 7 feet height
containing 25 cft. of anion resins. The water enter into the tank from top, flows
through the resin bed where anions are exchanged and flows out from bottom. The
anion bed is generally regenerated after it has passed 450 m3 of water.

Caustic soda is used for regeneration of anion bed. A caustic dilution tank is
provided in which dilute caustic is prepared by taking predetermined quantities of
water and caustic soda. 30 liters of caustic of 48% concentration is mixed with
water in dilution tank.
 The dilute caustic is then injected to anion bed by water eductor. 5% caustic
concentration is used for regeneration. The anion bed is generally regenerated after
it has processed 450 M3 of water. A flow integrator is provided at the outlet of
anion bed to measure the quantity of water processed by anion bed and by mixed
bed. After anion bed the water goes to mixed bed.

The mixed bed is a rubber lined steel tank of 3 feet dia. and 7 feet height
containing 9 cft of cation resins and 13 cft of anion resins. The water enters into
the tank from top, flows through mixed resins bed where anions and cations are
exchanged to remove remaining impurities, and flows out from bottom. A basket
strainer is provided at mixed bed outlet to prevent resin fines from going to demin.
water storage tank. The mixed bed is generally regenerated after it has processed
6000 M3 of water.

For regeneration of mixed bed, the resins are first separated and then
regenerated one after another. Acid and Caustic dilution tanks mentioned earlier
are used to prepare dilute acid or dilute caustic solution. For acid injection 27 liters
of 98% H2SO4 is taken in the acid dilution tank. 5% concentration dilute acid is
injected through the cation resins. 32 liters of caustic of 48% concentration is taken
in dilution tank. 5% concentration NaOH is injected through the anion resins. The
dilute acid is injected to the cation resins (settling at bottom) through a distributor
located at interface of resins. The effluents drain from normal outlet of bed. The
dilute caustic is injected to anion resins (settling at top) from top and the effluents
drain out from a distributor located at interface of resins.

The effluent from mixed bed is transferred to demin. water storage tank T-2.
The tank is made of aluminum and has a capacity of 30,000 gallons (1,13,400
liter). The tank high level and low level conditions are annunciated in Main
Control Room. From T-2, the demin. water is transferred to the various plant
services by demin. water transfer pumps. P-7A/B are two pumps, each of 75
gpm capacity and driven by 30 H.P. motor are provided. Normally one pump is in
service with other available as standby. A minimum recirculation line of 3 gpm
capacity is provided to prevent overheating of pump during periods of low
demand.

The system supplies the following services:

1) RBCW Surge Tank.
2) TBCW Surge Tank
3) BSCW Surge Tanks
4) Chilled water system compression tank
5) Poison system
6) Emergency condensers
7) Sampling stations
8) Miscellaneous Hose stations
9) Condensate storage tanks
10) Seal cooling water for core spray and post incident pumps
11) Demin. water to switchyard for hot line washing

DRG 16A
 Condensate Service and Make up Water System

The purpose of the system is to,

i) provide a surge reservoir for the main power loop consisting of feed water
and steam systems i.e. hot well, makeup and reject system
ii) Provide condensate service water to various plant processes i.e. condensate
service water system.

The system consists of two condensate storage tanks, three condensate

service pumps, piping, instruments and controls etc.

There are two condensate storage tanks T-1A and T-1B. The tanks are made
of aluminium to minimize contamination of water by corrosion products. Each
tank is of 20 feet dia, 28 feet height and has a capacity of 60,000 gallons (2,28,000
liters). Each tank receives water from demin. water storage tank T-2 and the
reprocessed clean radwaste from tank T-50. The tanks are vented to reactor
building exhaust system to prevent spread of radioactive contamination. Level
indicators and high-low level alarm are provided for each tank. The overflow lines
from both tanks discharge into a overflow seal chamber which is a 27 cft concrete
tank with a water seal and the water collected is drained to stack basement sump.

Hotwell make up reject system

The condensate storage tank is connected to hot well by a makeup reject

header. Normally T-1A serves for unit #1 and T-1B serves for unit #2. A tie line
and inter-tie valve is provided between two make up reject headers so that one tank
can serve both units in case of non-availability of one of the tanks. Normally inter-
tie valve is kept closed. Tanks conductivity is monitored on hot well conductivity
recorder at CO5/C15 panels.
 Hot well level is controlled by two level controllers and associated control
valves automatically. Makeup level controller (LC-1010) operates Make up CV-
1010A and CV-1010B and makes up hot well level in case it is falling. Reject level
controller (LC-1011) operates reject CV-1011 and brings down hot well level in
case it is rising. CV-1011 rejects the water from condensate demin. outlet header to
T-1A through make up reject header. Normally Make up level controller is kept on
Auto While Reject level controller is kept on Manual.

Suction to CRD booster pumps (1P-78A/B,2P-78A/B) is also taken from

Makeup- Reject header. Condensate storage tank thus supplies water to CRD
system, emergency feed and vessel head spray when Condensate system is not in
service.

The bottom of T-1A/T-1B is at elevation 106 feet, where as the entry of

Make up line to hot well is at elevation 116 feet. During normal operation, the
Makeup water is drawn to hot well because of vacuum in condenser. During
shutdown, T-1A/B tanks level must be above three meters for water to flow into
hot well by gravity.

Condensate Service Water System

Condensate service water requirement of various plant processes is also

supplied by T-1A/ B. Three Condensate service pumps (P-6A/B/C) each of 30 HP
motor ,360 gpm capacity at 225’ TDH and are provided to take suction from a
common header connected to both T-1A and T-1B, through which water comes to
the suction of P-6A/B/C. The condensate service pumps have a low level trip
when 15,000 gallons are left in the tank. This arrangement is provided to assure a
minimum of 15,000 gallons of water available for hot well make up under any
circumstances. The suction stand pipes serve as a back up. With a selector switch,
the low level pump trip is selected for a tank from which the pump taken suction.
Three pumps discharge into common discharge header. To prevent the overheating
of pump during periods of low demand a minimum recirculation line of 5 gpm
capacity is provided.

The condensate service water system has two modes of operation:

 i) Normal plant operation
ii) Refueling operation.

During normal operation one condensate service pump is kept running

continuously to meet the following demands.

1) Condensate demins. and regeneration facility.

2) Cleanup demin. Service water.
3) Radwaste system (Service water for filter precoating, pumps
seal/gland cooling, resin transfer etc.)
4) Emergency condenser makeup water (Alternate Source).
5) Mechanical Vacuum Pumps and vacuum breaker seal water.
6) Condenser tray fills.
7) Makeup water to fuel pool and suppression pools.

If some of the above demands come simultaneously, it is necessary to run

two condensate service pumps.

During refueling operations, it is necessary to fill reactor cavity and dryer

separator storage pool within four hours. The water quantity required is 1,62,500
gallons. The required pumping rate (677 gpm) is achieved by running two
condensate service pumps. As the storage capacity of T-1A/B is not sufficient to
meet the bulk demand, the water must be simultaneously transferred to T-1A/B
from T-2 and T-50 as it is being pumped out to reactor cavity and dryer separator
storage pool.
DRG 19A
 Condensate and Feed Water System

Condensate System

The steam exhausted from turbine is condensed in main condenser and it is

collected in the hot well. The condensate system draws the condensate from hot
well and delivers it into the primary feed water system. On its way the condensate
flows through tubes of air ejector condensers and gland seal condenser and
provides the cooling required. The condensate system also provides sealing water
and water for turbine exhaust hood spray. The system consists of hot well,
condensate pumps, air ejector condensers, gland seal condenser, minimum
recirculation line, demineralizers, condensate storage tank and makeup reject
system.

The hot well is of 23,500 gallons (88920 liters) capacity and is in two
halves. Each half has three conductivity cells to monitor sea water leakage from
inlet tube sheet, condenser tubes and the outlet tube sheet. All conductivity
readings are recorded continuously in control room and an alarm is annunciated if
any conductivity reading exceeds 0.5 umho/cm. The outlet from each half of hot
well connects to the suction header of condensate pumps.

There are three condensate pumps provided (1P-1A./B/C) each of 900 HP,
3150 gpm (198LPS) capacity at 826’ TDH (25 Kg/cm2). Each pump is a 5 stage
vertical pump. The pumps discharge into a common discharge header. Normally
two pumps are in service and third pump is kept on standby. Two pressure
switches are provided on discharge header. PS-1021 automatically starts the
standby condensate pump at 21.4 Kg/cm2 and PS-1025 gives low header
2
pressure alarm at 21.1 Kg/cm .

Two tapping are taken from the discharge header for supplying the sealing
water and the turbine exhaust hood spray. For sealing water supply the pressure is
reduced to 1.8 Kg/cm2 by two pressure reducers. Sealing water is supplied to valve
stems, pumps shafts and condenser neck joint to prevent air in leakage into the
condensate system. For turbine exhaust hood spray the pressure is reduced to 3.5
Kg/cm2 by one pressure reducer. The actual spray is controlled by turbine control
system. The condensate then flows through tubes of air ejector condensers and
gland seal condenser and goes to demineralizers.
 A minimum recirculation line is provided from the outlet of gland seal
condenser to the hot well, to ensure sufficient coolant flow to air ejector
condensers and gland seal condenser, when the feed water demand is low.
Differential pressure across air ejector condensers is used to measure the
condensate flow and also to control the position of minimum recirculation CV-
1029. If the feed water demand falls below the set value, the CV-1029 opens
(partly or fully) and maintains the minimum required flow. PS-1029 has an over-
riding action. It prevents opening of CV-1029 if the condensate discharge header
pressure is low. Opening of CV-1029 is made slow by providing needle valve on
air supply line. The feed for CRD hydraulic system is tapped off from outlet header
of demineralizers.

The hot well rejects line is tapped off from outlet header of demineralizers.
The reject CV-1011 rejects the water to make up reject header in case hot well
level is high. PS-1011 has an overriding action. It prevents opening of CV-1011, if
the pressure at feed pump suction header is low. The make up water for hot well is
taken from condensate storage tank. The make up CV-1010 admits water to hot
well as per signal from hot well level controller.

Feed Water System

The purpose of feed water system is to increase the temperature of

condensate and feed water by using extraction steam and moisture removed from
turbine and to raise the pressure of feed water sufficiently so that it can be supplied
to reactor. The system includes level controllers which control supply of feed water
to reactor as per the demand of steam by turbine generator. The feed water system
has two parts, namely–Primary Feed Water System and Secondary Feed Water
System.

Primary Feed Water System:

The Primary Feed Water System consists of three low pressure feed water
heaters 1E4A, 1E3A and 1E2A, two drain coolers 1E5 and 1E6, one high pressure
feed water heater 1E1A, primary feed pumps 1P2A, 1P2B and level control
system. From the outlet of condenser condensate water is pumped out by
condensate pumps 1P-1A/B/C. The water flows through 1E-9 (Air ejector off gas
condenser and 1E-8 (Gland Seal Condenser). Then water passes through the
Demineraliser beds for removing impurities.
 From the outlet of condensate demineralizers, the primary feed water is
progressively heated as it flows through the tubes of 1E6, 1E4A, 1E5, 1E3A and
1E2A. Steam extracted and moisture removed from turbine is used to heat the feed
water. After 1E2A the feed water pressure is increased from around 20 Kg/cm2 to
84 Kg/cm2 by primary feed pumps.

There are two primary feed pumps provided for each unit and a fifth spare
pump P-2 is provided which can be connected to either unit by swing elbows. Each
primary feed pump is a 5 stage horizontal centrifugal pump with mechanical shaft
seals. The pump is driven by 2000 HP, 3000 rpm motor and has a capacity of 2730
gpm (172lps) at TDH of 84 Kg/cm2. A recirculation line from each pump discharge
to the main condenser is provided to ensure minimum flow of 325 gpm (20lps)
through the pump and thus prevent overheating of the pumps during periods of low
feed water demand.

The feed pump discharge check valve is provided with a bypass line to
permit a small back flow through the idle pump so that the idle pump can be
warmed up to system temperature before it is taken in service.

Each pump has its own lubrication oil system consisting of lube oil tank, oil
cooler, a shaft driven oil pump, motor driven auxiliary oil pump and oil filter. The
oil is cooled by TBCW system. The motor winding and bearings temperature is
monitored in control room. Pressure switches are provided on lube oil header for
the purpose of alarms and interlocks. Suction and discharge header pressure of
primary feed pumps are recorded in control room.

From primary feed pumps discharge header the feed water goes through
tubes of high pressure feed water heater 1E1A and then to reactor through level
control valves. There are two LCVs namely main LCV and bypass LCV. Main
LCV is in service during normal operation and bypass LCV is used during periods
of low demand such as startup or shutdown. The reactor level control loop senses
the reactor level, primary feed flow and primary steam flow and adjusts the
position of LCV.

* Secondary Feed Water System:

The Secondary Feed Water System consists of three low pressure feed water
heaters 1E4B, 1E3B & 1E2B, one high pressure feed water heater 1E1B,
secondary feed pump 1P3 & level control system. From the outlet of condensate
demineralizers the secondary feed water is progressively heated as it passes
through the tubes of 1E4B, 1E3B & 1E2B. Steam extracted from turbine is used
for heating the feed water. After 1E2B the secondary feed water pressure is
increased from 20 Kg/cm2 to 52 Kg/cm2 by secondary feed pump. One secondary
feed pump is provided for each unit and a third spare pump is provided which can
be connected to either unit by swing elbows.

Each secondary feed pump is a horizontal, 4 stages centrifugal pump with

mechanical shaft seals. The pump is driven by 600 HP, 1500 RPM motor and has
capacity of 1870 gpm at 730 psig TDH (51.3 Kg/cm2) Shut off head – 78.8
Kg/cm2. A recirculation line from each pump discharge to main condenser is
provided to ensure minimum flow of 120 gpm through the pump and thus
preventing over-heating of the pump during periods of low feed demand. The
discharge permits a small back flow through the idle pump so that the idle pump
can be warmed up to system temperature before it is taken into service.

Each pump has its own lubrication oil system consisting of lube oil tank, oil
cooler, a shaft driven oil pump, a motor driven oil pump and oil filter. The oil is
cooled by TBCW system. The temperature of each bearing is monitored
continuously. Three pressure switches are provided on lube oil header for purpose
of alarms and interlocks.

Suction and discharge header pressures of secondary feed pump are recorded
in control room.

From secondary feed pump discharge the feed water goes through tubes of
high pressure feed water heater 1E1B. After 1E1B the feed line splits into two
branches, one for each SSG. The feed to each SSG is regulated through individual
LCV. The SSG level control loop senses level, feed flow, steam flow of SSG and
adjusts position of LCV.

A small inter tie line is provided to connect the primary and secondary feed
lines. This line is used for supplying feed water to SSGs. from primary feed water
system when SSGs are supplying only the requirements of steam jet air ejectors
and turbine gland seal system.

* Now a days this system is not in use.

DRG30A
DRG 30B
 Condensate Demineralizers
The purpose of condensate demineralizer system is to polish the feed water
going to reactor. It removes the soluble and insoluble impurities from feed water
and maintains high water quality so that corrosion is minimized and source of
corrosion products and activation products is also minimized. It also provides
protection against chloride intrusion into feed water system in case of condenser
tube leaks.

The system consists of five identical mixed beds, recycle pump, local control
panel, piping, instrumentation and controls etc.

The mixed beds 1T-16A, B, C and D are located in shielded vault, in

Turbine Building at 118 feet elevation. The fifth bed 1T-16E which was installed
to augment capacity is in shielded vault at 133 feet elevation of turbine building.
Each bed is a rubber lined carbon steel tank of 6 ft. dia. And 4 ½ ft. height. Each
bed contains 84 cft (2400 liters) of mixed resins. Each mixed bed consists of 56 cft.
(1600 liters) of cation resins and 28 cft. (800 liters) of anion resins. For
regeneration, the resins are transferred to centralized regeneration facility. Each
bed has two resin transfer openings, condensate inlet, condensate outlet and vent
openings. Air operated CV’s are provided on condensate inlet and outlet line. A
small bypass line is provided across inlet CV for filling and pressurizing the bed at
slow rate before it is taken in service. An interlock is provided to prevent opening
of main inlet CV unless the bed is pressurized nearly up to system pressure.

A flow sensor is provided on inlet line for measuring flow rate through the
bed and the total flow passed through the bed. A flow distributor is provided on the
inlet to bed for distributing flow uniformly over the resin bed. On condensate
outlet end an under drain system is provided to prevent escape of resins from the
bed. Also a basket strainer is provided in outlet line to trap any resin particles
escaping under drain system. A conductivity cell is provided on outlet of individual
bed for monitoring the conductivity of effluent. Also two conductivity cells are
provided to monitor conductivity of gross inlet and gross outlet from condensate
demineralizers.
 Each bed is rated for 5500 lpm flow. Normally four beds are kept in service
to meet the requirement during full power operation. The fifth bed is transferred to
regeneration facility if the outlet conductivity reaches 0.1umho/cm or when the bed
has processed 20 x 107 liters or for cleaning the resins.

After receiving regenerated bed it is first recycled for one hour. The recycle
pump takes the suction from outlet of bed and returns into inlet header. The bed is
thus rinsed and compacted to service conditions. During recycle, it is ensured that
the bed outlet water quality is acceptable. The bed is then kept on standby. Apart
from regeneration the resins sometime require cleaning. The differential pressure
across the condensate demineralizers is monitored continuously. When the
differential pressure reaches limit 3.5 Kg/cm2) the bed having least flow rate
(i.e. the dirtiest) is transferred to regeneration facility for cleaning. After cleaning,
the bed is transferred back, recycled and taken in service. Sometimes, the cleaning
of resins is done locally when the regeneration facility is not available. The water
from demin. tank vents and drains goes to the Condensate Drip tanks at Turbine
bldg 87 elevation.

A local control panel is provided for condensate demineralizers. The

controls for inlet CVs, outlet CVs, resin transfer CVs and recycle pump are located
on local panel. Conductivity, flow recorders, flow integrators and annunciations
are also located on local panel. Any alarm coming on local panel gives trouble
alarm in main control room.
DRG 25A
 Steam Extraction and Feed Water Heating

The purpose of the system is to improve plant thermal efficiency by

continuously extracting steam from the turbine and heating the feed water going to
reactor. The feed water is heated in steps as determined by plant design heat
balance, turbine extraction stages and moisture removal requirement of turbine.
Removal of moisture from various stages is very essential for minimizing erosion
of turbine internals. The system utilizes the available heat effectively because of
cascading of heater drains and provision of drain coolers. The system from each
unit consists of feed water heaters, drain coolers, heater drain tank, heater drain
pumps, bleeder trip valves, spill valves, bypass flash tank, cascade drain CVs,
dump CVs and heater level control instruments.

The extraction steam for feed water heating is taken from 6th, 10th, 15th and
19th stages of turbine. Extracted steam from 6th stage goes to heater 1E-1A,
th th
Steam from 10 stage goes to heater 1E-2A, Steam from 15 stage goes to heater
1E-3A and Steam from 19th stages goes to heaters 1E-4A and B. Moisture removed
from 2nd, 3rd and 4th stages goes to heater 1E-1A, Moisture from 13th stage goes to
1E-3A and Moisture from 18th, 20th and 21st stages goes to 1E-4A and B. Moisture
separator drains also goes to 1E-4A and B.

Extraction steam lines from 6th, 10th & 15th stages are provided with power
(air) assisted bleeder trip valves (BTVs). The BTVs normally allow steam flow
from turbine to feed water heater. When the turbine trips, the BTVs go close to
prevent backflow of steam from heaters to turbine and thus prevent over-speeding
of turbine. The air operators of BTVs ensure that BTVs are positively closed in
case of turbine trip. The 6th stage extraction line going to high pressure feed water
heaters has two BTVs in series to ensure stoppage of reverse flow to turbine. 19th
stage extraction lines have spring loaded check valves instead of BTVs. MOVs are
provided on extraction feed water heaters.
 All the drain lines from turbine moisture removal stages are orificed at the
turbine to limit the flow from the turbine and to permit use of heat contained in a
lower pressure heater. The moisture drain lines carry high percentage of moisture,
so to minimize erosion of piping at the Tee connections these lines are not
connected to extraction steam lines but are run separately up to feed water heaters.
MOVs are provided on moisture drain lines going to heaters 1E-1A and 1E-3A.

Train A of feed water heaters heat primary feed water going to the reactor
and it consists of heaters 1E-1A, 1E-2A, 1E-3A, drain cooler 1E-5, heater 1E-4A
and drain cooler 1E-6 in the decreasing order of pressures. Train B of feed water
heaters heat secondary feed water going to SSGs and consist of heaters 1E-1B, 1E-
2B, 1E-3B & 1E-4B in the decreasing order of pressures. Due to tube leaks in
SSGs, Train B of feed water heaters are not kept in service.

All heaters and drain coolers except 1E-4A & B are vertical, U tube type
heat exchangers. Heaters 1E-1A and 1E-2A have integral drain coolers. Heaters
1E-4A and B consist of two horizontal U tube bundles in a common horizontal
shell which is located inside main condenser.

Drains from 1E-1B, 1E-2B & 1E-3B go to 1E-1A, 1E-2A & 1E-5
respectively. Drains cooled in integral drain cooler of 1E-1A go to 1E-2A through
cascade drain CV-1086. All drains cooled in integral drain cooler of 1E-2A go to
1E-3A through cascade drain CV-1070. Drains from 1E-3A and 1E-3B are cooled
in drain cooler 1E-5 and then go to heater drain tank 1T-30 through cascade
drain CV-1063. The low pressure heaters 1E-4A/B also drain into heater drain tank
1T-30. Heater drain pumps 1P-5A/B take suction from heater drain tank and pump
the drains through the final drain cooler 1E-6 to the condenser through CV-1040.

Each feed water heater has a normal drain control system to control the level
in the shell and allow the drains to cascade to the next low pressure heater shell.

For instance, the level control system of 1E-2A consists of LT/LC/CV-1070.

In addition to the normal level control system each heater has a separate high level
drain bypass control system or “dump” system. For 1E-2A the “dump” system
consists of LT/LC/CV-1103. The dump system allows the heaters to drain directly
to condenser, if the normal level control system cannot maintain the heater water
level. For an additional safety backup, a high level switch is provided to close inlet
to heater, thus stopping the cascading drain flow into the heater upon high water
level. For 1E-2A the system consists of LS-1103 and SV-1086. The last part of
level control system is another high level switch which closes the extraction steam
coming to heater by closing the associated BTVs. For 1E-2A the system consists of
LS-1071, LS-1071B and BTV-1071.

During turbine operation, the continuous removal of moisture from turbine is

necessary to minimize erosion of turbine internals. During normal operation the
extraction steam lines and moisture drain lines remove moisture from turbine and
carry it to feed water heaters. To ensure continuous moisture removal from
extraction and moisture removal stages when a feed water heater is isolated, a
system of extraction bypass lines and CVs (spill CV’s) is provided to discharge
minimum required moisture removal flow to the condenser. The system consists of
CVs-1087, CV-1413, CV-1071, CV- 1414 and CV-1064 with associated solenoid
valves. These spill CVs open automatically whenever BTVs are closed or MOVs
on extraction/moisture drain lines are closed. The steam bypassed through spill
CVs is discharged into the Bypass Flash Tank 1T-28, which separates steam from
water and discharges both to condenser. The vent is provided for each heater to
collect the non-condensible gases and discharge them to condenser. The orifices
are provided to limit flow through these vent lines.
 TABLE FOR FEED WATER HEATER INLET/ OUTLET TEMPERATURE
WITH EXTRACTION
AVERAGE VALUES OBSERVED AT 160 MWe

Inlet/
Feed Moisture Steam Outlet Steam
Water Type Extraction Extraction Temp. Pressure Material
Heaters Stages Stages of & Temp.
F.W.
Tube 304 SS
Vertical U tube 157oC 13.5Kg/
1E-1A 2nd, 3rd & 6th stage Shell-A-
with integral 190oC cm2
4th stages 212B Carbon
drain cooler 195.9 oC
Steel
Tube 304 SS
Vertical U tube
103 oC 5.5 Kg/cm2 Shell-A-
1E-2A with integral - 10th stage
157 oC 161.4 oC 212B Carbon
drain cooler
Steel
Tube 304 SS
Vertical U tube
81 oC 0.6 Kg/ cm2 Shell-ASTM
1E-3A with separate 13th stage 15th stage
103 oC 113.3 oC SA-285
drain cooler
Carbon steel
Heater Tube 304 SS
74 oC
1E-5 Vertical U tube 1E-3A - - Shell-ASTM
81 oC
drain SA-285C

Horizontal U
tube having Tube 304 SS
45 cm of
common shell Outlet Shell-ASTM
1E-4A 18th stage 19th stage Hg
with 1E4B with 74 oC SA-285
76.7 oC
separate drain Carbon steel
cooler
Heater Inlet Tube 304 SS
-
1E-6 Vertical U tube drain pump - 48 oC Shell-ASTM
discharge SA-285-C
Gland Seal
Horizontal U 47 oC
Condenser - - - -
tube 48 oC
1E-9
Tube SS 304
Steam Air
Steam nozzle
ejector Horizontal U 45 oC -
- - SS air
condenser tube 47 oC
chamber
1E-8
CS/SS
 SET
LEVEL
LOCAL SWITCHES POINTS HEATER LEVEL CONTROL STATIO
(CMS.)
(CMS.)
CM above bottom Instrument Tap CM above lower Instrument Tap
Heater 1A & 1B Levels
CV-
22.2 Starts open
LS 1086 HCS LI
56.0 Alarm Hi level
1087A Fully CV- 1086 1086
37.0
Opens 1086
BTV-1087 WHEN HTRS
CV-1113 1A & LS
Closes ALARM
BTV 1601 STARTS 1B 1113
LS OPEN DUMP HCS
20.3
1087B CV- 1113
CV-1087 38.0 Starts Open
1113 LI
Opens
Fully CV- 1113
CV-1413 53.0
Opens 1113
Heater 2A & 2B Levels
25.0 Starts open CV-1070
LS HCS LI
56.0 Alarm Hi level Fully
1071A 40.0 CV-1070 1070 1070
Opens
Closes BBTV- Alarm
1071 WHEN heaters
CV-1103 2A/2B LS
90% Drain Inlet HCS
1063
LS OPEN Closed
50.8 1103
1071B (CV-1086)
41.0 Starts Open CV-1103
LI
Opens Fully
CV-1071 56.0 CV-1103 1103
Opens
Heater 3A & 3B Levels
22.4 Starts open CV-1086
LS HCS LI
52.1 Alarm Hi level Fully
1064A 38.0 CV-1086 1063 1063
Opens
Alarm
WHEN heater
BTV-
Closes LS CV-1097 3A/3B HCS LS
27.9 1064
1064B 90% Drain inlet 1097 1097
OPEN closed
(CV-1070)
 CV-
37.5 Starts Open CV-1097
1064 LI
Opens
CV- Fully 1097
37.5 CV-1097
1414 Opens

DRG 30C
 Sea Water Intake
Sea water is used to meet all the cooling requirements of the Power Station.
The sea water required is taken in from the Arabian Sea through an intake canal
and the intake structure. The intake canal extends west wardly approximately 1
km. into the Arabian Sea. The protective Jetties on either side extend to a distance
of about 400 meters. The width of canal is 100 feet (30.5 meters) at the mouth and
60 feet (18 meters) at the intake structure. The canal is sized to provide 2500
cu.ft./sec. of water at the minimum tide level of 74 feet. Present requirement of
cooling water is 1000 cu.ft./sec. (28.32 M3/sec.) The design temp. difference
between incoming water and discharge water is 8oC.
The intake structure is divided into 5 bays of 13 feet width each. Each bay
has:
1) Its individual trash rack that traps large size trash coming along with
water.
2) Its stop log gate for isolation and dewatering of the bay for
maintenance work.
3) A travelling screen to screen out small size trash, sea weeds, Jelly
fishes etc.

The water level within tidal zone varies from elevation 72 ft. to 96 ft. The
elevation of intake canal bottom is 50 feet and it rises to 55 feet at the inlet of
circulating water pump.

A separate three compartment bay is provided at the south end of intake

structure to supply the sea water requirements of salt service water system, screen
wash system, fire protection system and chlorination system. One of the three
compartments can take its feed from bay No.1, 2 and 3 through a 36 inch header
located at 67ft. elevation. The second compartment can take its feed from bays.
No.3, 4 and 5 through another 36 inch header also located at 67 ft. elevation. The
third compartment can be fed from either of the above two compartments. The
headers are provided with butter fly/gate valves to enable isolation of any bay or
compartment.

Equipment subjected to sea water has to be protected from corrosion. The

methods used for protection include use of sacrificial anodes, cathodic protection,
epoxy coating, use of special materials like monel, stainless steel, aluminum brass
etc.
 Circulating Water System

The purpose of circulating water system is to condense the steam coming to

main condenser from turbine exhaust. The sea water is passed through tubes of the
condenser and is discharged back to sea via discharge canal.
The system consists of five half capacity circulating water pumps (1P-8A,
1P-8B, P8, 2P-8A and 2P-8B), condenser water boxes, main condenser, outlet
conduits, discharge canals, motor operated valve, piping, valves and controls. Sea
water from intake canal flows through the trash racks and travelling water screen to
the circulating water pumps from which it is pumped through the main condenser
tubes and returned to the sea. Each CW pump is rated for 1,13,900 gpm (25,832
M3/hr) at 32.2 ft. TDH, 366 rpm and is driven by 3.3 KV motor of 1250 HP. Each
pump has two discharge MOVs and it discharges into two parallel headers.
Normally two pumps are running for each condenser. One pump discharges into
one header and thus serves one half (either north half or south half) of the
condenser. By opening appropriate discharge MOV, any pump can be used to feed
any half of the condenser or both the halves of condenser simultaneously.

The spare pump P8 can be used to serve either half of either condenser. It
has four discharge MOVs, two for feeding Unit #1 condenser and two for feeding
Unit #2 condenser. The pump cannot be used to feed both the condensers
simultaneously. An electrical interlock prevents opening of any MOV towards Unit
#2 if any MOV towards Unit #1 is open and vice versa. The pump can feed both
halves of one condenser simultaneously.

For each pump an electrical interlock is provided to prevent starting of pump

with discharge MOVs in closed condition, to protect the motor from over loading.
The interlock prevents starting of pump until one discharge MOV is opened by 10
to 12o. The further opening of discharge MOV can be done only after starting the
pump.

A bypass control system is provided for each half of the condenser to limit
the water velocity in condenser tubes to a maximum of 7 ft./sec. (2.43 M/sec.),
irrespective of tide level and the pump discharge flow. The system consists of 42
inch dia. (107 cms.) bypass line, bypass CV and DP controller. The DP controller
senses DP between inlet and outlet water boxes and positions bypass CV so as to
bypass excess flow.

The outlets from two outlet water boxes are connected by backwash MOV.
This MOV facilitates backwashing of either half of condenser.

Water box vacuum pump is provided for each unit. It can suck out air from
any water boxes of the condenser. The pump is run to fill the system before
starting of the CW system. During normal operation, the pump is run to remove the
trapped air and non-condensible gases from water boxes, particularly during low
tide period.

The condenser effluents from outlet piping up to discharge canal pass

through underground rectangular tunnels of reinforced concrete. The liquid
radwaste from the plant is also discharged into discharge canal and thus is diluted
by effluents of CW system. These effluents are monitored for radioactivity by CW
discharge radiation monitoring system. The system consists of a sample pump,
sample tank, sample sump and a radiation detector. The radiation level is
continuously recorded in control room and gives alarm on high radiation level. A
flow switch is provided to monitor sample flow. It gives alarm in case of low
sample flow.

Rubber bearings of CW pump are cooled and lubricated by water. This lube
water requirement is supplied by raw water system. 30 lpm of lube water flow is
required for each pump. Lube water from SSW system is available as alternate
supply. An electrical interlock in starting circuit of pump prevents pump starting if
lube water flow is below 26 lpm. Also low lube water flow gives alarm in the
control room if lube water flow is below 24 lpm during normal C.W. pump
running. High discharge pressure protection trip is provided to the pump. Pressure
switch trips the pump at a discharge pressure of 25 psig. to protect the pump from
running on shut off.
DRG 33A
 Chlorination System
Chlorination of sea water is done to prevent algae growth on heat transfer
surfaces of various cooling water systems using sea water. Liquid chlorine supply
is obtained in one-ton containers and is used for chlorination purpose.

The system consists of a service water booster pumps P-81A and B,

Evaporators E-19A and B, Chlorinators T-15A and B, Chlorine Cylinder Banks,
Control Valves, Instruments etc. One set of equipments i.e. booster pump,
evaporator, chlorinator etc. meet the requirement of chlorination while other set is
available as stand by. Interconnecting piping is provided between evaporators and
chlorinators so as to have different combinations of equipments available for use.
Any evaporator can be used with either chlorinator.

There are two booster pumps P-81A and B, each of 250 gpm, 85’ TDH
capacity and driven by 10 H.P. Motor. The pump takes suction from salt service
water system and provide high pressure water supply to chlorine ejectors.
Normally one pump is required. The other pump starts automatically if the running
pump does not develop adequate pressure.

The liquid chlorine from chlorine cylinder goes to evaporator. The

evaporator is a hot water bath surrounded liquid chlorine container. The water bath
is heated by 15 KW electric heaters. The water temp. is controlled at about 80oC by
a thermostat which puts the heater on or off. Two temperature switches are
provided for giving a high temperature alarm (98o C) and a low temperature alarm
(65o C). The water level in bath is controlled by continuously feeding a small water
flow and allowing excess water to overflow. A water level indicator is provided to
monitor water level.

A level switch is provided to give alarm in case of low water level. A relief
valve is provided to prevent over pressurization of evaporator above 200 psi. The
liquid chlorine coming to evaporator is evaporated and superheated to some extent.

The chlorine gas leaving evaporator goes to chlorinator through an air

operated pressure controller valve (PCV-3058,3059). The pressure controller
maintains constant pressure at inlet to chlorinator. Air supply to PCV is controlled
manually.
 The function of chlorinator is to supply chlorine gas to ejector at a controlled
pressure and flow. The chlorinator consists of vacuum regulator, flow meter, flow
control valves differential measure regulator, vacuum breaker/emergency relief
valve etc.

The chlorine solution from the outlet of ejector is fed to different bays of
intake structure. Flow to individual bay is controlled by a manual valve.

The system is operated manually. The various control switches required for
operation are mounted on control panel C-37. The sequence of operation to be
done is as below:

a) Check evaporator level, temperature and water overflow is correct.

b) Check power supply to control panel is “ON”.

c) Select one of booster pump by the selector switch.

d) Select the required combination of evaporator and chlorinator using S-

11.

e) Open manual valve for bay to be chlorinated.

Now, turn the on-off switch (S-1) to “ON” position. The booster pump
starts. Open PCV-3058 (3059) by valving in air to PCV. Adjust the chlorine flow
rate and continue chlorination for specified time. After chlorination is over, close
PCV-3058 (or 3059) by isolating and bleeding off air. Continue flushing for
specified time. This completes chlorination of one bay.

Bays No.1 to 5 are chlorinated for 20 minutes at a chlorine flow rate of 104
Kg/hour. Bays No.6 and 7 are chlorinated for 20 minutes at a chlorine flow rate of
20 Kg/hour. After chlorination of each bay the flushing is done for 10 minutes. The
rates of chlorination are chosen to give a free chlorine concentration of 2 to 3 ppm.

In addition to daily chlorination, every bay is given booster dose once in a

week. For booster dose chlorination is done at the normal rate, but for a period of
one hour. Three new chlorine leak detectors are installed in Chlorination plant to
detect any chlorine gas leak. The detectors give alarm at 0.5 ppm in Main control
room as well as locally.

Chlorine gas being heavier than air settles at the floor level. Exhaust fan V-
42G is provided to exhaust air from the plant. The fan takes suction at the floor
level. Fresh air line respirator is provided at Chlorination plant which can be used
during chlorine leak. Self contained breathing apparatus is also available at the
chlorination plant. Safety shower and eye washer is provided near the chlorination
plant.

Chlorine Emergency Kit is available in the Chlorination plant which can be

used to isolate the leaky chlorine cylinder.
DRG 36A
 Travelling Screen and Screen Wash System

The System is provided for collection and removal of debris from incoming
sea water at the intake structure. This screened water is used for circulating water
system, salt service water system, screen wash system, fire protection system and
chlorination system.

The screen wash system is provided for cleaning of travelling screens by

water jets. The screen wash system also supplies to fire protection. In case of fire,
the system supplies the requirement of fire system on priority.

The system consists of 5 travelling screens (one for each bay) 1F-1A, 1F-1B,
F-1, 2F-1A & 2F-1B, three screen wash pumps, piping, control valves,
instrumentation etc.

Each screen consists of a series of 10 ft. wide, 3/8 inch mesh wire covered
baskets attached to motor driven chain drive system. The driving motor is of 3 HP
capacity. Speed of the screen is 2.5 ft./min.

Each screen wash pump is a vertical turbine type, rated at 1200 gpm. at a
TDH of 249 ft. It is driven by 100 HP, 1500 RPM motor. Three screen wash
pumps discharge into a common header. The common discharge header branches
into two headers. One header connects to fire protection system and other serves
screen washing. The screen wash water header has five branches for serving five
screens. At the end of each branch there are 18 spray nozzles for washing the
screen. The water flow to spray nozzles is controlled by CV which open only when
the screen is rotating.

The flow towards fire protection system or towards screen wash system is
controlled by CVs 257 A and B. (Only one CV will remain open at any time).

Each travelling screen is controlled by a control switch which has four

positions i.e. Manual Jog, Manual run, OFF and Auto. Auto position is not used.
Manual Jog position is used to advance the screen during maintenance works. This
position is also used during manual cleaning of the screens.

Each screen wash pump is controlled by a control switch having three

positions e.g. Manual, Auto and Standby. In “Manual” position the pump is started
and stopped by the push buttons provided. One selector switch is provided to select
one of the screen wash pump for fire system requirement.

Normally all screens are kept on “Manual Jog” and controlled by the local
Toggle switch provided near screen. Two screen wash pumps are kept on auto. The
third screen wash pump is kept on standby. One of the pump which is on auto is
selected for fire system. Five differential level instruments are provided to sense
the differential level across each screen. The dirtiness of screen is sensed in terms
of differential level. Differential level of 10 cms gives alarm. The screens are
rotated continuously to manually remove collected plastic, sea weeds, jelly fishes.
Lot of plastic and jelly fishes arrives during monsoon.

If the pressure in screen wash pumps discharge header is low, the standby
pump starts automatically. As P-10A pump is supplied by 1MVA sub-station, it
can be used during station blackout condition also. P-10B and P-10C pumps are
supplied by BO7 and BO8 buses respectively.

Operation during fire

Screen wash pumps provide the water supply for fire fighting. Fire
protection system pressure is monitored by a pressure switch PS-257. When the
pressure in fire protection system drops, the PS-257 trips and,

1) Starts the screen wash pump that is selected for fire.

2) Opens CV-257B to supply fire protection system and closes CV-257A
to stop supply to screens.

Once the pump starts, it has to be stopped manually after resetting

PS-257 by a push button provided on the screen wash control panel.

Bearings of screen wash pumps are cooled and lubricated by water. The
lube water supply is from SSW system. Alternate lube water supply is from raw
water system.
DRG 38A
 Plant Cooling Water Systems

The plant cooling water systems are provided to pick up waste heat from
plant processes (other than Main Condensers) and dispose it off to the external
environment. Due to decay heat of fission process, the cooling water systems are
necessary even after complete shutdown of plant.

The plant cooling water systems actually consists of three separate systems:

1) Salt Service Water System (SSW System)

2) Turbine Building Cooling Water System (TBCW System)
3) Reactor Building Cooling Water System (RBCW System)

The SSW System cools RBCW system and TBCW system by circulating sea
water through tubes of RBCW heat exchangers (E-10A, E-10B, E-10C) and
TBCW heat exchangers (E-11A, E-11B, E-11C). The RBCW system is a separate
closed loop cooling water system that uses demineralized water (mixed with
Potassium Dichromate and Caustic Soda to protect piping from corrosion) to cool
the processes and equipments located inside Drywell, Reactor building,
Containment cooling building and Radwaste building. The TBCW system is also a
separate closed loop cooling water system that uses demineralized water mixed
with Potassium Dichromate and Caustic Soda (to protect the piping from
corrosion) to cool the processes and equipments located in Turbine building. Air
compressors located in Service building are cooled by RBCW system. The feed
pumps located in Service building are cooled by TBCW system.

The use of two closed loop cooling water system (using chromated demin.
water) cooled by one sea water system has following main advantages.

1) Provides protection against leakage of radioactive process liquid into

the Salt Service Water.

2) Provides protection against leakage of corrosive and impure sea water

into nuclear systems that need cooling.
 As the cooling water systems serve many different processes and
equipments which are independent of each other, it is essential that the cooling
water systems must be always in operation. These systems must be in operation
even during plant shutdown and during emergency situations to remove decay heat
from spent fuel.

Brief description of SSW, TBCW and RBCW systems is given below:

SSW System

The SSW System consists of five SSW pumps P-11A, B, C, D, E, service

water basket strainer F3, Discharge seal weir, Valves, Piping, Instrumentation and
Controls etc.

The five SSW pumps are located in the intake structure building at elev.97
ft. The pumps take suction from bay No.6 and 7 and discharge into common
header. Each pump is rated to deliver 5500 gpm at 54 ft. head and is driven by 100
HP motor. Pumps P-11A, P-11B and P11C are supplied from emergency power
supply bus BO4, BO5 and BO9 respectively. After passing through service water
basket strainer, the SSW serves following loads:

1) RBCW heat exchangers - E-10A/B/C

2) TBCW heat exchangers - E-11A/B/C
3) Turbine building air cooler - 1V-16A/B and 2V-16A/B
4) Oil coolers of transformers – X01, X03A, X04 and X05.
5) Lube water supply to screen wash pumps.
6) Chlorination system.
7) Standby Lube water supply to SSW and CW pumps.

Supply to chlorination plant is controlled by CV-700. The SSW outlet from

TBCW heat exchangers, turbine building air coolers goes through CV-384. The
SSW outlet from RBCW heat exchangers goes into a seal weir, so as to maintain
the siphon after initial startup.

An immersible scintillation detector is provided in seal weir to monitor the

radioactivity of water flowing out. This gives warning if any radioactive material
from RBCW system enters into SSW system due to leak in heat exchangers. SSW
process radiation monitor continuously monitors the radiation level and gives
alarm if radiation level increases to the preset value.
 During normal operation CV-700 and CV-384 are open. Three pumps are
sufficient to meet the cooling water requirement. Remaining two pumps are
available as back up. Differential Pressure across the basket strainer F-3 is
monitored by DPIS-365 which gives alarm in control room when ∆P exceeds 0.25
Kg/cm2. PS-302 gives alarm in control room when the SSW header pressure falls
below 0.5 Kg/cm2. The remedial action to improve header pressure e.g. Starting of
back up pumps or controlling flow has to be taken manually.

During total loss of power (TLOP) only one SSW pump is automatically
started to supply the essential cooling requirements. In such situation SSW is
supplied only to RBCW heat exchangers and all other loads i.e. non-essential loads
are isolated. PS-303 located at SSW inlet to RBCW heat exchangers performs the
auto actions during emergency operation to isolate non-essential loads.

When total loss of power occurs, all running SSW pumps trip and PS-303
also trips on low pressure. When PS-303 trips, CVs 384 and CV-700 go close and
isolate SSW to TBCW heat exchangers, turbine building area coolers and
chlorination system. SSW to transformers has to be isolated manually. After
emergency diesel generators have started P-11A or P-11B is started automatically
and SSW to RBCW heat exchangers is resumed. Pump P-11C can be started
manually if required.

Epoxy coating and sacrificial anodes are provided to protect the system
piping and equipment from corrosion.

TBCW System

The TBCW system consists of three TBCW pumps P-14A, B and C, a

chemical feeder T-53, three TBCW heat exchangers E-11A, B and C, a Surge tank
T-4 ,necessary piping, valves, instrumentation and controls etc.

The pumps, heat exchangers and chemical feeder are located in Turbine
Building at 87 ft. elev. The surge tank is located in Turbine building at 156 ft. elev.
on top of the regeneration facility. Each pump is rated to deliver 2800 gpm at 70 ft.
TDH and is driven by 75 HP motor. Pump P-14C is supplied from emergency
power supply bus BO9.
 The TBCW system supplies following loads:

1) Turbine lube oil coolers.

2) Generator hydrogen coolers.
3) Seal coolers and lube oil coolers of primary feed pumps.
4) Oil coolers of motors of condensate pumps.
5) Sample coolers in turbine building.
6) Coolers of hydrogen seal oil vacuum pumps.

The system is initially filled by demin. water via Surge tank. During
operation, any losses of water from system are made up by filling the surge tank
whenever the low level alarm comes.

The chemical feeder is provided to feed a 50% solution of potassium

dichromate into system to inhibit corrosion in the carbon steel piping. Caustic
soda is also fed by chemical feeder to control pH of the system water. Potassium
dichromate and caustic soda are added to the system after weekly analysis of the
system water.

During normal operation of the system, two TBCW pumps are running with
two heat exchangers are in service. Third pump is kept as standby. Two pressure
switches PS-165 and PS-166 are provided on discharge header after heat
exchangers. PS-165 gives low header pressure alarm when pressure goes below
3.25 Kg/cm2.

PS-166 starts standby pump when pressure goes below 3.2 Kg/cm2. TS-168
is provided to give header high temp. alarm at 100oF (38oC). Manual corrective
action is necessary to bring down TBCW header temperature.

During total loss of power (TLOP) the TBCW system shuts down
completely. Usually the system is not required during total loss of power incident.
However, the pump P-14C is connected to emergency power supply bus and can
be taken in service manually if necessary.

RBCW System:

The RBCW system consists of three RBCW pumps P-13A, B and C, three
RBCW heat exchangers E-10A, B and C, a chemical feeder T-52, a surge tank T-3,
necessary piping, valves, instrumentation and controls etc.
 The pumps, heat exchangers and chemical feeder are located in Turbine
building at 118’ elev. on South side. The Surge tank is located in Reactor building
at 184’ elev. Each pump is rated to deliver 3000 gpm at 100 ft. TDH and is driven
by 100 HP motor.

All RBCW pumps P-13A/B/C are supplied from emergency power supply
buses BO4/BO5/BO9 respectively.

The RBCW system supplies the following loads:

1) Air compressors K-1A, B, C and K-1D.

2) BSCW heat exchangers.
3) Post Incident Heat Exchangers.
4) Equipments inside drywells of Unit # 1 and 2.

a) DW equipment drain sump coolers.

b) DW area coolers.
c) Seal coolers and oil coolers of reactor recirculation pumps.

5) Clean-up system equipments of Unit #1 and Unit #2.

a) C.U. non-regenerative heat exchangers.

b) Oil coolers of C/U recirculation pumps.
c) Seal coolers and oil cooler of C/U Aux. pumps

6) Shutdown and fuel pool cooling equipments

a) Shutdown and fuel pool cooling heat exchangers.

b) Oil and seal coolers of shutdown cooling pumps.

7) Radwaste system equipments:

a) Waste collector tank cooler.

b) Radwaste compressor K-1D.

8) Sample coolers in reactor building for Unit # 1and 2.

 All these loads do not occur concurrently, e.g.

a) Post incident heat exchangers come in service only when core

spray and post incident system is initiated.
b) Shutdown cooling heat exchangers are in service when either
units is in shutdown condition.
c) Cooling water flow to air compressors is established only when
the equipment is in service.

The system is initially filled by demin. water via surge tank. During
operation, any losses of water from system are made up by filling the surge tank
whenever the low level alarm comes on CO2 panel in Main Control Room. Surge
tank high level alarm is usually an indication of tube leak in either C/U non-
regenerative heat exchangers or in fuel pool cooling heat exchangers.

The chemical feeder is provided to feed a 50% solution of potassium

dichromate into system to inhibit corrosion in carbon steel piping. Caustic soda is
also fed by chemical feeder to control pH of the system water. Potassium
dichromate and caustic soda is added to the system after periodical analysis of the
system water.

A scintillation type radiation detector is provided to monitor the presence of

any radioactive material which could have leaked into RBCW system from nuclear
systems. The radiation level is continuously recorded and an alarm is provided on
high radiation level in the main control room. RBCW process radiation monitor
continuously monitor the radiation level and given alarm if radiation level
increases to the preset value.

During normal operation, two RBCW pumps are running and two heat
exchangers are in service. The third pump is kept as standby. Four pressure
switches are provided on discharge header after heat exchangers. PS-293 gives
header low pressure alarm when pressure goes below 4.05 Kg/cm2. PS-294 starts
standby pump when pressure goes below 3.9 Kg/cm2. Function of PS-295 and PS-
511 is described later. TS-196 is provided to give header high temperature alarm at
102oF (39oC). Manual corrective action is required to bring down RBCW header
temperature.
 During total loss of power (TLOP) only one RBCW pump is started
automatically to supply the essential cooling requirements. In such situation
RBCW is made available only to following essential loads: (Refer to the list of
loads supplied by RBCW system).

1) Air compressors K-1A, K-1B and K-1C.

2) BSCW heat exchangers.
3) Post incident heat exchangers.

All other loads i.e. non-essential loads are isolated as described below:

a) Equipment inside drywells:- Isolation of RBCW is done by automatic

closure of supply and return MOVs 1342, 1343, 2342 and 2343. These
MOVs are closed by EMTR.

b) C.U. system Equipments: - Isolation of RBCW supply to pumps 1ND-

06A/B/C, 2ND-06A/B/C and non-regenerative heat exchangers is
done by closure of CV-1542 and CV-2542. Closure of these CVs
occur when PS-511 trips on low pressure.

c) Shutdown and fuel pool cooling equipment:- Isolation of RBCW is

done by closure of CV-678 and CV-3213 respectively.

d) Radwaste Equipments:- Isolation of RBCW is done by closure of CV-

679.
e) Sample coolers:- Isolation of RBCW is done by de-energizing SV-
1669 and 2669.
When RBCW header pressure goes down to 3.76 Kg/cm2, PS-511 trips and
closes CV-1542, CV-2542, CV-678, CV-679, SV-1669, SV-2669, CV-3213. PS-
295 is used for starting P-13A or P-13B after emergency diesel generators have
started.
When total loss of power occurs, all running RBCW pumps trips. PS-511
and PS-295 trip on low header pressure. On tripping, PS-511 isolates all non-
essential loads. After EDG’s have started P-13A or P-13B starts automatically by
EMTR. P-13A or P-13B runs and supplies essential loads.
DRG45A
DRG45B
DRG45C
 Ventilation and Air Conditioning System

General: The ventilation and air conditioning system is provided to:

i) Cool equipment spaces and personnel spaces.

ii) Control humidity where it is essential.
iii) Prevent spread of air borne contamination.

Plant equipment spaces and spaces of limited occupancy are ventilated and
cooled with outside ambient air. The maximum design ambient air temperature
being 35oC, the maximum space temperature varies from 40 to 49oC. Turbine
building, radwaste building, part of service building etc. are ventilated and cooled
by ambient air.

All air entering the plant buildings is filtered by high velocity washable
filters, except the transformer vaults.

The plant spaces requiring more cooling than that can be accomplished by
ambient air are supplied with cooled and dehumidified air. The air conditioning
chillers and common chilled water system is provided to cool and dehumidify the
air. The reactor building is supplied with cool and dehumidified air to limit
maximum space temperature of 36oC to 38oC. In places like main control room,
offices, cable spreading room etc. the space temperature is controlled at 25 + 2oC
and the relative humidity is controlled at 50 + 5%.

The equipments having high heat rejection rate are hooded and exhausted
through ducts to prevent spreading and build up of heat in surrounding areas.
Similarly, spot cooling of equipments by supplying cool air through ducts is
adapted where it is impractical to cool the entire space.

The systems used for ventilation are mainly of induced draft and forced draft
type with the use of fans and supply/exhaust through the ducts. Use of natural draft
is made only for transformer vaults.
 To prevent spread of air borne contamination, the air flow is maintained
from low radiation area towards high radiation area. Differential static pressure
regulators are used to maintain negative pressures in equipment compartments and
between controlled and non-controlled spaces to maintain air flow in desired
direction. Exhaust from the equipment compartments is discharged at high altitude
through the stack exhaust from some of the compartments is filtered by High
Efficiency Particulate Filters (HEPA) before releasing through stack.

To maintain uninterrupted service, the ventilation system equipments are

installed with standby equipments.

1) Reactor Building Ventilation System

The reactor building and containment cooling building form the

secondary containment structure. The ventilation system for these two
buildings is described under single title of reactor building ventilation
system. To prevent ground level release of radioactivity the reactor building
ventilation system is designed to keep the reactor building always under a
slight vacuum with respect to outside environment. Inside the building the
equipment compartments are kept at negative pressure compared to non-
controlled areas to prevent spread of contamination.

The reactor building ventilation system consist of air supply system,

space cooling units, normal exhaust system, emergency ventilation and
clean-up system, ducts, instrumentation and controls.

The air supply system consists of two full capacity fans V-

15A/B and associated cooling coils and dampers. The outside air is drawn
through louvers and filters and then it is cooled by cooling coils through
which chilled water flows. The temperature of air is controlled by
temperature controller which controls the flow of chilled water through the
cooling coil. The discharge from two fans joins into a common duct which
carries the cooled air to reactor building. This supply air duct has two air
operated dampers (PO-9156 and PO-9157) in series which open only when
one of the supply fan is running.
 The fans are controlled by a three position (V-15A-OFF- V-15B)
selector switch on C-80 panel. When one of the fan is selected by control
switch, the selected fan starts, chilled water to its cooling coil is turned on,
its discharge damper opens, common discharge dampers PO-9156 and PO-
9157 also opens. The performance of running fan is monitored by pressure
switch PS-9154. If running fan fails, the standby fan automatically comes in
service. The cooled discharge air from fans V-15A/B is distributed to all
floors of reactor building by ducts and flow balancing dampers. The air can
also be supplied to drywells for their ventilation and purging. The
containment cooling building gets its fresh air supply from radwaste
building supply fans V-26A/B. The supply air duct has two air operated
dampers PO-9284 and PO-9285 in series.

The 103 ft., 125 ft., 143 ft., and 160 ft. elev. floors of reactor building
are provided with space cooling units consisting of fans, filters and cooling
coils supplied with chilled water. The fan sucks air from the space, filters it,
cools it and delivers it through distribution duct. The discharge air
temperature is controlled by TCVs. Each space cooling unit consists of two
fans, associated filters and cooling coils. One of the fan is normally in
service and the other is available as standby. The containment cooling
building is also provided with one identical space cooling unit. These space
cooling units are controlled from Exhaust system panel C-80 at stack
basement.

Reactor building 200’ elevation ventilation is supplied through two

ducts, one each located along the east and west walls of the space. Normal
exhaust from the space is from two exhaust ducts located in the roof truss
space. One exhaust duct is located over reactor cavities and spent fuel pools.
The other exhaust duct is located over the lay down area. Water vapors are
exhausted through slots above the water level of the spent fuel pools, steam
dryer and separator storage pools, and reactor cavities. Spent fuel pools are
designed for covers to restrict the escape of contaminated vapour or gases to
the area.

During refueling mode, the control valve located on the ventilation

control panel at the west wall of 200 ft. elevation is closed. This closed
valve will bleed air from supply and exhaust duct damper operators, causing
one each of the two supply and exhaust duct damper to close, leaving one
supply duct discharging from the West
wall and one exhaust duct exchange air from reactor cavity and fuel pool
area.

Prior to cavity flooding, reactor cavity valve is opened and flexible

duct attached to supply duct to supply ventilation air to workmen removing
reactor head bolts. A blind flange with gasket is installed on the cavity
exhaust in normal operating condition.

The normal exhaust system consists of DP controllers, ducts and

dampers. The exhaust from the equipment compartments, R.B. 200 ft. floor,
reactor cavity, fuel pools, vertical pipe tunnels, sample hoods etc. join
together to form a single exhaust duct. The individual exhaust duct from
equipment compartment is provided with DP controller and air operated
dampers to maintain the equipment compartments at slight vacuum with
respect to reactor building.

The single exhaust duct (i.e. the reactor building exhaust duct) leads
the reactor building exhaust to exhaust plenum. The reactor building exhaust
duct has two air operated dampers PO-9184 and PO-9185 in series, one
DPC-9188 and PO-9188 to control the exhaust flow to exhaust plenum such
that the reactor building is at slight vacuum with respect to outside
environment. The air from exhaust plenum is discharged through stack by
main exhaust fans V-24A or V-24B. The exhaust from reactor building is
continuously monitored by two radiation monitors and is indicated and
recorded in control room.

The normal exhaust from containment cooling building is brought to

exhaust plenum through radwaste building exhaust duct. Two air operated
dampers (PO-9282 and PO-9283) are provided on exhaust duct from
containment cooling building.

The emergency ventilation and clean-up system consists of emergency

clean-up fans V-25A and B, high efficiency particulate filters (HEPA) and
activated carbon charcoal filters, dampers, radiation monitor and controls.
During emergency mode of operation, the reactor building and containment
cooling building are isolated from normal supply and exhaust by closure of
dampers PO-9156, PO-9157, PO-9184, PO-9185, PO-9188, PO-9282, PO-
9283, PO-9284 and PO-9285.
 The emergency exhaust from reactor building and containment
cooling building are connected to suction of V-25A/B by opening dampers
PO-9187 and PO-9281 respectively. High efficiency particulate and
activated carbon charcoal filters are installed at suction of fans V-25A/B to
capture radioactive particulates and absorb radioactive gases from exhaust
air.

The discharge from V-25A/B is continuously monitored by radiation

monitor before release through the stack. The system is designed to maintain
the reactor building and containment cooling building at a vacuum of at least
0.25 inch H2O.

The system is designed for auto operation and comes in service on following
signals.

i) High radiation in reactor building exhaust duct.

Setting is 17 mr/hr (Tripping of any one out of two radiation
monitors).
ii) Drywell high pressure scram of either reactor.
iii) Loss of normal ventilation system (Due to loss of power or
tripping of both V-24A /B fans).
iv) Manual operation of control switch.

On actuation of the system the following actions occurs,

i) V-15A/B fans trip and PO-9156 and PO-9157 go close. PO-

9184, PO-9185 and PO- 9188 go close.
ii) PO-9282, PO-9283, PO -9284 and PO-9285 go close.
iii) PO-9187 and PO- 9281 open.
iv) Selected fan V-25A or B starts.

V-25A/B are normally controlled by three position control switch

(V25A-OFF-V25B) at panel C-80. The selected fan comes in service when
system is actuated. The stand by fan comes in service automatically if the
selected fan fails.

The fan V-25A/B and associated filters can be used for clean-up of
drywells also. The operation is controlled manually.
2) Drywell Ventilation System:

Drywell, suppression pool and common chamber form the primary

containment and are closed and locked during normal operation of reactor.
As suppression pools and common chamber do not have any equipment that
needs cooling, and as they are not open any time for personal entry, they
have not been provided with any normal ventilation system. However,
provision is there to vent and exhaust suppression pools and common
chamber. The operations are done manually.

The vent CVs of suppression pool and common chamber go close

automatically if the reactor scrams on drywell high pressure.

The drywell has been provided with ventilation and cooling system as
there are equipments requiring cooling during normal operation and persons
enter drywell during shutdown for works. The fresh cooled air supply to
drywell is supplied by fans V-15A/B through two air operated purge inlet
dampers (CV-1735 and CV- 1736 for Unit #1 and CV-2735 and CV-2736
for Unit#2) and one flow controller damper (PO-9160 for Unit #1 and PO-
9163 for Unit #2) all three in series. The exhaust from drywell is controlled
by two air operated purge outlet dampers in series. (CV-1737 and CV-1738
for Unit #1 and CV-2737and CV-2738 for Unit#2). The exhaust from
drywells, suppression pools and common chamber form a common
discharge duct. The exhaust is continuously monitored by radiation
monitors, and can be exhausted either to V-24A/B exhaust plenum through
CV-9171 or through emergency ventilation and clean-up system through
CV-9170.

The purge inlet and purge outlet dampers of both drywells go close if
exhaust duct show high radiation. These dampers also go close if the
associated reactor scrams on high drywell pressure.
The exhaust CV-9171 closes automatically on.

i) Drywell exhaust high radiation.

ii) Reactor building exhaust high radiation.

Three drywell cooler units are provided inside each drywell to cool
the drywell space and equipments inside drywell. The cooling unit consists
of fan, cooling coil and damper. RBCW system supplies the cooling water to
cooling coils. The fans are controlled from push buttons located in cable
spreading room. When the fan is started, the cooling water is turned on and
damper is opened automatically. The inlet and outlet air temperatures for fan
are indicated on T1-9144 on Exhaust system panel C-80 at stack basement.

There are four modes of operation of drywell ventilation system. The

mode of operation is selected by drywell purge switch (DPS) and manual
actions. The drywell purge switch has four positions, namely OFF, Clean-
up, Ventilation and Purge. The function of each position is described below:

a) OFF Mode: In this mode the drywell remains isolated as far as

ventilation and exhaust is concerned. No air is supplied to drywell and
no exhaust goes out. The three drywell cooler fans will be running to
control drywell temperature and cool equipments inside drywell.

b) Clean-up Mode: This mode is used to clean-up the drywell

atmosphere just before shutting down the unit or to clean-up the
primary containment following an accident. During this mode the
primary containment exhaust is prevented from going to main exhaust
plenum be closing of CV-9171 and it is passed through filters and fans
of emergency ventilation and clean-up system, by opening CV-9170.
When the DPS switches are kept in “Clean-up” mode, the selected V-
25A/B fan starts and CV-9170 opens automatically. The exhaust CVs
from concerned drywell or suppression pool or common chamber are
opened manually. A limited cool air supply (fromV-15A/B) of 2000
SCFM can be given to drywell by manually opening purge inlet CVs.
Auto closure of drywell purge inlet and outlet CVs on drywell exhaust
high radiation is bypassed in this mode of operation.

c) Purge Mode: This mode is used to cool down drywell at a faster rate
during shutting down. During this mode cool air of 6000 SCFM (from
V-15A/B) is supplied to drywell and exhaust plenum through CV-
9171. When the DPS switches are in “Purge” the standby V-15 fan
also starts automatically to meet the extra flow demand and the
CV-9171 opens. Purge inlet CVs and Purge outlet CVs of the
concerned drywell are opened manually.

d) Ventilation Mode: This mode is used to supply cool air to drywell

and provide ventilation during shutdown periods. When the DPS is in
“Ventilation” mode the drywell is exhausted to exhaust plenum
 through CV- 9171. The purge inlet CVs and purge outlet CVs of
concerned drywell are opened manually.

3) Radwaste Building Ventilation:

The radwaste building is supplied with filtered ambient air and the
exhaust is led to the plant main exhaust plenum. The system consists of
supply system, exhaust system, associated ducts and instrumentation.

The supply system consists of two 100% capacity fans V-

26A/B, filters, dampers, distribution ducts and DP controllers. The fan takes
outside air through filters and delivers it to distribution header. The fans are
controlled by three position control switch (V26A- OFF -V-26B) located at
panel C-80. When the control switch is selected for one of the fan, the
selected fan starts and its discharge dampers open automatically. From
distribution header the air is supplied to various areas and equipment
compartments of radwaste building. The supply to equipment compartments
is controlled by DP controllers and dampers to have slight negative pressure
in equipment compartments compared to surrounding areas.

Fan V-26A/B also supply air to containment cooling building through

dampers PO-9284 and PO-9285.

The exhaust from various areas and equipment compartments join

together to form a single radwaste exhaust header leading to plant main
exhaust plenum from where it is released to atmosphere through stack by
main exhaust fans V-24A/B. High efficiency particulate filters are provided
on exhausts from certain equipment compartments.

The normal exhaust from containment cooling building also joins the
radwaste exhaust header through dampers.
4. Turbine Building Ventilation System and Service Building (Non-air
conditioned areas) Ventilation System:

In general, the spaces in turbine building and part of service building

(i.e. non air conditioned part) are supplied with ambient, filtered air for
ventilation. The direction of air flow is controlled from areas of low
radiation towards areas of high radiation. The exhaust from uncontrolled
areas is directly released to atmosphere, where as exhaust from areas of
radiation hazards and from few equipment cells is led to plant main exhaust
plenum.

From exhaust plenum it is released into atmosphere at high altitude

through stack by main exhaust fans V-24A/B. The entire supply and exhaust
system consists of few sub-systems as described below.

a) Make Up Demineralisers and Lube Oil Area Ventilation System

The air supply system consists of two 100% capacity fans V-4A
and B, filters, flow controllers and dampers. The fans are controlled
by a local selector switch. The selected fan runs and supplies air to
make-up demin. area, lube oil area, TBCW heat exchanger area and
instrument vaults 1A and 2A through the ducts. The flow controller is
provided to give uniform flow rate irrespective of wind pressure at
supply louver. The flow is controlled automatically by adjusting
position of suction damper of fan.

The exhaust system consists of two 100% capacity fans V-5A

and B, and DP controllers. The fans are controlled by a local selector
switch. The selected fan runs and exhausts the air outside the building.
A DP controller is provided to control exhaust flow such that make-up
demin. area is at slight positive pressure compared to condenser
compartments. A small air flow is maintained from make-up demin.
area towards condenser compartments.

To prevent spreading of fire and loss of CO2, the fans V-4A/B

and V-5A/B trip automatically when cardox system actuates for lube
oil area.
b) Condensate Pump Compartments

The ventilation to condensate pump compartment is provided

by exhaust fan. There are two 100% capacity exhaust fans (1V-2A/B
and 2V-2A/B) for each unit. The fans are controlled by a local
selector switch. The selected fan runs to draw air from condensate
pump cell and discharge it to condenser compartment. The ambient
filtered air then enters the condensate pump cell. A temperature
controller is provided to adjust fan discharge flow and control the
temperature in condensate pump cell to about 50oC. The temperature
can be read on multipoint temperature indicator (T1-9054) mounted
on Ventilation Panel C-36 at Service building 148’ elevation.

c) Switchgear Areas

The ventilation to switchgear area is provided by supply fan.

There are two 100% capacity supply fans (1V-3A/B for Unit #1 and
2V-3A/B for Unit #2) for each unit. The fans are controlled by local
selector switch. The selected fan runs and supplies filtered ambient air
to switchgear area. The switchgear area remains at positive pressure
with respect to condensate pump cell, condenser compartment and
turbine building 133’ elev.

d) Turbine Building 133’ elev.(i.e. operating floor)

The normal ventilation to turbine building 133’ elev. floor is

provided by roof exhausters. There are 14 roof exhausters provided
out of which 12 will be in service and 2 will be as standby. The roof
exhausters are controlled by individual control switches provided at
133’ elev. The roof exhausters exhaust the air to atmosphere while
ambient air enters at operating floor through 8 wall louvers through
filters.

During radiation emergency in turbine building, the exhaust

from 133’ elev. is not released to atmosphere directly. During such
emergency the roof exhausters are stopped, supply air louvers are
closed and the exhaust from 133 ft. elev. is diverted to condenser
compartments. The exhaust air ultimately goes to plant main exhaust
plenum from where it is exhausted to atmosphere by main exhaust fan
 through the stack. Both main exhaust fans V-24A and B are run
during such situation.

e) Condenser Compartments

Condenser compartment of each unit has been provided with

area coolers (1V-16A/B for Unit #1 and 2V-16A/B for Unit #2).
There are two 100% capacity cooler units for each condenser
compartment. Each cooler unit consists of filter, cooling coil and fan.
SSW system provides the cooling water.

The fan sucks air through filter over cooling coil and distributes
it through ducts over condenser compartment area. The fans are
controlled by control switch located on Ventilation Panel C-36 at
Service building 148’ elevation. The fan selected by control switches
starts and the cooling water supply CV and discharge damper open
automatically. Temperatures of inlet and outlet air from fan are
indicated on T1-9054 located on panel C-36.

The air supply to condenser compartments is mainly by

infiltration of air from turbine operating floor, switchgear areas,
make-up/lube oil area etc. and exhaust from condensate pump cell.
The exhaust from condenser compartment goes to plant exhaust
plenum through horizontal pipe tunnel. The exhaust flow and vacuum
in horizontal pipe tunnel is maintained by DPC/PO-9180 for unit #1
and DPC/PO-9181 for unit #2. From exhaust plenum, the air is
released to atmosphere through stack by main exhaust fans.

f) Balance areas of Turbine building and part of Service Building

Filtered ambient air to balance areas of turbine building and

part of service building is supplied by supply fans V-11A/B and V-
11C/D. The fans are controlled by control switch located on panel C-
36. The selected pair of fans remain in service and supply filtered
ambient air through distribution ducts to feed pump area, air
compressors room, LCV room, Condensate drip tank area,
Mechanical vacuum pump and air ejectors room, Condenser
compartment, Chiller area, Corridor at 118’, RBCW heat exchangers
area, Feed water heater area 118’ elev., Turbine operating floor 133’
elev. etc.
 The exhaust from the above areas is classified in two categories
and is exhausted in different manners. Two 100% capacity exhaust
fans V-13 A and B are provided to exhaust areas of no radiation
hazards e.g. Feed pump area, Compressor room, Chiller area, RBCW
heat exchangers area, Exciter cubicles etc.

The exhaust air is released to atmosphere just outside the

building. The fans are controlled by control switch located on panel
C-36. The selected fan runs and its performance is observed by
pressure switch PS-9145. The standby fan starts automatically if the
running fan fails.

The exhaust from areas of radiation hazards e.g. from cells

containing air ejectors, condensate demineralizer and regeneration
facility is routed to plant main exhaust system through ducts. These
equipment cells are kept at negative pressure compared to surrounding
areas. The exhaust flow and vacuum in exhaust duct is controlled by
DPC/PO- 9182 (for Unit # 1) and DPC/PO- 9183 (for Unit # 2). The
exhaust is ultimately released to atmosphere via stack by main exhaust
fan V24A/B.

The supply and exhaust of air compressors room is controlled

by air operated dampers. Ventilation to service building 148’ elev. is
provided by 4 roof exhauster (V-43A, B, C and D).

5. Service Building Ventilation System (Air conditioned areas).

The service building is provided with central multi zone air

conditioning system. The system consists of air supply units, the distribution
ducts, temperature controls, exhaust system.

There are two 100% capacity air supply units. Each unit consists of
two fans (V6A/B and V6C/D), cooling coil, discharge dampers etc.

The outside ambient air is first filtered and cooled to approx. 21°C by
pre cooling coil. The pre cooling coil is supplied with chilled water and
chilled water flow is controlled by TIC/TCV- 9071 to pre cool air up to
 21°C. The pre cooled ambient air and return air from various air conditioned
areas mix together and go to suction of fans V6A/B and V6C/D.

The discharge air from V6A/B and V6C/D flow over after cooler
cooling coil in cooler section of air supply unit. Fourteen outlet ducts from
cooler section join together in fourteen distribution headers. Each header
supplies air to one zone of multi zone air conditioning system. The
modulating dampers (one for each zone) at outlet of cooler section maintain
cooled air supply to the various zones.

The fans V6A/B and V6C/D are controlled by the control switch
located on panel C-36. The selected pair of fans runs and their performance
is monitored by PS- 9245. The standby pair of fan starts automatically if
running pair of fans fails.

When control switch selects fans V-6A/B, the selected fans start and
solenoid valves SV-9074A and SV-9075 energize. SV-9075 admits air of 20
psi and open supply dampers PO 9075-1 thru’ PO 9075-14 for 14
zones. It also admits air and close chilled water CV-9079 associated with
cooling coil of V-6C/D fans. SV-9074A admits output of dew point
controller DS/DC 9074 to PE 9427 and Pre 9077 also receives output of TIC
9077.

Following are fourteen zones of air conditioning system:

Zone-1 Service Building 133’elev. - NMS battery bank and chargers

for Unit#2, Invertors DY-02A/C, SOE
and Refueling Office.

Zone-2 Service Building 133’elev. - 240V DC Battery Bank Unit #2.

Zone-3 Service Building 133’elev. - 240V DC Battery Chargers

G- 4C/D, SE(O) room, Toilets.

Zone-4 Service Building 133’elev. - Main Control Room.

Zone-5 Service Building 133’elev. - Shift Briefing room, Control
Room Corridor, 240 V DC
Battery Bank Unit #1.

Zone-6 Service Building 118’elev. - Invertor DY02-B, YO5-B panel, D15-

B room, Toilets.

Zone-7 Service Building 118’elev. - Health Physics Offices.

Zone-8 Service Building 118’elev. - Lab Counting Room.

Zone-9 Service Building 118’elev. - Hot Laboratory.

Zone-10 Service Building 118’elev. - Cold Laboratory and Office.

Zone-11 Service Building 118’elev. - Cable Spreading Room

Division#1 and Division#2

Zone-12 Service Building 118’elev. - H.P. Calibration Room, Portal

Monitors/Turnstile Gate area.

Zone-13 Service Building 103’elev. - Service Building North Entrance

Zone-14 Service Building 103’elev. - ROE room, Nuclear Inst.

Calibration room, Locker room, Service
Building South Entrance.

The most of the conditioned air (about 75%) supplied to the above zones is
recycled for economical reasons. The areas from where the air cannot be recycled
are exhausted to atmosphere as described below:

a) Exhaust from Compressor room, RBCW heat exchanger area, Both units
exciter cubicles, Chiller area, Both Units Condensate demin. Operating area,
NMS battery chargers #1, ROE room, Locker room, 118’ ele. And 133’ ele.
Toilets are connected to exhaust fan V-13A/B.

b) Exhaust from hot lab, cold lab and counting room is exhausted by separate
fan V-9A/B. The fan material is corrosion resistant. High efficiency filters
are provided at suction of fans. The fans V-9 A/B are controlled by control
switch located at panel C-36. The fan selected by control switch runs and its
 performance is monitored by PS-9024. The standby fan starts automatically
if running fan fails.

c) The exhaust from H.P.Calibration room and Portal Monitors/Turnstile Gate

area is exhausted by separate fan V-10A/B. Here also fan material is
corrosion resistant and high efficiency filters are provided at suction of fans.
The fans V-10A/B are controlled by control switch located at panel C-36.
The selected fan runs and its performance is monitored by PS-9126. The
standby fan starts automatically if running fan fails.

d) New change room is provided with two exhaust fans V-53A/B, out of two
exhaust fans one will be in service which takes outside air through louvers.
One exhaust fan V-54 is provided for above fan room.

6) Battery Bank Unit #2 Ventilation

240 V DC Battery bank Unit#2 located in Service building zone-2 is

supplied cool air from V-6 A/B or V-6C/D. Two Separate exhaust fans 2V-
8A/B located inside V-53A/B room are provided for exhaust, one of which
is normally running while other remains standby.

7) New Laundry Building Ventilation

New laundry building is provided with a supply fan V-56 and an

exhaust fan V-59. Electrical interlock trips supply fan V-56 whenever
exhaust fan V-59 trips. Radiation monitor is provided in suction duct of V-
59 which trips the fan at preset value.

8) Intake Structure Ventilation

The ventilation of intake structure is provided by seven roof

exhausters V-42A through G. The fans are controlled from local panel in
intake structure. The hot air is exhausted from top and ambient air enters
through wall louvers. The chlorination equipment area is exhausted by fan
V-42G. Ducts are provided at fan suction for taking suction from ground
level as chlorine gas is heavy and settles at the ground level during leak.
9) Workshop Building Ventilation

The general ventilation to workshop building is provided by roof

exhausters V-38F, G, H, J. The fans are controlled from local panel in
workshop. The hot air is exhausted from top and ambient air enters through
wall louvers

10) Administration Building Ventilation System

The administration building is provided with multi zone air

conditioning system similar to that of service building. The system has nine
zones and four air supply units. Each unit consists of a fan, discharge
damper, cooling coil, filter, TCV for controlling chilled water flow. V-28 fan
supplies cool air to Zone- 1, 2 and 3 (C.S. office, Offices of Superintendents
and PA lobby). V-30 fan supplies cool air to Zone-4, 5, 6 (Model room,
Offices in north side and lobby in front of north side offices). V-32 fan
supplies cool air to Zone-9 (Old Conference hall and S.M. HR Office), V-34
fan supplies cool air to Zone-8 (Administration Staff at ground floor).
DRG 61A
 Compressed Air System
The purpose of the compressed air system is to supply clean oil free service
air and clean, oil free and dry instrument air to all plant services which require
them. The instrument air is mainly used for pneumatic instruments and valve
operators. Major uses of service air are sparging and transfer of resins, air
agitation of filter sludge tanks and spent resin tank, backwashing of radwaste
filters, pressurization of hydro-pneumatic tanks. The normal operating pressure of
system is 100 psig.

The original compressed air system consisting of suction air filter, silencer,
three air compressors K1A, K1B, K1C, three after cooler E12A, E12B, E12C, four
air receivers T11A, T11B, T11C, T11D, pre-filters F2A/B, after filters F7A/B, air
dryers S-27A/B, piping, instrumentation and controls etc. To augment the system
capacity an additional compressor K-1D, after cooler, air receiver T-11E and
filter E-18 has been installed in year 1979 and one more new instrument air dryer
installed in year 2009.

K-1A, K-1B, K-1C are identical non lubricated, horizontal reciprocating,

single stage, double acting, teflon piston ring type air compressors. Each
compressor is driven by 100 H.P. motor and has capacity of 320 SCFM at 105 psi.
(7.4 Kg/cm2). The after cooler of each compressor cools the discharge air to 45-
50oC and removes the moisture that condenses during cooling. RBCW system
provides cooling for after coolers and compressor cylinder jackets. The cooled
compressed air is then delivered to individual air receiver of 96 CFT capacities. A
check valve is provided on air inlet to receiver to prevent back flow of air. Outlets
from all three air receivers are connected into common header.

Two separate air supplies, the instrument air supply and the service air
supply are taken from the common outlet header of the air receivers. Instrument air
is processed through pre filters, after filters and instrument air dryer. Service air is
distributed in the plant without further processing. Service air is normally supplied
by K-1D but in case of K-1D unavailability it is supplied by K-1A/B/C.
 A back pressure regulator PCV-220 is provided on service air header to
maintain the upstream pressure. In case the compressed air system pressure is
falling the PCV 220 cuts down service air supply and helps to maintain instrument
air supply.

PS-222 is provided to give service air header low pressure alarm in control
room. The fourth air receiver T-11D is provided to take care of large service air
requirement of Radwaste in radwaste building at 87’ elevation.

The instrument air supply is filtered and dried before distribution in the plant
so as to meet the requirement of clean and dry instrument air supply. Two sets of
filters (pre filters and after filters) are provided to remove particulate matters of 0.3
micron and larger and air dryers are provided to remove moisture. There are two
instrument air dryers which are twin tower, regenerative, desiccant type using
silica gel for moisture removal. The old air dryer is located between pre-filters and
after filters and new air dryer is located in front of Compressors K-1A/B/C.It
reduces the instrument air dew point to – 50oF (– 45oC) at 105 psig.

Out of two air dryer chambers, one will be in service and other will be under
regeneration. Regeneration of air dryer chamber is done by passing hot air through
the silica gel. A blower and electric heater is provided for regeneration of air
chambers. The regeneration cycle is automatically carried out by timer. The cycle
time of old instrument air dryer is 5 hours and the new air dryer is 8 hours. Dew
point temperature indicator is provided at the outlet of after filters. PS-224 is
provided on instrument air header to give “instrument air header low pressure”
alarm in control room. PS-229 is provided to automatically bypass filters and
instrument air dryers in case instrument air header pressure falls down to 80 psig.

Compressors K-1A, K-1B, K-1C have an automatic three step load control.
In this method of control, the compressors run continuously but, they deliver 0%,
50% or 100% of their capacity depending on demand of the compressed air.
Normally two compressors are kept running and third is on standby.

The running compressors run on no load if system pressure reaches 105 psig.
The compressors start delivering 50% if the system pressure falls to 100 psig. and
they start delivering 100% if the system pressure falls to 98 psig. The standby
compressor starts automatically if system pressure falls to 95 psig.

Compressor K-1B and C are supplied from emergency bus BO4 and BO5
respectively. In case of total loss of power incident, K-1B or K1C can be started
manually to meet the instrument air requirement. Compressors K-1A/B/C are
provided with” Discharge air high temperature” alarm in Main Control room.

In order to ensure more supply of service air without affecting instrument

air, the system capacity was augmented by installing a separate compressor K-1D
for service air. K-1D is a horizontal, reciprocating, two stage, double acting and oil
lubricated piston ring type compressor. It is driven by 125 H.P. motor and has a
capacity of approximately 500 CFM at 105 psig. RBCW system provides cooling
for inter cooler, after cooler and cylinder jackets. The cooled compressed air is
delivered to air receiver T-11E. T-11E outlet line is connected to service air
system in the radwaste building. During normal operation K-1D is supplying all
the service air requirements of the station. Power supply to K-1D is from 1 MVA
sub station. Compressor K-1D has an automatic three step load control. The
compressor runs continuously and will deliver 0%, 50% and 100% of its capacity
depending on demand of service air.

As per new FCN K-1D air supply is connected across PCV-220 with non-
return valve and manual valve, so that in case air supply for instrument air is not
sufficient from compressors K-1A/B/C then air supply for instrument air can be
obtained from K-1D air compressor. K-1D is provided with Discharge air high
temperature, Low lube oil pressure protection. If there is any alarm on K-1D
annunciation control panel, Main control room will receive “K-1D trouble alarm”.
Relief valves are provided on all the air receivers to protect them from over
pressurization.
New Instrument Air Dryer

The instrument air is filtered and dried by a twin tower, regenerative,

desiccant type dryer with pre-filter and after filter. The instrument air system
provides the energy used by the pneumatic instrumentation and the pneumatic
control valves in the control of the individual processes. In addition, it supplies the
energy required to open and/or close the reactor and drywell air operated isolation
valves.

Drier has 320 CFM capacity with operating pressure of 7.0 kg/cm2. The
dryer has two desiccant bed towers or chambers. One chamber will be under
Adsorption mode and the second chamber will be under regeneration mode. Drier
has two parallel pre-filters at inlet and two parallel after-filters at outlet along with
one number of electric heaters and two number of blowers. The heaters and
blowers of air dryers are supplied by 415 V AC, class-IV electric power supply.
Each drier bed is provided with RV set at 8.2 kg/cm2.

Four way ball valve with double air ports are used for tower isolation.
Desiccant used in Drier beds is silica gel with operating life of 36 months.

These units remove all particulate matter of size 3 microns and larger and
reduce the instrument air dew point to – 50 o F (– 45.56 o C) at 105 psig (7.38
kg/cm2).

New Instrument Air Dryer Chambers and its associated control panels are all
installed in service building 103’ ele. air compressor room.

The new air dryer is installed parallel to existing air dryer and one of the two
is acting as a stand by unit. The Drier is of heat convection blower regeneration
type.
 The regeneration system is completely independent of adsorption system and
uses air drawn from atmosphere by an external blower. The air is heated in an
external electric heater and made to pass through the tower under regeneration. The
hot air regenerates the desiccant and removes the moisture absorbed by the
desiccant.

Operating cycle time of air drier (Chamber under regeneration) is of 8 hours.

Operating cycle consist of depressurization of chamber, regeneration, re-
pressurization and drying operation. Cycle change over, depressurization and re-
pressurization operations are automatic. The control system is fully automatic
operation and based on Programmable Logic Controller (PLC). The control system
is designed such that the air drying process is continuous.

Air drying plant can be operated manually, if required.

Working of new IAD on AUTO:

Assuming RHS chamber (B) is under regeneration. Total 8 hours is required

for complete regeneration of the chamber. The complete regeneration cycle with
timing for each activity is described below:

IAD Cycle: 8 Hrs.

A) 15 min. Depressurization Cycle

Total

i) SV1 ON for 2 min. 0 to 2 min. 2 min.

ii) SV5 ON for 18 min. 2 to 20 min. 18 min.
B) 5 Hrs. Heating Cycle

i) Blower ON for 7 Hrs 10 min. 20 to 450 min

7 Hrs 10 min
ii) SV4 ON for 7 Hrs 10 min. 20 to 450 min
7 Hrs 10 min
iii) Heater ON for 5 Hrs. 25 to 330 min
5 Hrs.
iv) SV3 ON for 5 Hrs. 25 to 330 min.
5 Hrs.
v) LS3 Actuated for 5 Hrs. 25 to 330 min.
5 Hrs.
vi) LS4 Actuated for 7 hrs 10 min. 20 to 450 min
7 Hrs 10 min

C) 2 Hrs. Cooling Cycle

i) Heater OFF for 2 Hrs. 330 to 450 min 2 Hrs.

D) 30 min. Re-pressurization Cycle

i) SV6 ON for 30 min. 450 to 480 min 30 min

E) 15 min. Idling Cycle

i) SV2 ON for 2 min. 0 to 2 min 2 min

DRG 67A
DRG 67B
DRG 67C
DRG 67D
 Turbine Generator

The purpose of turbine-generator is to convert the heat energy of nuclear

steam supply system (NSSS) into the electrical energy. The turbine converts heat
energy into mechanical energy and drives the generator. The generator converts
mechanical energy into electrical energy.

Almost dry saturated (0.23% moisture) steam from reactor at the rate of 904
MT/Hr. at 68.5 Kg/cm2 pressure is used. The generator is rated for 248 MVA at
0.85 lagging power factor and 12 KV voltage.

Turbine

1) Description

The turbine is a tandem compound impulse type with dual

admission, single flow, high pressure unit and single admission, dual
flow low pressure unit, with 35 inch long last stage buckets. The
rated speed of turbine is 1500 RPM. The high pressure (H.P.) unit has
18 stages and low pressure (L.P.) unit has 4 stages (19th to 22nd). A
cross with over with high integral moisture separator is provided
between H.P. and L.P. unit.

The saturated primary steam is admitted to the first stage of the

H.P. unit through two primary stop valves and four primary control
valves. Seven bypass valves are provided upstream of primary stop
valves to bypass primary steam directly to condenser whenever
primary steam generated in the reactor is more than the requirement of
turbine. The steam exhausts from the H.P. unit after 18th stages and
flows to L.P. unit through a crossover. The steam exhausts to the
condenser after 22nd stage.

As the steam passes through the turbine stages, it expands and

becomes more and more wet. It becomes necessary to remove
moisture from steam at certain stages to minimize erosion of turbine
blades. Moisture is removed from turbine at 2nd, 3rd, 4th, 13th, 18th, 20th
and 21st stages. These are known as moisture removal stages. All
 moisture removal lines are provided with orifices to limit the flow
from turbine.

The moisture removed is taken to next low pressure feed water

heater for heating the feed water. In addition, the steam is extracted
from 6th, 10th, 15th and 19th stages of turbine for heating the feed water
and improving plant thermal efficiency. These are known as
extraction stages. Turbine blades at moisture removal stages and
extraction stages have grooves machined into their backsides near the
leading edge. These grooves trap moisture which is then centrifugally
thrown away in to the turbine casing.

2) Turbine Control

The turbine is controlled by a compound control mechanism

which operates the primary control valves and bypass valves in proper
co-ordination so as to control the reactor pressure, speed and load of
turbine at desired set values. The normal input signals to the
compound control mechanism are:

i) Reactor pressure set point as set by one of the two mechanical

pressure regulators – P-1.
ii) Actual reactor pressure.
iii) Turbine speed/load set point as set by the speed/load changer –
S-1.
iv) Actual speed/load of turbine.

The signal P-1 represents primary steam available from the

reactor and the signal S-1 represents total steam flow requirement of
the turbine.

The normal output signals of compound control mechanism are:

i) Position of primary control valves V-1.
ii) Position of bypass valves V-3.

Positions of primary control valves and bypass valves are

adjusted by compound control mechanism, such that reactor pressure
and turbine speed/load is controlled at desired set points. For
example:
 If primary steam generation (P-1) is more than steam required
by turbine (S-1) then bypass valves are opened to bypass steam to
condenser and maintain the reactor pressure. If steam generation (P-
1) is less than steam requirement of turbine (S-1) then secondary
control valves are opened to meet the turbine requirement. (presently
secondary steam system is not in use)
The normal input and output signals from compound control
mechanism can be manually over-ridden by following control devices:

i) Main load Limit:

It can over-ride the speed/load changer signal and call for lesser
steam flow to the turbine than that desired by speed/load
changer.

ii) Primary lift limit:

It can over ride the signal V-1 and call for lesser opening of
primary control valves than that desired by compound control
mechanism.

iii) Bypass valves opening Jack:

It can over ride the signal P-1 and call for higher opening of
bypass valves or primary control valves than that desired by
mechanical pressure regulator.

The main operating controls of compound control system can

be operated from the main control room by means of D.C. gear motors
mounted on their adjusting mechanisms. The position of each
adjustment is tele-metered back to the main control room by means of
selsyn transmitters and receivers.

3) Turbine Protections

The protective devices are provided to cut off steam supply

from turbine so as to protect the turbine and/or other plant equipments
under abnormal conditions. These devices are:

i) The Emergency Governor

 It trips the turbine (i.e. closes all steam admission valve and
bleeder trip valves) when the turbine speed reaches 110% of
rated.

ii) The Back-up overspeed trip

It trips the turbine when the turbine speed reaches 112% of

rated. It acts as back-up in case the emergency governor does
not work.

iii) Turbine Master Trip

This device is provided to trip the turbine. It can be operated:

a) Manually from turbine front standard.

b) Manually from control room by a control switch and a
push button.
c) Automatically by the operation of turbine lockout relay.

iv) Vacuum Trip No.1

This device senses condenser vacuum. It gives condenser low

vacuum alarm at 24 inch of Hg Vacuum (61 cms. Hg vac) and
scrams the reactor at 23 inch Hg Vacuum (58.5 cms Hg Vac).
The device trips at 20 inch Hg Vac (51 cms Hg vac) and causes
turbine trip. The device can also be tripped:

a) Manually from control room by a control switch.

b) Automatically by the operation of turbine lockout relay.

v) Vacuum Trip No.2:

This device also senses condenser vacuum, gives condenser low

vacuum alarm and scrams the reactor like vacuum trip No.1.
Further, it trips Turbine through Turbine lockout relay at 18
inch of Hg Vacuum. (46 cms Hg Vac). The device trips at very
 low vacuum of 10 inch Hg. (25 cms Hg.) and closes the turbine
bypass valves.

vi) Anti monitoring protection

This protection prevents running of turbine by drawing power

from grid when the steam admission valves are closed. The
generator breaker opens automatically if steam supply to
turbine is interrupted.

vii) Turbine Lockout relay

Tripping of turbine lockout relay trips the master trip, vacuum

trip No.1, generator breaker and generator field breaker. The
turbine lockout relay trips on following unsafe conditions.

a) High water level in the reactor.

b) Exhaust hood high temperature.
c) Cross over high pressure.
d) Condenser low vacuum.
e) Turbine thrust bearing wear.
f) Generator lockout relay trip.
g) Manual (by vacuum trip No.1 control switch)

4) Turbine Supervisory Instruments

Turbine Supervisory instruments are provided to assure safe

startup, operation and shutdown of turbine. Most of the turbine
parameters are continuously recorded in control room. e.g.

a) Turbine bearing vibrations.

b) Turbine shell and differential expansion.
c) Turbine valve positions (Primary Control Valves and Bypass
valves).
d) Turbine Speed.
e) Turbine Eccentricity.
f) Turbine Bearing oil temperatures.
g) Turbine Bearing metal temperatures.
h) Turbine shell, valve chests and exhaust hood temperatures.
 Also number of annunciations are provided in main control room to
indicate abnormal conditions.

5) Turning Gear

When the turbine is shutdown, the cooling of its inner elements

continues for many hours. If the turbine rotor is allowed to remain
stand still during this cooling down, it results in uneven cooling and
the distortion of rotor. Turning gear is provided to rotate the turbine at
low speed (about 2 RPM) during cooling down so that cooling is
uniform.

Turning gear consists of 20 HP motor and a gear train. When

the turbine speed comes down below 2 RPM, the turning gear
automatically engages to mating gear on turbine shaft. The facility is
provided to engage turning gear manually also. During turbine
startup, the turning gear automatically disengages when turbine speed
exceeds the turning gear speed. Lubrication to gear train is supplied
by turbine bearing oil system.

Generator and Exciter

1) Description :

The generator is a Y connected, three phase, 50 cycles, 1500

RPM four pole machine with a maximum rating of 248 MVA at
12KV, 11.93 KA and 0.85 (Lagging) power factor, when excited by
1045 amps. D.C. and cooled by hydrogen at 15 psig (1kg/cm2). The
excitation is provided by a main shaft coupled, gear driven, air cooled,
amplidyne controlled, self excited D.C. generator of rating 685 KW at
375 V. D.C.

The generator is housed in a gas tight cylindrical casing of

welded steel plate construction. The frame supports stator core
punchings from spring mounted key bars and also the rotor from the
heavy end shields containing bearings. The six hydrogen coolers are
bolted to the top of frame.
 The generator stator core is made of steel laminations to reduce
eddy current losses in the core. Groups of laminations are separated
by spacers to form hydrogen cooling ducts.

The laminations are punched and mounted so as to form long

slots in which the stator core windings lie. The top of these slots are
dovetailed for the insertion of slot wedges which hold the windings in
place.

The stator winding is formed of insulted bars, assembled in

stator slots, joined at the ends to form coils, and connected in the
proper phase belts by bus rings. Six winding terminals are brought out
to six high voltage bushing mounted on the bottom of generator
frame. Three bushings are used to form neutral terminal and other
three bushings are used to connect three phases to the isolated phase
bus.

The generator rotor is vacuum cast and machined from a single

ingot. The rotor has longitudinal slots machined radially in its body
for insertion of the field winding. Smaller slots are machined within
these field winding slots to allow circulation of hydrogen coolant. The
field coil assembly is made of layers of insulated copper conductors.
The field coils are connected to the collector rings by conductors fed
through a hollow bore in the shaft and up through gas tight insulated
bushings mounted in radially drilled holes. Axial flow fans are
mounted on each end of rotor for circulation of hydrogen gas and
cooling of the generator.

The exciter is air cooled, 685 KW, 375V, self excited D.C.
generator driven by the main shaft through an insulated flexible steel
coupling and a reduction gear. The exciter output is controlled by an
amplidyne in its field circuit, which in turn is controlled by a solid
state voltage regulator connected to main generator potential
transformers. Increase or decrease in generator voltage is sensed by
the voltage regulator which changes the excitation of amplidyne
control field windings. This action causes the amplidyne to Buck or
Boost the excitation of the exciter, so that exciter output (i.e. main
generators field current) decreases or increases to adjust the generator
terminal voltage.
2) Generator Protection :

Following protection relays are provided to isolate the

generator in case of fault so that the damage to the generator by fault
current is minimum.

a) Generator over current start-up.

b) Generator over current voltage restraint.
c) Generator differential – zone A.
d) Generator and Main transformer differential zone-B.
e) Generator neutral over voltage – start up.
f) Generator neutral over voltage.
g) Generator under frequency.
h) Volts/Cycle over excitation.
i) Main transformer sudden pressure.
j) Auxiliary transformer sudden pressure.
k) Auxiliary transformer differential.
l) Auxiliary transformer ground over current.

The actuation of any one of the above protection relays trips the
generator lockout relay which isolates the generator by carrying out
following actions.

a) Trip Turbine lockout relay.

b) Trip generator main breaker.
c) Trip generator field breaker.
d) Trip Secondary breakers of unit auxiliary transformer.

Following protections are provided to trip the main generator breaker

alone so as to seperate the generator from feeding the outside faults.

a) 220KV switchyard zone differential.

b) Main transformer phase over current.
c) Generator loss of excitation.
d) Generator negative phase sequence over current.
3) Generator Supervisory Instruments :

Generator supervisory instruments are provided to assure a safe

operation of the generator. Following generator parameters are
continuously recorded in control room.

a) Generator stator temperature.

b) Generator rotor temperature.
c) Generator Hydrogen gas temperature.
d) Generator voltage.
e) Generator frequency.

Also there are some indicating instruments and number of

annunciations provided to indicate abnormal conditions.
 TURBINE LUBE OIL SYSTEM
The oil required for bearing lubrication and hydraulic control system of each
turbine is stored in its Turbine lube oil reservoir .The oil is pumped to the various
services by the Main shaft driven oil pump. This centrifugal pump is gear
connected to the turbine shaft and takes suction from the Turbine lube oil reservoir
via the oil Booster pump. The main shaft pump discharges directly to the hydraulic
header at about 200 psig. A second line from the Main pump discharge carries the
bearing lube oil through the oil cooler before discharging in to the lube oil header
at about 25 psig. The 150 psig pressure loss in the Oil Booster pump turbine drives
the oil booster pump.

The Main shaft pump is backed up by two 150 hp A.C. motor driven
auxiliary oil pumps. These can be manually started or automatically by low
pressure in the Main shaft pump discharge header. These auxiliary oil pumps are
used in the initial start-up of the turbine when main shaft pump is turning too
slowly to develop sufficient pressure as well as providing back up, should the main
shaft pump fail during normal speed operation. Backing up the auxiliary oil pumps
and to protect the bearings for an orderly shutdown is the Turning Gear Oil Pump,
which will start automatically on low pressure in the bearing oil header. This pump
operates when the unit is on turning gear and supplies only the bearing lube oil, not
the operating oil.

An auxiliary power failure could render the turning gear oil pump and
Auxiliary oil pumps useless, so they are further backed up by a small D.C. motor
driven Emergency Bearing oil pump. This unit is automatically started upon
abnormally low pressure in the bearing oil header.

Before oil is fed to the bearing oil header it is pass through one of two oil
coolers. These coolers are cooled by TBCW. A small motor driven blower is
mounted on the Turbine lube oil reservoir to extract any moisture laden air or
traces of hydrogen that might be present in the tank. This small motor driven
blower keeps the tank at a slight vacuum (approx. 1.5” W.G.) and runs
continuously.
 Turbine lube oil can be continuously extracted from either of the turbine
lube oil reservoirs and passed through the lube oil conditioner. This unit can
process 2600 gallons of lube oil per hour.

The storage capacities of the Turbine lube Oil Reservoirs are backed up by a
6200 gallons clean lube oil tank and 6200 gallons Dirty Lube oil tank. These tanks
along with the lube oil pumps and lube oil conditioner are located at 103’ elevation
in the Turbine Building Make-up demin area.

Each turbine has a motor driven turning gear which will revolve the turbine
shaft at 2 rpm. The turning gear should be engaged before start-up and after
shutdown to prevent temperature gradients from bowing the shaft.

LUBE OIL CONDITIONER

General Description:

The system consists of bowser type conditioner, a circulating pump

(filter pump P-75), a transfer pump (P-29), a clean oil and a dirty oil storage
tank of 6,200 gallons capacity each and all the associated piping for
transferring oil from one to another. The oil to be conditioned comes from
the turbine reservoir 1T-29 and 2T-29 through automatic over-flow
arrangement and the conditioned oil is returned back to the reservoir by a
filter pump. Fresh stock of oil from clean oil tank is also transferred via
bowser to the lube oil reservoirs.

The lube oil conditioner itself consists of 3 compartments

i) Precipitation compartment.
ii) Filter compartment
iii) Clean oil storage compartment.

i) The precipitation compartment:

The oil enters the precipitation compartment either from the

turbine lube oil reservoirs or from clean oil tank and the water from
the oil is separated here. The oil rises through large mesh screens and
overflows to the filter compartment. The precipitation compartment
has a water seal at the bottom. Raw water is added in the compartment
before putting oil. Water being heavier than oil settled at the bottom
 and oil floats over it. A stand pipe and nipple arrangement is provided
to remove precipitated water in the compartment. Water Seal level can
be seen in level glass.

ii) The filter compartment:

The oil that is overflowing from the precipitation compartment

passes through a number of filter elements (bag type filters). The oil
passes through these filters and flows into the storage compartment
through nozzles. The filter removes particles larger than 2 micron and
also the remaining water.

iii) Clean oil storage compartment:

Here, the filtered oil is stored and also provides suction for the
filter pump. The polishing cartridge type filters are housed in this
compartment. The filter pump, pumps oil through the cartridge type
filter before delivering it into the reservoirs.
DRG 79A
DRG 79B
 Turbine Shaft Sealing System

The steam seals are provided at each point where the turbine shaft penetrates
the turbine casing. These seals prevent escape of steam or inhalation of air from
these shaft penetrations and allow full vacuum to be drawn in condenser while the
turbine is on turning gear. There is a steam seal at each end of H.P. and L.P.
turbine, total four shaft seals are there in all.

The seals are of labyrinth type which provides series of throttling paths that
limit steam or air leakage along the rotating shaft to a minimum as it is throttled
from the high pressure space to low pressure space. The seals consist of stationary
and rotating teeth arranged concentrically with small radial clearances, thus
presenting a high resistance to the flow of steam/air and greatly reducing the
amount of leakage.

The rotating portion of seal consists of step recesses machined directly on

the turbine shaft while the stationary elements are bronze segment rings with teeth
machined integral in the material.

The entire shaft sealing system consists of pressure packing, vacuum

packing, seal steam supply. Seal steam pressure regulator, seal steam exhauster,
hold up line, motor operated valves, piping and instrumentation.

Pressure packing are those that seal against steam leakage at full load. At
light loads, when vacuum exists throughout the turbine, they seal against air in
leakage into the turbine. The pressure packing have a so called “atmospheric leak
off” which is held at 3 to 4 psig. by supplying seal steam. Steam is fed into the
packing through this leak off line at light loads. At higher loads when turbine stage
pressures build-up, steam flows from the packing into the atmospheric leak off.
Pressure packing also has one (or more) pressure leak off which discharges
steam to high pressure extraction points.

Beyond the atmospheric leak off, there is a vent annulus which is held at
slight vacuum (3” to 5” of water gauge) by steam seal exhauster. The steam seal
exhauster takes steam from vent annulus and air pulled from the atmosphere.
 Vacuum packing are those which always seal against air in leakage into
turbine. The vacuum packing have atmospheric leak off. It is always maintained at
3 to 4 psig, by supplying steam from seal steam header.

Beyond atmospheric annulus, there is a vent annulus similar to that of

pressure packing. The vent annulus is held at slight vacuum by seal steam
exhauster.

The steam requirements of steam seal system depend on the load of turbine.
At low loads, there is little or no steam leaking into atmospheric leak off from
pressure packing and therefore steam is supplied to seal steam header to maintain
the seal steam header pressure. At high loads the steam leaking into atmospheric
leak from pressure packing is in excess of steam required by vacuum packing and
therefore steam is unloaded from seal steam header so as to maintain seal steam
header pressure. The steam unloaded is led to low pressure extraction points.

The steam supply for steam seal system is taken from primary steam line
before turbine stop valves. A seal steam pressure regulator is provided to maintain
seal steam header pressure at 4 psig. The seal steam pressure regulator is a
hydraulic device operated by turbine operating oil. The regulator operates two
valves namely steam admission valve and steam unloading valve. The regulator
maintains seal steam header pressure by admitting the steam or unloading steam
from seal steam header depending on pressure.

During start-up, when the supply steam pressure is low, seal steam header
pressure is maintained by opening regulator bypass valve (MOV-1212) from
control room. The regulator starts functioning when supply steam pressure is
around 350 psig. The bypass valve is then closed. Another valve (MO-1214) is
provided to unload seal steam header manually, in case the regulator is not
working. The regulator is provided with isolation valves which permits its isolation
while turbine is in operation.

A pressure switch is provided to give alarm in main control room, when seal
steam pressure falls below set value.

The seal steam exhausters are provided to maintain a vacuum of

approximately 10 inch to 12 inch of water in seal steam exhaust header and vent
annuli of shaft seals so as to prevent steam escape to atmosphere and air in leakage
into turbine. Air and steam from vent annuli are carried to gland seal condenser,
where steam is condensed and air/non-condensable gases are extracted by
exhauster fans.

The condensed steam is drained to condensate drip tank through a loop seal.
The exhausted gases go through a 20 inch dia hold up line to the plant stack.

The gland seal condenser is a shell and tube type condenser. The cooling is
provided by main condensate system. Two exhausters, each driven by 5 H.P. motor
are provided. Normally one exhauster is in service and other is available as
standby. A hold-up line is provided to give decay time for radioactive gases. It
gives decay time of 1.75 minutes.
DRG82A
 Generator Cooling System

Heat is generated in the generator as a result of eddy current and hysteresis

losses during its operation. The purpose of generator cooling system is to remove
the heat generated within the machine so as to assure efficient operation. Hydrogen
is used for generator cooling which in turn is cooled by T.B.C.W. system.

Hydrogen gas is used for cooling the generator because of its low density
and high thermal conductivity results in low windage losses and cooler operation.
The other advantages are cleaner operation and longer insulation life. The high
purity hydrogen does not support combustion so that fire danger is eliminated in
properly sealed machine.

The cooling of all generator components is achieved by closed loop

hydrogen cooling system. Hydrogen gas is circulated within generator by a single
stage fan at each end of generator, mounted on generator rotor. Stator ventilation is
achieved by forcing the cooling gas both inwardly and outwardly through the
radial ducts in the core forced by the punching and the spacer blocks. The
circumferential plates in the frame and back of the core, together with the outside
wrapper plate form sections which separate the frame into high pressure and low
pressure regions, through which the cooling gases are forced into or discharged
from stator core. The gas supplied to and discharged from these sections is
conveyed through ducts which direct the gas from the fans through the machine
and back to fans through the cooler.

Cooling of rotor winding is accomplished by hydrogen gas flow in direct

contact with copper winding. The gas from fans at each end of rotor is fed under
the retaining rings towards the center of field to cool the windings. The end turns
are cooled in the first portion of gas flow, before the gas enters a series of sub slots
under the coils. Gas entering these sub slots from each end and progressing
towards the center of field is allowed to flow radially outward through the
windings in a series of parallel paths created by multiple elongated holes in the
winding and the wedges.
 Six hydrogen coolers are installed in stator frame, three on either side of
rotor. Each cooler consists of a pair of water boxes and tube sheets with bank of
externally finned tubes supported by a frame. The cooling water (i.e. TBCW)
flows through tubes and the gas to be cooled flows over the finned tubes.
Temperature sensors are provided in the gas path entering and leaving the coolers.
These temperatures are continuously recorded in control room. Temperature
indicator is provided on TBCW outlet from each cooler.

Hydrogen Control

1) Hydrogen Supply

The hydrogen supply is contained in a number of commercial

H2 cylinders at a pressure of about 2000 psig. These cylinders are
connected to manifold through flexible connectors. The cylinders are
arranged in two equal banks with three cylinders on either side of
manual valve center. Two pressure regulators are provided in parallel,
one from each bank. The pressure regulator reduces hydrogen
pressure between 10 to 50 psig. for admission of H2 to generator. For
each cylinder a shut off valve is provided at the manifold.

2) Machine Gas pressure regulators :

The machine gas pressure regulator is provided to maintain

constant machine gas pressure at desired value. The inlet pressure to
machine gas pressure regulator should be approximately 10 psi. above
the desired machine gas pressure, but, not higher than 100 psi. A relief
valve (G-08) set at 90 psi. is provided at inlet to pressure regulator to
prevent accidental high pressure. The discharge from relief valve is
piped outside the turbine building. Machine gas pressure regulator is
in bypassed condition and not used now.

3) Water and Oil detector :

Water and oil detector (63-L9) is provided to protect the

generator winding from water entering the generator casing as a result
of tube leak in H2 cooler and from oil which could enter from shaft
seals due to imperfect functioning of the oil deflectors. The water and
oil detector is connected to the bottom of generator casing. The
detector has a float switch which gives alarm when some water or oil
 accumulates in the detector. Sight glass is provided to monitor the
water/oil accumulation. An isolation and drain valves are provided to
remove the oil/water accumulated in the oil detector.

4) Hydrogen Control Panel :

This panel houses the H2 gas analyzing equipment, H2 system

annunciation and various other instruments for supervising the
operation of generator cooling system and H2 seal oil system. Two H2
lines one from high pressure side and other from low pressure side of
rotor mounted fan are provided to circulate H2 through instruments
located in hydrogen control panel. The various equipment in hydrogen
control panel are as described below:

a) Hydrogen gas analyzer

A gas analyzer is provided on H2 control panel for

continuously indicating the percent purity of hydrogen in
generator. The analyzer consists of detector, power supply unit
and indicating instrument. The indicating instrument is
calibrated to read from 50% to 100% hydrogen in air by
volume. A filter and dryer unit is connected on the inlet side of
the detector unit to prevent foreign matter or moisture from
entering detector unit.

A flow meter on discharge side assures the rate of sample

flow through detector unit. A rheostat for adjusting the current
through detector unit and milli-ameter to indicate current
through detector unit are located on front of H2 control panel.
The purity indicator is equipped with an alarm contact to give
alarm on H2 control panel at preset low value of purity. A purity
indicator is provided in main control room also.

b) Sample flow meter

A flow meter is provided in H2 control panel to measure

the rate of gas flow through the detector unit of gas analyzer.

c) Fan differential pressure gauge

 The instrument measures the dP developed by the rotor
mounted fan when unit is operating. Since the pressure
developed by fan at constant speed is proportional to gas
density, the reading of fan differential pressure gauge provided
independent check of the purity of hydrogen in generator.

d) Machine gas temperature indicator

A temperature indicator is provided on H2 control panel

for indicating the temperature of the gas leaving the gas coolers.
The indicator is provided with an alarm contact to give alarm
on H2 control panel at preset high value of temperature.

e) Machine gas pressure indicator

A pressure indicator is provided on H2 control panel to

indicate H2 pressure in the generator casing. A remote pressure
indicator is provided in main control room also.

f) Machine gas pressure switches

Two pressure switches are provided in H2 control panel

which give the alarm to indicate high and low gas pressure in
machine.

Filling/purging of Hydrogen from the generator

To avoid having any explosive mixture of H2 in air in the

generator at any time either during initial filling of hydrogen or during
removal of H2, an inert gas (carbon dioxide) is used for purging out of
air or hydrogen initially from the generator casing. During purging
operations the generator should be standstill (or on turning gear) and
seal oil system must be in service. CO2 supply for purging is usually
obtained from several CO2 cylinders connected to a manifold through
flexible connectors and check valves. The cylinder valves are
normally kept full open and purging rate is controlled by valve G-15.
a) Removing air from generator
For removing air from generator, CO2 is admitted to the
bottom of generator through CO2 distribution pipe and air in the
generator is discharged to atmosphere through the hydrogen
 feed pipe. The admission of CO2 to the generator is controlled
by valve G-15 at the CO2 manifold.

A pressure between 2 to 5 psi. should be maintained in

the generator casing during purging operation, while the
generator is being purged with CO2. The percentage of CO2 in
the discharge to atmosphere is measured on the CO2 in air scale
of portable analyzer. Purging should be continued till the
percentage of CO2 in discharge goes beyond 70%.

b) Filling generator with hydrogen :

After purging air from generator and obtaining more than

70% CO2 in discharge, H2 filling can be done. H2 is admitted to
the top of generator through the H2 distribution pipe, and CO2-
air mixture from the generator is discharged to the atmosphere
through the CO2 feed pipe. Admission of H2 to generator is
controlled by pressure regulator at manifold and valve G-05,
and 2 to 5 psi. pressure is maintained in the generator.

During H2 filling operation the percentage of H2 content

in the discharge to atmosphere is measured on H2 in CO2 scales
of portable analyzer. H2 should be admitted to the generator
until the percentage of H2 in the discharge is in excess of 90%.
The gas analyzer at the H2 control panel may be then placed in
operation and it should read about same as the portable
analyzer.
c) Removing H2 from generator :

The procedure and valve line up for removing H2 is same

as that for removing air from generator casing with CO2. CO2 is
admitted to generator and generator casing pressure is
maintained between 2 to 5 psi. The purging with CO2 is
continued till the percentage of CO2 in discharge is in excess of
95%. After removal of H2 and prior to any maintenance work
on generator, the CO2 should be purged out by using dry air.
DRG 88A
 Hydrogen Seal Oil System
The oil seals are provided at each end of generator to prevent escape of
hydrogen from generator along the shaft. Each shaft seal consists of a seal housing
supported from the outer end shield at each end of generator. Each seal housing
contains two annular segmental sealing rings. (four segments in each ring). These
rings have an inside diameter only a few thousandths of an inch larger than the
diameter of the generator shaft. The segments are held together radially inward by
a garter spring to form rings. These garter springs also separate the two rings
axially. The rings are free to move radially with the shaft but, are prevented from
rotating by the pin to which the garter springs are attached.

Oil is fed through the seal housing then between the rings, at a pressure that
is greater than gas pressure within the generator. The oil then flows between the
rings and the shaft in both directions. The oil fill in constricted area between
generator shaft and the rings form a seal which prevents the gas in the generator
from leaking out along the shaft. After flowing past the sealing rings, the oil is
drained from the seal housing. The oil which flows towards generator passes into
seal oil drain, while the oil which passes towards the bearing mixes with the oil
discharged from generator bearings.

The hydrogen seal oil system consists of seal oil vacuum tank, vacuum
pump, main seal oil pump, Emergency seal oil pump, differential pressure
regulator, hydrogen detraining section, air detraining section, float trap, liquid
detector, Instrumentation and piping. During normal operation, the seal oil supply
is taken from bearing oil system of turbine generator and seal oil drain is returned
to turbine lube oil reservoir.

Vacuum Tank

During normal operation, oil from lube oil system enters the vacuum
tank through spray nozzles and float valve (H-10). The incoming oil is
vacuum treated so that a minimum of moisture or air is released into the
generator casing. The float valve (H-10) regulates the oil level in the seal oil
vacuum tank. The inlet spray nozzles are directed upward and separate some
of gases from the oil as it enters the tank. Most of the gases remaining in oil
are separated by recirculation through a second set of spray nozzle directed
upwards. A float switch is provided on vacuum tank to give an alarm on H2
control panel if the oil level in tank goes more or below normal level by 3
inch.

The seal oil vacuum tank gets bypassed when the main seal oil pump
is not in service.

Vaccum Pump

A rotary, positive displacement type pump is provided to maintain

high vacuum (1 inch Hg. abs) in the seal oil vacuum tank. The pump is
driven by 2 H.P. motor and has capacity of 42 CFM at a speed of 234
R.P.M. The discharge from vacuum pump goes into the baffled air oil
separator, where the oil drains back into reservoir and the air is exhausted.
The air exhausted is routed to the top of turbine building.

Main Seal Oil Pump

Oil from vacuum tank is pumped to shaft seals by a rotary, gear type
pump. The pump is driven by 10 H.P. Motor and has 66 gpm. capacity at a
speed of 1000 RPM. A relief valve H-12 is provided to recirculate the excess
oil back to vacuum tank through spray nozzles. The pump suction has a
strainer in the vacuum tank. The pump shaft has mechanical seals.

Emergency Seal Oil Pump

Emergency seal oil pump is provided to supply seal oil in case the
main seal oil pump is not available. It is a gear type pump driven by 3
H.P.DC motor. The pump has 36 gpm capacity and speed of 1750 RPM.
This pump starts automatically when the pressure at discharge of Main seal
oil pump falls below 80 psi. A relief valve H-15 is provided to recirculate
the excess oil back to the pump suction. An alarm comes on H2 control panel
whenever emergency seal oil pump starts.
 Differential Pressure Regulator

The differential pressure regulator (H-19) is provided to maintain the

seal oil pressure more than H2 pressure in the generator. It is adjusted to
maintain a differential pressure of about 4 psig. A differential pressure
switch is also provided to give alarm on H2 control panel if the differential
pressure goes below 2.5 psig.

Hydrogen Detraining Section

The seal oil detraining from hydrogen side of shaft seals is received in
H2 detraining section. H2 detraining section is an enlarged horizontal length
of pipe just below the generator. The section provides large surface area for
oil so that large H2 bubbles get released from oil. A transverse partition
divides the section into two parts which are connected through a loop seal.
This arrangement prevents circulation of oil vapors through the seal drain
piping resulting from the difference in pressure between the two ends of
generator.

A liquid detector is connected to H2 detraining section to indicate

excess level in the section. If the oil level rises above the centre line, the oil
flows to liquid detector. A float switch 63L-20 mounted on liquid detector
gives alarm on H2 control panel. A separate liquid detector 63L-9 is
provided to detect hydrogen cooler leak or oil accumulation inside generator
casing.

The oil from H2 detraining section flows out through the float valve
H-58. The valve maintains oil level in the float trap and prevents escape of
hydrogen. During normal operation, the oil from float trap goes to air
detraining section and then to bearing oil drain header. During non-
availability of oil supply, the same oil recirculates through the seal oil
system.

Air Detraining section and drain trap System

The drain trap system is provided to isolate generator bearing drains from
the turbine lube oil tank and rest of the oil system. It is designed to protect against
entry of Hydrogen into the turbine lube oil tank. Protection is accomplished by
placing an air detraining section and a loop seal between generator bearings and
turbine oil tank.
 The oil from air side of generator shaft seals and from generator bearings
flows to an enlarged section of pipe designated as air detraining section, which
serves to detrain air from the oil before it passes into main bearing oil drain header.
This air detraining section also serves to detrain hydrogen which would be present
if the H2 seal is not functioning properly. In the event, H2 escapes into the air
detraining section, it is diverted from the turbine oil tank by the loop seal which
connects the air detraining section to the bearing oil header. The detrained air and
hydrogen pass to the atmosphere through a vent in the top of detraining section.

The air detraining section consists of an enlargement containing a series of

dams, baffles and screens to reduce oil velocity, maintain levels and hold back and
break up foams. A plugged drain and clean out is provided at low point of the loop
seal to remove any foreign material that may deposit.

If both main seal oil pump and emergency seal oil pump are not available,
the oil from bearing oil header can supply seal oil up to limited pressure of
hydrogen in generator casing.
DRG 92A
 Steam Jet Air Ejector System

Purpose of the system is to remove all the non-condensible gases released

into the condenser by creating vacuum in the condenser, otherwise, the gases may
develop a high back pressure to prevent the work done by steam below
atmospheric pressure and thus thereby reduce the efficiency of the turbine.

In Nuclear Power Station in addition, Air Ejector serve to remove the

radioactive gas isotopes of N16, N13, O19, Xenon and Krypton formed in the reactor
and carried out by steam, through off gas system to the ventilation stack.

A Steam Jet Air Ejector consists of two stages. One stage is called Inter
Condenser and second is After Condenser. A driving steam at 150 psig. (10
Kg/cm2) is taken from pressure reducing control station (PCV) and passed through
the nozzles of Inter-Condenser and After-Condenser. (presently primary steam is
used as driving steam). The steam and water vapour is condensed by cooling water
condensate passing through the tube side of the Inter and after condenser. The
condensed steam and water vapour is drained from inter-condenser through loop
seal drain to main condenser and from after-condenser through loop seal drain to
Clean Radwaste (CRW) sump.

The steam requirement for driving steam at 150 psig. (10 Kg/cm2) is about
1700 lbs/hr. (770 Kg/hr.) and the gases/air removal capacity of each set is 35
lbs/hr. (15.87 Kg/hr.) O2, 4.5 lbs/hr. (2.2 Kg/hr.) H2, 56.25 lbs/hr (25.5 Kg/hr.) Air
and 325 lbs/hr. (147.3 Kg/hr.) of water vapour.

There are two sets of Air Ejectors (Top set and Bottom set) out of which one
set will be on line continuously and the other is a spare which is changed over
whenever necessary. There are two steam pressure reducing valves (PCV), out of
which one will be on line and the other as a spare which is changed whenever
necessary. The nozzle of the air ejector are of stainless steel and condenser tubes
are of SS-304 and shell is carbon steel.
 Off Gas System

Basic source of the radioactive gases is the reactor. In the reactor, certain
gaseous activation products are continuously formed by irradiation of reactor water
(Radiolysis). The major ones are the Nitrogen and Oxygen isotopes such as N-13,
N-16, N-17 and O-19. Also, in the reactor the coolant water under goes some
decomposition to form gaseous hydrogen and oxygen. These non-condensible
gases are carried to the main condenser along with the steam via turbine. Very
small fraction i.e. 0.1 percent of radioactive gases leave the turbine via. turbine
gland seal system and rest along with non-condensible gases through air ejector
system.

There are two types of gaseous waste from the primary system in addition to
non condensable gases i.e. normal gaseous activation product viz N13, N16, N17 and
O19 and fission products noble gases like Xenons and Kryptons and their daughter
products.

To minimize the stack gas releases 30 minutes of delay time is provided by

Off gas hold up line to reach for the activation gaseous products extracted by air
ejectors from condenser to stack. Majority of hold-up time is in 230 ft. (70 m) 42
inch (106.7 cms) ID pipe which is properly sloped with drains and loop seals at
low point to remove any condensed moisture from the pipe. The activation gaseous
product extracted by gland seal system is having a delay time of 1.75 minutes.
Majority of the hold-up time is in a 237 ft. (72 m) section of 20 inch (51 cms) pipe.

There are two filters in series for each Off gas filter after delay loop of 30
minutes. The filter elements consists of particulate filters stacked one over the
other in the same filter holder. The particulate removal efficiency of the filter is
99.97% of 0.5 micron and larger size particulates. In the event of failure of
particular unit filter set the other unit filter set can be valved in for the affected unit
without disturbing the plant operation. Generally filter elements are replaced
during unit refueling outage or any maintenance outage.

The temperature and pressure switches are provided down stream of air
ejector to close inlet CV to air ejector to cut off source of Hydrogen and Oxygen
from the condenser in event of temperature rise or pressure rise or due to explosion
in the delay loop piping.
 One CV is also provided before filters which closes if the off gas radiation
monitors show rise in radiation level than the preset value, indicating fuel failure in
the reactor. This CV is having time delay of 15 minutes in closing after the
radiation monitors have tripped.

The radiation levels after air ejector and from the ventilation stack is
continuously monitored in the control room for the gases released to environment
through the ventilation stack. Sampling arrangements is provided for verification
of the radiation levels indicated by the monitors. In short, the functions of off gas
system are:

i) To delay the release of the normally occurring activation product

gases for a period of time to permit decay, so that, their radioactivity
is minimum possible by the time the gases are released to atmosphere
through ventilation stack.

ii) To filter air ejector gases and remove radioactive particulates formed
by decay.

iii) To dilute and disperse gases into the atmosphere and thus minimize
the radiation dose rate from the released gases.

iv) To provide the operator with time for decision and corrective action if
the monitors indicate fission gases release rate approaching the
instantaneous rate limit.
DRG 95A
 Reactor Vessel

The reactor vessel is the main part of the nuclear steam supply system. It
contains the reactor core consisting of nuclear fuel, control rods, nuclear
instruments and other associated components. The nuclear fission reaction takes
place in the reactor core and the energy released is utilized for generating steam in
the reactor vessel.
The reactor vessel is mounted vertically and consists of shell, lower head
and top closure head. The shell is cylindrical and heads are hemispherical in shape.
The lower head is permanently welded to shell, whereas the top head is bolted to
the shell. The top head is made removable to facilitate refueling and servicing of
vessel internals. The reactor vessel and the closure heads are all welded high
strength low alloy manganese-molybdenum steel plates and forged construction.
The minimum thickness of the shell base metal is 4 7/8 inch and the all internal
surface of the vessel is clad with 7/32” thick corrosion resistant stainless steel. The
vessel is supported on a continuous skirt welded to the lower head. The flanged
lower part of support skirt is bolted to a ring girder of vessel foundation. Also, four
stabilizer brackets are welded to vessel shell. These stabilizer brackets engage with
spring loaded tension bars to provide lateral support to the vessel while permitting
thermal expansion.

Reactor Vessel Data:

a) Dimensions:

i) Internal dia. = 12 ft. (3.66 m.)

ii) Outside dia of shell = 12.875 ft.
iii) Internal height = 52.5 ft. (16 m.)
iv) Overall height = 66 ft. (20 m.)
(from vent nozzle to
CRD housing flange)

b) Weight: Approx. 236 Tons.

c) Design Data:

i) Orientation = Vertical, Insulated

ii) Design pressure = 1250 psi (87.88 Kg/cm2)
iii) Design temperature = 600oF (315.6oC)
iv) Heating rate = 100 oF/hr. (55 oC/hr)
v) Normal cool down rate = 100 oF/hr. (55 oC/hr)
vi) Emergency cool down rate = 300 oF/hr. (165 oC/hr)

d) Normal Operating Conditions:

i) Pressure = 1000 psi (70.3 Kg/cm2)

ii) Temperature = 285oC

Vessel Connections:

The lower head of vessel has 120 nozzles for different purposes as below:

a) Control rod drive housing - 89 (20 spare)

b) Local power range monitors - 18 (5 spare)
c) Startup nuclear instruments - 7
(SRMs & IRMs)
d) Reactor coolant recirc. Inlet - 2
e) Instrument lines (core dp) - 2
f) Poison injection - 1
g) Vessel drain - 11

The vessel shell has 18 nozzles as below:

a) Steam outlet - 4
b) Instrument lines (Level & pressure) - 6
c) Feed water inlet - 2
d) Core spray - 3
e) Reactor coolant recirc. outlet - 2
f) Cleanup system return - 1
 The top of vessel is formed into a flange over which the top head is bolted.

Cylindrical skirt is welded to the outside of shell flange. This forms the part
of metallic below seal between reactor vessel and the drywell.

A conical skirt is welded to the lower end of vessel shell between coolant
inlet and outlet nozzles. The bigger end of skirt is welded to vessel shell. A
stainless steel support ring is welded to other end of the skirt. This support ring
supports all reactor internals.

The closure head has a mating flange and is fixed over shell flange by 54
studs of 4 ¾ inch dia. Centering sleeves are provided on two studs for aligning the
head over the shell flange in a fixed lateral position. A hydraulic tensioner is used
for tensioning the studs during removal/fixing of vessel head. Leakage of the
water/steam from mating surface of flange is prevented by two concentric inconel
`O’ ring seals of ½ inch dia. cross section. The area between two concentric `O’
rings is vented and monitored to provide indication of leakage from the inner `O’
ring.

The head has three nozzles as below:

a) Vent - 1
b) Head spray - 1
c) Instrument - 1 (Blind flanged)

Thermo couples are provided for monitoring the heating/cooling rate of

reactor vessel as well as differential temperature between different parts of vessel.
Totally 39 thermo-couples are fixed on outside surface of vessel at 13 ft. different
elevations. 13 selected points (one at each elevation) are monitored continuously
by a temperature recorder in control room.
Vessel internals:

a) Diffuser :

The diffuser is a perforated cylinder welded to the lower end of the

support ring. The perforation holes are of 1 inch dia. The purpose of the
diffuser is to uniformly distribute the coolant flow. A triangular vane is
provided infront of each coolant inlet nozzle to divert the coolant flow into
the annulus between diffuser and the reactor vessel.

b) Liquid poison sparger:

The poison injection sparger encircles the diffuser and is supported by

the diffuser. The poison sparger distributes the liquid poison in the core
coolant inlet plenum in the event it is used for shutting down the reactor.
c) Shroud:
The shroud is a cylindrical component welded to the upper end of the
support ring. The upper end of shroud is formed in flange. The height of
shroud up to flange level is 21 feet. Six stabilizer brackets are provided just
below flange level for supporting the shroud laterally. The shroud and the
conical skirt welded to the vessel shell between coolant inlet and outlet
nozzles form the barrier between inlet core coolant flow inside the shroud
recirculation flow and feed water which flows down the annular down comer
between shroud and vessel shell.

d) Bottom Core Plate:

The bottom core plate is permanently fixed to the shroud. It supports

and locates the guide tube top casting in which the fuel bundles are
supported.

e) Fuel top grid:

The top grid is supported on 12 brackets on the inside of the shroud. It

is prevented from lifting by four latches and is laterally positioned by four
locating pins. The top of fuel bundles are laterally guided and positioned by
top grid.
f) Thermal Shield:

Thermal shield is placed in down comer annulus, close to reactor

vessel wall. It is used for minimizing neutron and gamma exposure of
reactor vessel. It is supported by brackets welded to reactor vessel and it
extends over entire active length of core.

g) Shroud Head, Steam Separator and Steam Dryer Assembly:

The top of shroud is closed with a torispherical dished head, flanged

to the shroud and held in place with 36 bolts. This shroud head separates the
core exit plenum containing steam water mixture from the down comer
annulus. The steam separators are mounted on pipes that penetrate the
shroud head and are welded to shroud head. The steam dryer is fixed over
steam separator by six welded tie bolts. Thus, shroud head, steam separator
and steam dryer form a single assembly. This assembly is removed during
refueling for getting access to reactor core.

During normal operation, the steam dryer separator assembly separate

the steam from steam water mixture leaving the reactor core so that the
steam leaving reactor vessel does not contain more than 0.1% moisture by
weight.

h) CRD Housing:

There are 89 CRD housings welded to the lower head of reactor

vessel. 69 CRD housing contain one control rod drive each and the twenty
spare CRD housing are blind flanged. The bottom end of CRD housing is
formed into flange which mate with flange of CRD. Hydraulic connections
of CRD are welded to the flange of CRD housing, so these need not
disturbed while replacing the CRD.

i) Guide Tube:

The function of guide tube is to support and guide the control rod
drive and the control blade. The casting welded to the top of guide tube has a
cruciform opening at centre for control blade and has four cups to support
the bottom end of fuel assembly. The top casting is supported by bottom
core plate. The bottom of guide tube is supported by mating surface of CRD
housing.
j) Fuel Orifices:

The fuel orifice is used to fix the coolant flow through the fuel
assembly. Earlier these were fixed on vertical pin fixed in the cup of guide
tube. Now-a-days the orifices are modified and most of them are welded to
fuel bundles itself in the peripheral locations adaptor orifices are used in
addition to welded orifice.

k) Fuel Spacers:

The function of spacers is to prevent tilting of fuel assemblies within a

partially loaded cells. The spacers are fixed in notches in the top of the top
grid. They are hooked under the grid to prevent their lifting out.

l) Reactor Core:

The reactor core consists of nuclear fuel assemblies, control blades, in

core instruments and neutron sources. The bottom of fuel assembly seats in
the guide cup and the top is supported by top grid and spacers. The control
blade is cruciform in shape and moves in a cruciform gap between four fuel
assemblies.

The locations of core components like fuel assembly, control blade, in core
monitor etc. are designated by X and Y co-ordinates of reactor core. The X co-
ordinate number ranges from 00 to 44 increasing from west towards east. The Y
co-ordinate number ranges from 01 to 45, increasing from south towards north.
DRG 101A
 Nuclear Steam Supply System

The type of nuclear steam supply system used in TAPS is a forced

recirculation, single cycle plant with internal steam separation. The rated power of
each reactor is 530 MW thermal. The forced circulation overcomes limitation on
power density of natural recirculation system.

The steam which is generated in the reactor and is directly obtained from the
reactor is known as primary steam. The pressure of the primary steam will be same
as reactor operating pressure and the steam will be slightly radioactive. Presently
SSG A/B are kept isolated due to tube leaks on both the units.

The reactor has internal steam separator unit. The steam leaving reactor is
more than 99.9% dry. The primary steam gives 160 Mwe power.

Primary Steam:

Four 10 inch lines come out of the reactor vessel and join into two 14 inch
lines namely line A and line B. These two primary steam lines go to turbine
through the vertical and horizontal pipe tunnels connecting reactor building and
turbine building. Between the reactor and turbine there are equipments/instruments
provided on primary steam lines for protection and control. These are described
briefly below (starting from reactor end).

a) Reactor safety/Relief Valves:

There are total eight safety valves (A to H) provided for each

reactor, four on each steam line inside drywell. The number and size
of safety valves are chosen so that reactor pressure will not exceed
design overpressure limit under any circumstances. The safety valves
are set to lift at progressively increasing pressures as below:
Safety Valves Set Point

A, B, E 1200 psi (84.36 Kg/cm2)

C, D 1210 psi (85.06 Kg/cm2)

F, G 1220 psi (85.77 Kg/cm2)

H 1230 psi (86.47 Kg/cm2)

The safety valves A, C, E and G are mounted on steam line A

and B, D, H and F are mounted on steam line B. The discharge from
safety valves A, B and E are led to suppression pool where as
discharges from other safety valves are open to drywell. A
temperature sensor is provided on discharges of each safety valve to
monitor the leakage of safety valve.

Three safety valves A, B and E are provided with air cylinders

and solenoid valves. These valves can be opened any time by
admitting air to cylinders, irrespective of reactor pressure. The valves
A and B designated as relief valves are set to operate at 1080 psi. Two
pressure switches sense the reactor pressure and admit air to cylinders
and lift these relief valves.

In addition, the valves A, B and E are operated by auto blow

down system also.

b) Tapping for Emergency Condenser:

Emergency condenser removes the decay heat and cools

the reactor in case the reactor is isolated from main condenser.
There are two loops in emergency condenser system. Inlet to
loop A of Emergency condenser is from steam line A and that
for loop B is from steam line B.

c) Velocity Limiting Orifices:

One orifice is installed in each line to limit the primary

steam flow in case of a line rupture. Differential pressure (DP)
across each orifice is measured by four DP instrument.
 These DP instruments are used to sense high steam flow
and close the primary steam isolation valves (PSIVs) in case the
flow in any line exceeds 140% of rated. The orifices are inside
drywell and DP instruments are outside drywell (RK01/RK11).

d) Primary Steam Isolation Valves (PSIVs):

There are two PSIVs on each steam line. Valves 4A and

3A are on line A and valves 4B and 3B are on line B. The
valves 4A and 4B are of Y type and are inside drywell. The
valve 3A and 3B are of right angle type and are in vertical pipe
tunnel. Each valve is capable of closing within 3 seconds
against full DP of 1000 psi, in case of a line break. Each valve
is held open by air pressure in operator and is closed by spring
when air pressure is bled-off. The control air supply to valve
operators is through two solenoids, one supplied by D.C. power
and other one by AC power. The air is bled-off only when both
DC and AC solenoids are de-energised. These PSIVs go close
automatically on the following conditions:

i) Primary Steam line high flow.

i) Primary Steam line area high temperature.
j) Primary steam line low pressure.
k) Primary steam line high radiation.
l) Reactor water low level.
m) Drywell high pressure.

e) Primary Steam Radiation Monitors:

Four ion chamber type radiation detectors are provided

on primary steam lines in the horizontal pipe tunnel. These
monitors cause reactor scram and PSIVs closure on steam line
high radiation.

f) Sample Lines:

A sample line from each steam line is brought up to

sample station in the reactor building.
 g) Flow and Pressure Monitoring Instruments:

A flow sensor is provided in each steam line for

measuring the primary steam flow. The flow signal is also used
in reactor level control system. A pressure transmitter is
provided on each line for measurement of pressure. The
pressure signal is also used in reactor level control system.
There are four pressure switches, two on each line for sensing
low pressure in steam line. These pressure switches cause
reactor scram and PSIVs closure on steam line low pressure.

h) Area Temperature Monitors:

The pipe tunnel from reactor to turbine is monitored for

any steam leakage by temperature sensors. Four temperature
sensors at different locations in pipe tunnel are provided for
giving temperature indications and alarm on high temperature.
A separate set of 16 temperature switches are provided to
sense steam leak in pipe tunnel and close the PSIVs.

i) Steam Traps:

Any condensation of steam taking place in steam lines is

drained by steam traps to main condenser. Each steam line has
one steam trap. The steam traps have motor operated bypass
valves which are kept open during start-up of unit.

The primary steam coming from the reactor either goes to turbine through
turbine primary control valves or to main condenser through bypass valves. The
opening of primary control valve/bypass valves is controlled by pressure regulator
which control the reactor pressure. There are two Mechanical Pressure Regulators
(MPR) provided for each unit.

One MPR is in service and second is kept as back up. Depending on primary
steam generation rate and primary steam demand by turbine the MPR will position
primary control valves/bypass valves so as to keep steady reactor pressure.
 The rate of generation of primary steam in reactor is controlled by
withdrawing/inserting control rods in the reactor.

Secondary Steam (This system is presently not in service):

As the secondary steam is not expected to be radioactive and the fact that
secondary steam pressure cannot be higher than the primary steam pressure the
secondary steam lines do not have elaborate controls and instruments.

Each SSG has a motor operated steam outlet valve in vertical pipe tunnel.
Each secondary steam line has sample line, flow and pressure measuring
instruments and steam trap similar to primary steam lines.

The secondary steam is fed to turbine at 5th stage. Being non active, the
secondary steam is used for turbine gland seals and steam jet air ejectors. Tappings
on secondary steam line for these services are from upstream of secondary stop
valves.

The rate of generation of secondary steam is controlled entirely by demand

of secondary steam by turbine. If demand is more the secondary control valves are
opened more by turbine governer and more secondary. steam flows to turbine.

In dual cycle operation of nuclear steam supply system, the reactor power
(over a limited range) automatically adjusts to the turbine demand. This feature is
known as automatic load following and is described below.

When the demand increases the turbine governor opens secondary control
valves more. This increases the Sec. Steam flow to turbine and causes decrease in
sec. Steam pressure. The decreased Sec. Steam pressure decreases the temperature
on shell side of SSG. This decreased temperature on SSG shell side increases heat
transfer rate as primary side temperature is essentially constant.

As higher heat transfer occurs, the temperature of water entering reactor

from SSG decreases. Since the reactor has a negative temperature co-efficient of
reactivity the decreased water temperature increase reactor power till new
equilibrium state is reached. A reverse process takes place when the demand
decreases.
DWG 107A
DWG 107B
 Reactor Recirculation System

The purpose of Reactor Recirculation system is to provide forced

recirculation of primary coolant in the boiling water reactor. The forced
recirculation improves heat transfer and overcomes the power density limitation of
natural recirculation system.

The system consists of reactor vessel and two recirculation loops. Each
recirculation loop contains a vertical recirculation pump, a secondary steam
generator (SSG), interconnecting piping and motor operated valves.

Recirculation Pump:

The recirculation pump is a motor driven, vertical, double suction, single

stage, centrifugal pump with mechanical shaft seals. The driving motor is of 1500
HP, 990 RPM motor mounted directly over the pump. The motor has thrust bearing
at top and radial bearings at top and bottom. All bearings are lubricated by oil bath.
The top oil reservoir has a cooling coil supplied by RBCW system. Sight glasses
are provided for checking level of oil in top and bottom oil reservoirs. Also, level
switches are provided to give alarm if abnormal oil level conditions occur. The
motor winding temperatures and bearing oil temperatures are continuously
recorded in control room.

Each motor has an integral flywheel designed to provide sufficient inertia to

prevent abrupt decrease in coolant flow in the event of pump trip. This prevents
fuel cladding damage arising from abrupt decrease in coolant flow.

The pump is designed for 1310 psi (92.1 Kg/cm2) and is rated for 5215
MT/hr. flow and 50 meter head. The pump bearing is a self aligning water
lubricated radial bearing.

The pump and motor are coupled by a precision spacer coupling which
provides proper alignment of pump and motor shafts and transmits the pump axial
thrust to the motor shaft and thrust bearing. The mechanical seal is a replaceable,
two stage, face type seal system. There are two Byron-Jackson pressure balanced
mechanical seals in tandem on the pump shaft above the casing. Each seal has one-
half of the system pressure across its face.
 The rotating seal is tungsten carbide and the stationary seal seat is a carbon
ring. Each seal chamber is practically a closed chamber which is cooled by
circulating the chamber water with an integral auxiliary impeller through an
external cooling system. RBCW is used for providing the cooling.

Pressure indicators, temperature indicators and flow switches are provided to

monitor the condition of the seal.

Secondary Steam Generator (SSG):

There are two SSGs, one in each recirculation loop and presently they are
not used for generating secondary steam due to excessive tube leaks. SSGs are
isolated on steam side and are used for recirculation path only.

SSG Data:

i) Orientation - Vertical

ii) Size - Shell height = 27 ft. –8 inch

- O.D. Upper shell = 8 ft.- 8 inch
- O.D. Lower shell = 6 ft. – 1 inch

iii) Weight (Empty) = 58 MT.

iv) Design Pr. - Shell = 1275 psi. (89.6 Kg/cm2)

- Tubes = 1310 psi. (92.1 Kg/cm2)

v) Design Temperature = 575oF (301oC)

vi) Tubes = 1589, ¾ inch OD.

vii) Secondary side operating conditions:-

Steam flow = 180 MT/hr (205 MT/hr)
Steam pressure = 500 psi (35 Kg/cm2)
Recirculation Piping and Valves:

The recirculation piping is fabricated from stainless steel and is designed for
1210 psi. (85 Kg/cm2) at 575oF (301oC). The I.D. of piping is 24.75 inch and the
wall thickness is 1.055 inch. The piping is supported by constant support hangers
to reduce the thermal expansion stresses.

For both the units each recirculation loops has three motor operated valves
namely suction MOV discharge MOV and discharge bypass MOV, provided for
isolation of recirculation pumps and SSG together. The recirculation pump has
adequate interlocks in respect of position of these MOVs to protect the pump from
damage. Position of MOVs is also interlocked with Rx. Protection system so as to
scram the reactor if both the recirculation loops are isolated.

An intertie line is provided to connect suction of `B’ loop to the discharge of

`A’ loop, for giving the natural recirculation flow and remove decay heat in case
both loops are isolated. Also, by connecting the annulus and core region, the
intertie line provides communication between core and shroud for proper water
level monitoring.

A provision is made to collect reactor water sample from one of

recirculation loops. The sample line has remotely operated pneumatic valves.

The tapings for the shutdown cooling system and reactor water cleanup
system are taken from recirculation loop `B’, such that isolation of loop does not
affect operation of these systems.

Primary coolant flow path:

From the discharge of each recirculation pump the water flows through the
tubes of SSG and then enters the lower head of reactor vessel through two 28 inch
size nozzle.

Formed vanes are provided in front of each recirculation inlet nozzles for
diverting the inlet water flow to the annular space between the vessel walls and the
perforated diffuser. The water then flows in through perforations of diffuser and
comes under the bottom grid. It then enters the guide tube cups from underside
and flows up around the fuel rods within fuel channel where bulk boiling takes
place.

The guide tube cup has an orifice for adjusting the flow of coolant through
individual fuel bundle. A portion of coolant flows outside the fuel channel through
some leakage paths for cooling control blades, in core instruments and structural
components.

Steam water mixture emerging from fuel channel passes into plenum and
mixes with leakage flow and the total flow enters the steam separators.

Steam centrifugally separated from the mixture flows upward through the
dryer and leaves reactor vessel through steam nozzles. The water flows downward
from the separators over the top of shroud where it mixes with incoming primary
feed water injected through feed water sparger. The water then flows down the
annuli between vessel wall and thermal shield and the thermal shield and shroud. It
then flows out through two 28” size nozzles and go to suction of recirculation
pump.
DWG 111A
DWG 111B
 Emergency Condenser System

The emergency condenser is one of the safety related system or engineered

safeguard system. Such systems are normally not in service but are required only
in case of some abnormal or accidental condition so as to mitigate the
consequences of such occurrence. The distinguishing features of nuclear reactor
from conventional boiler are decay heat and radioactivity.

The purpose of Emergency Condenser is to depressurize the reactor by

removing decay heat in the event that the turbine generator and main condenser is
not available as heat sink. If the reactor gets isolated from normal heat sink, the
reactor pressure would go on increasing due to decay heat till the relief/safety
valves open. The lifting of relief/safety valves is undesirable as it results in loss of
coolant from reactor and it may result in uncovering of reactor core if feed is not
available. A refluxing type emergency condenser precludes such occurrence by
depressurizing the reactor without loss of coolant. The steam generated in reactor
rises up to emergency condenser, condenses in the cooling coils of emergency
condenser and returns back to reactor by gravity. The emergency condenser is
located at 200 ft. elevation of reactor building.

The system consists of emergency condenser, solenoid operated vent valves,

motor operated valves, make-up water system, piping and instruments.

Emergency condenser is a tank of 4.88m (16 ft.) dia., and 10.67m. (35 ft.)
length. Two full capacity parallel condensing coils are located inside this tank and
are connected to reactor primary system by MOVs and piping. Each condensing
coil is a U tube type heat exchanger with 18 tubes of 2 inch dia., submerged in the
water. Each condensing coil has capacity of 3 percent heat removal. Steam lines
from reactor are connected to inlet end of condensing coil and the outlet ends are
connected to recirculation loop-A suction. The steam inlet piping to the condensing
coil have a elevation higher than condensing coils so that the condensing coils
remain full of water and do not get heated during normal operation of the reactor.
 Eight temperature switches (two groups of 4 temp. Switches) are provided in
the emergency condenser pipe way to monitor any steam leakage from the pipes.
The emergency condenser is automatically isolated if two temperature switches,
one each from group of 4 temp. Switches sense high temperature.

The emergency condenser is the highest point in the Primary System and can
trap non-condensible gases. To preclude such possibility, the inlet lines are
continuously vented to main steam lines through solenoid operated vent valves.
This continuous venting also keeps the inlet line in hot condition. The vent valves
provide a path around primary steam isolation valves and are closed automatically
whenever primary steam isolation valves are closed. The vent valves also close
automatically when the emergency condenser gets isolated automatically. Pressure
and temperature of inlet lines are monitored in control room.

The shell side of emergency condenser contains approximately 125000 liters

(33000 gallons) of water of which at least 83400 liters (22000 gallons) is available
for heat removal. With this minimum water volume available the emergency
condenser can remove decay heat for at least six hours and cool down primary
system to 177oC (350oF).

The shell side water level and water temperature are monitored in control
room. High level and low level alarms are provided to ensure that shell side water
level is normal. The shell side temperature gives indication of tube leak or return
valve passing through during normal operation. During emergency cooling
operation the steam generated on shell side is vented to the atmosphere. A
radiation monitor is provided on vent line to ensure that there is no radioactivity
released to environment. The radiation monitor gives indication of tube leak should
one occur.

The make-up water to shell side is normally supplied from plant

demineralized water system. The water from condensate service system is
available as backup supply.

There are seven motor operated valve MOVs-1375, 1378, 1376, 1379, 1388,
1389 and 1390. MOVs-1375, 1378 and 1390 are A.C. operated and others are
D.C. operated. Further, MOVs-1388 and 1389 are of throttle type. Normally MO-
1388 and MO-1389 are closed and all others are kept open.
 The emergency condenser comes in service automatically if the reactor
pressure is persisting above 1050 psi. (73.8 Kg/cm2) for more than 10 seconds.
Return line MOVs-1388 and 1389 automatically opens under such conditions. The
time delay of 10 seconds is provided to avoid emergency condenser operation
during short time pressure transients.

The emergency condenser is automatically isolated if the pipe way

temperature switches sense high temperature. The MOVs which are open, go close
automatically under such condition.

DWG 114A
 CRD and CRD Hydraulic System

1) CRD Hydraulic System :-

The purpose of CRD hydraulic system is to provide filtered water for

normal operation of CRDs, charging the scram accumulators and cooling the
CRDs. The system takes water supply from condensate system or
condensate storage tank (T1A or T1B).The water is filtered, pressurized and
supplied to CRDs at three different regulated pressures.

The system consists of CRD feed pump, CRD booster pump, CRD
main filters, strainers, pressure control valves, pressure headers, piping
instrumentation etc.

Each unit has two CRD feed pumps 1P4A, 1P4B (2P4A, 2P4B) and
two CRD booster pump 1P78A, 1P78B (2P78A, 2P78B). All these pumps
are supplied from the emergency buses. CRD feed pump is rated for 110
gpm (415 lpm) at 2665 ft (812.5 M) TDH and is driven by 150 HP motor.
During normal operation it takes suction from condensate system after
condensate demineralizers and delivers water at 105 to 110 kg/cm2.

CRD booster pump is rated for 110 gpm (415 lpm) at 790 ft (240.8
M) TDH and is driven by 40 HP motor. This pump takes suction from
condensate storage tank (T1A/T1B). The pump is started automatically by
PS-1636 when suction pressure for CRD feed pump falls below 17.5 kg/cm2.
CRD feed and booster pump then run in series. The CRD feed pump is
automatically tripped by PS-1637 if the suction pressure falls below 3.5
kg/cm2. During the periods of low flow demand, the CRD feed pump is
protected from over heating by providing a minimum recirculation line and
CV-1638.

The CV-1638 is opened automatically by FIS-1638 if the flow

demand is less than 100 lpm. During periods of high flow demand, the CRD
feed pump is protected from overload by partial closing of CV-1640. CV-
1640 is normally full open. If the flow demand exceeds 450 lpm, the FIS-
1640 closes CV-1640 by 85% thus restricting the flow. The CV-1640 re-
opens if the flow demand drops to 300 lpm.
 PS-1005 is provided to annunciate CRD feed pump low discharge pressure
condition in control room.

After CV-1640, the discharge of CRD feed pump splits into three
braches namely,

i) CRD hydraulic system

ii) Emergency feed system
iii) Reactor Vessel head spray system

As CRD feed pumps have high discharge pressure, they are used to provide
emergency feed to reactor in case of emergency situations like total loss of power.
All CRD feed pumps and booster pumps are supplied from emergency supply
buses so that, they are available during total loss of power also. CRD feed pumps
are also used for providing cooling water spray to reactor vessel head during
shutting down of the unit. CRD hydraulic system is described further below.

Three filters (NC-06 A, B, C) are provided to filter the water going to CRDs.
The filters remove foreign material greater than 25 microns. Normally two filters
are in service while third filter is on standby in clean back washed condition. A DP
instrument DPIS-NC61 is provided to monitor filter DP. It gives high DP alarm if
DP exceeds 1.7 kg/cm2. A flow indicator, FI-NC72 is provided upstream of filters
to monitor total system flow. Strainers NC-07 A, B & C are provided downstream
of filters NC-06 A, B & C respectively in order to protect the CRD hydraulic
system from large particles in case the filter element fails.

After filters and strainers the water passes through three stages of pressure
control. The first stage of pressure control consists of pressure controllers PIC-
NC112A & B and pressure control valves NC-30 A & B.

Normally one pressure controller is in service and other is on standby. The

pressure controller reduces the water pressure to 100 kg/cm2 and supplies to
“Accumulator Charging Header”. The accumulator charging header has 69
tappings (Additional 20 tappings are spare). Each accumulator is charged by
opening its charging valve NC-50. The charging valve does not allow flow in
reverse direction and thus prevents discharging of accumulator in case the CRD
feed pump trips. The function of charged accumulators is to quickly insert or scram
the CRDs when the reactor protection system demands so. A pressure switch PS-
NC37 is provided on accumulator charging header. It prevents withdrawal of
control rods if the accumulator charging header pressure is below 87.5 kg/cm2. The
pressure of this header is indicated in control room by pressure indicator PI-NC36.

The second stage of pressure control consists of differential pressure

controllers DPICT-NC113A & B and pressure controller valves NC-18A & B.
Normally one pressure controller is in service and other is on standby. The
differential pressure controller maintains the downstream pressure at 21.5 kg/cm2
above the reactor pressure and supplies it to “Drive water header” or “PR+200
Header”. PR+200 header has 69 tapping’s (additional 20 tapping’s) are spare. Each
CRD is supplied with PR+200 header water through the valve NC-96. The valve
NC-96 does not allow flow in reverse direction. PR+200 header water is used for
inserting or withdrawing the CRD at a rate of 6 inch/sec., for normal manual
control of reactor. A flow indicator (FIT NC-121) is provided on PR+200 header to
monitor flow during CRD movement. The pressure of this header above reactor
pressure and the flow are indicated in control room.

The third stage of pressure control consists of differential pressure

controllers DPICT-NC 114A & B and pressure control valves NC-17A & B.
Normally one controller is in service and other is on standby. The differential
pressure controller maintains the downstream at 1.5 kg/cm2 above the reactor
pressure and supplies it to “cooling & exhaust water header” or “PR+30” header.
PR+30 header has 69 tapping’s (Additional 20 tapping’s are spare). Each CRD is
supplied with PR+30 header water through the valve NC 89-2.

Normally about 1 lpm cooling water goes to each CRD. A minimum flow
line branches from PR+30 header and goes to reactor through MOV-1383. The
minimum flow required for smooth operation of controllers is adjusted by
throttling MOV-1383.

All pressure controllers are air operated. Individual air PRVs supply air at 20
psi to controllers. The pressure control valves go open on loss of air supply.

2) CRDs:

There are 69 identical control blades (additional 20 locations are

spare) in each TAPS reactor. These control blades are positioned in reactor
core by an individual Control Rod Drive (CRD) mounted below the reactor
vessel. Each CRD is an integral unit wholly contained in a CRD housing
which is an extension of reactor vessel extending below the reactor vessel.
The lower end of CRD housing terminates in a flange which mates with the
drive flange. The drive is attached to housing by eight mounting bolts.

The hydraulic connections to drive are welded to the housing flange

so that drive can be removed without disturbing the hydraulic connections.

As the CRDs are mounted at bottom of reactor vessel and the control
blades enter the core from bottom, raising or inserting a rod decreases the
reactivity and lowering or withdrawing a rod increases the reactivity.

The CRD is capable of inserting or withdrawing the control rod at a

slow speed of 3 inch/sec. This controlled movement is used during normal
manual operations of reactor like start-up shutdown, increasing power or
decreasing power. The CRD is also capable of inserting the control rod at a
fast speed of 5 ft./sec. in case of reactor scram.

A locking mechanism in CRD allows the drive to be positioned at a

stroke increment of 6”.

The basic CRD mechanism is a double acting, mechanically latched

hydraulic cylinder using reactor feed water as the operating fluid. The use of
reactor feed water as the operating fluid eliminates the need of special
hydraulic system and leak tight seals. Drives are able to use simple piston
seals with leakage into reactor without risk of contamination of reactor
water.

The CRD mainly consists of piston tube, stop piston, Drive piston,
index tube latching mechanism, outer cylinder, coupling spud, CRD flange
and position indication system.

The CRD hydraulic cylinder piston mechanism differs from

conventional fixed cylinder and moving piston rod. The CRD mechanism
consists of a stationary central hollow piston rod (or piston tube) over
which the piston moves. The central hollow piston tube is fixed to the
bottom flange of CRD and remains stationary during drive operation. Water
is brought to the upper side of drive piston through this hollow piston tube.
A series of orifices are provided at the top end of the piston tube. These
orifices are progressively covered by moving piston thus providing a
cushioning effect at the upper end of drive stroke. A small stationary piston
called stop piston is mounted on the upper end of the piston tube. This
provided the seal between reactor pressure and area above the piston. It also
serves as positive stop for insert stroke of drive.

The drive piston and index tube form the main moving assembly of
drive. The drive piston is mounted at the lower end of index tube. The drive
piston operates between positive end stops with a hydraulic cushion at the
upper end only. The piston has both inside and outside seals and it operates
in the annular space between piston tube and outer cylinder. The effective
under-piston area used during “Insert” or “Scram” is 4.1 Sq. in. The
effective over-piston area used during “Withdraw” is 1.2 Sq. in.

The index tube is a long hollow shaft. This tube has locking grooves
spaced at every 6” along the outer surface. The upper end of index-tube is
threaded to receive the coupling spud. The coupling spud has six spring-
fingers which enter the mating socket at the bottom of control blade. A lock
plug then enters the spud and prevents uncoupling.

A ratchet type locking device is located in the upper end of drive

mechanism. Locking is accomplished with a collet or finger type latch
mounted on a collet piston at the top of outer cylinder. When the drive is
stationary the collet engages in the locking grooves of index tube to hold
index tube in that position. The shape of locking grooves is such that the
collet does not prevent the insert motion of index tube, but, unlocking is
necessary for withdraw motion, the unlocking is achieved by inserting the
index tube slightly and then applying hydraulic pressure to collet piston. A
collet return spring is provided to restore the collet piston after removal of
hydraulic pressure.

Welded to the outer cylinder is a heavy CRD flange. A sealing

surface on the upper face of this flange is used in making a station seal to the
housing flange. In addition to the reactor vessel seal, two hydraulic control
lines to the drive are sealed at this face. The drive flange contains an integral
shuttle valve. This shuttle valve is so situated as to direct the reactor pressure
or CRD hydraulic system pressure, whichever is higher, to the underside of
the piston. Normally the shuttle valve directs PR+30 header pressure to the
underside of piston. This valve, by shifting its position prevents any
situation of under piston pressure falling below reactor pressure. The same
feature provides capability to scram the CRD by reactor water when the
reactor is at pressure higher than 450 psi and the accumulator pressure is
low.
 The CRD position indication system consists of position indication
probe, a magnet attached to bottom of drive piston, wiring and readout
system.

The position indicator probe is mounted in the central hollow piston

tube of CRD. The position indicator is an aluminium extrusion attached to
cast aluminium housing. Mounted on the extrusion are magnetically
operated switches held by spring clips. The reed switches are operated by
magnet attached to the drive piston. One switch is located at each position
corresponding to latching position of index tube and at each midpoint
between latching positions. When the reed switch is actuated by magnet, it
displays the position of CRD in control room.

A thermocouple is mounted at the top end of position indicator probe

to monitor the CRD temperature. Excessive drive temperature is annunciated
in the control room.

3) CRD Operation:

a) Normal Operation :
Normal drive operation is done by connecting the hydraulic
ports of CRD to PR+200 and PR+30 headers. For inserting the drive
the PR+200 header pressure is supplied to under piston area and over
piston area is exhausted to PR+30 header. For withdrawing the drive
the PR+200 header pressure is applied to over piston area and under
piston area is exhausted to PR+30 header. Before any withdrawing of
CRD, it must be slightly inserted for unlatching.
The operation of connecting hydraulic ports of CRD to the
required headers is accomplished by a “hydraulic control unit” or
“combination selector valve NC-20”. This unit consists of four
solenoid operated normally de-energised solenoid valves V1, V2, V3
& V4, two no. of flow control valves V5 & V6, two check valve V7 &
V8, and two mini-filters to protect the valves. Four solenoid operated
valves are used for connecting the proper headers to the two hydraulic
ports of CRD.
By energizing and opening two solenoid valves at a time, the
PR+200 header can be connected to under or over piston area and the
 opposite side to the exhaust header. Insert motion of drive is obtained
by opening V1 & V3. This pair of valve is also opened for about 1
sec. for unlatching the CRD during withdraw operation. Withdraw
motion of drive is obtained by opening V2 & V4. The opening of
appropriate valves and duration of opening is accomplished by an
electrical sequence timer and occurs automatically when CRD control
switch is operated. V5 & V6 are speed control valves. These valves
are adjusted to get drive insert/withdraw speed of about 3 inch / sec.
V5 is used to adjust insert speed and V6 is used to adjust withdraw
speed. Check valve V7 prevents PR+30 header pressure from going to
over piston area in case V3 is passing through. Normally check valve
V8 provides the path for drive cooling water. During scram action V8
prevents loss of water going to CRD.
b) Scram Operation:

CRD hydraulic system has a independent scram sub system to

accomplish fast simultaneous insertion of all control rods in case of
Scram. The scram sub system consists of accumulators (NC-05). Flow
control valve (NC-28), scram valves (NC-09 & NC-10), scram pilot
solenoid valves (NC-14 & NC-15), scram backup solenoid NC-35,
scram dump tank (NC-04), vent and drain valves of scram dump tank
(NC-11 & NC-12), instrumentation of piping.
The bladder type accumulator (NC-05) on each drive provides
an independent source of stored energy to scram the drive. The
accumulator consists of two cells, each of 1095 cubic inch capacity,
connected together.
The lower cell contains nitrogen. The upper cell contains water
and transfer barrier (bladder) made of rubber. The inner side of
bladder is in contact with N2 of lower cell outer side is in contact with
water. The N2 side is pre charged to about 56-57 Kg/cm2, and then
final charging up to 100 Kg/cm2 is done by charging the water from
accumulator charging header. The accumulator stores enough water to
provide for full scram stroke of CRD.
A level switch (NC-69) and pressure switch (NC-59) are
provided on N2 side of each accumulator to monitor the healthiness of
accumulators. The flow control valve (NC-28) is in line leading from
the accumulator to the CRD. The valve is used to adjust the scram
speed of the drive and to make adjustments for uniform scram speed
of all drives. By design NC-28 cannot be fully closed.
The inlet and outlet scram valves (NC-09 & NC-10) are ¾ inch
globe type, quick opening, air to close valves. Quick opening of
valves is by internal spring and seat area force. The valves are held
closed by applying air pressure on top of the diaphragm operator. The
opening force of the spring is about 700 lbs. The spring pre-load of
outlet scram valve is such as to produce an earlier opening than that of
an inlet valve to avoid objectionable pressure increase in the area
above piston during start of scram. Each valve has a position
indicator switch. The switch gives “open” indication for valve as soon
as the valve starts opening. During normal operation the inlet and
outlet scram valves remain closed, and open as the air in the valve
operator is vented to atmosphere by solenoid operated scram pilot
valves NC-14 and NC-15 which are operated by reactor protection
system.
The scram dump tank (NC-04) is tank of 250 gallons capacity
used to contain and limit the loss of reactor coolant from CRDs during
a scram condition.
Scram dump tank has air to open type vent and drain valves
(NC-11 & NC-12). During normal operation the scram dump tank is
empty with both the vent and drain valves held open. The vent and
drain valves close as the air in the valve operator is vented to
atmosphere by solenoid operated pilot valves NC-22 & NC-23.
During scram the dump tank partly fills with water from above piston
area. The CRDs cannot complete the scram stroke unless there is
sufficient free volume in the scram dump tank. Six level switches are
provided to monitor the water accumulation in the scram dump tank.
LS-NC70B gives scram dump tank high level alarm when water
starts accumulating in the tank. LS-NC70A prevents the CRDs
withdrawal if water further accumulates in tank. Four level switches
LS-NC71A, B, C & D initiate reactor scram when 100 gallons of free
volume is available in the tank.
During normal reactor operation the scram pilot solenoid valves
NC-14 (one for each drive) and NC-22 are energized by channel A
reactor protection system and NC-15 (one for each drive) and NC-23
are energized by channels B. reactor protection system. Inlet and
outlet scram valves remain closed and vent and drain valves of scram
dump tank remain open. When both the channels of reactor protection
system trip, all scram solenoid valves de-energizes and vent air to
atmosphere.
Scram inlet valve opens and supplies accumulator water to
CRD under piston area, Scram outlet valve opens and connects over
piston area to scram dump tank. Thus 100 Kg/cm2 differential
pressure is applied to CRD piston and CRD is scrammed. Vent and
drain valves of scram dump tank get closed and contain the water
coming from scram outlet lines. If the scrammed condition persists the
CRD seal leakage continues to flow to scram dump tank till the tank is
pressurized up to reactor pressure. When either channel of reactor
protection system is reset, the inlet & outlet scram valves go close and
vent & drain valves of scram dump tank open.
To ensure venting of air during scram, a backup scram solenoid
NC-35 is provided on common air inlet header as an added protection.
This solenoid is supplied from 240V DC supply and is normal de-
energized. It energizes during scram to cut off air supply and vent the
air header of scram pilot solenoid valves.
DRG 123A
DRG 123B
DRG123C
DRG 123D
 Liquid Poison System

The purpose of liquid poison system is to provide means of rendering reactor

sub critical and holding it sub critical while it cools own; in the event that the
control rods are unable to do so. The system is not intended as a back-up to scram
function of CRD system but, is the last resort to make reactor sub critical in the
extreme conditions. The system is common for both units. The system is designed
to bring the reactors from full power to cold xenon free shutdown condition
assuming none of the withdrawn control rod can be inserted. The required negative
reactivity of 18% ∆ K (including shutdown margin and calculation uncertainties)
for each reactor is provided by 5110 liters (1350 gallons) of 13.5% sodium
pentaborate solution by weight. The system contains minimum 10,200 liters (2700
gallons) of sodium pentaborate solution for simultaneous requirement of both
reactors. The solution is maintained above 18°C (65°F) temp. to prevent
precipitation. The solution is prepared by dissolving stoichiometric amount of
boric acid and borax to produce sodium pentaboarate.

The system consists of poison tank, high pressure positive displacement

pumps, positive shut off explosive type valves, test tank, piping and
instrumentation.

The poison tank is stainless steel tank of 4000 gallons capacity. It contains
normally 3400 gallons of sodium pentaborate. The tank has an immersion type
electric heater. The heater is used to heat tank contents during addition of
chemicals for making up the losses. The heater is not normally required as ambient
temperature is generally higher than required temperature. The tank has an air
sparger. The air sparging is done while adding the chemicals. A demineralized
water connection is provided to tank, which is used for making up solution level
and temperature monitoring instruments are provided for the tank. Level switch
IL01 is provided to give high level alarm at 3500 gallons and low level alarm at
2967 gallons. Another level switch LS-IL10 is provided to give poison tank mid-
level alarm. This alarm, sounds when 1350 gallons of solution is remaining in tank.
 The low temperature alarm is provided by TIS-IL09 at 25°C. The pumps
provided are of high pressure positive displacement type. There are two pumps,
each of 50 gpm capacity and driven by 50 HP motor. The motors are supplied from
emergency busses. Normally one pump is sufficient for injecting poison. The other
pump is on standby and starts automatically if the selected pump fails to develop
the pressure. Relief valves are provided on pump discharge lines to prevent
dangerous over pressurization of system in case the pumps operate against closed
discharge valves.

Leakage of poison solution into reactor is undesirable. To prevent any

leakage into reactor, positive sealed, explosion type injection valves are used.
When this valve is welded into the line, an internally welded cap prevents any
leakage through the valve. When the squib is fired, a shear plate is forced across
the welded cap, shearing it off and allowing the solution to flow through the valve.
The firing circuit of squib valve is supplied from 240 V DC system and there is
provision for checking healthiness of squibbs. Failure of squib or firing circuit
gives annunciation.

Test tank is a stainless steel tank of 200 gallons capacity. The tank is filled
with demineralized water and is used for routine testing of poison injection pumps
and the Squibb valves. During test firing of Squibb valves, the demineralized water
is injected into the reactor. Monthly pump operability is tested by circulating
demineralized water from test tank to test tank. Normally all piping of poison
system is kept filled with demineralized water to prevent crystallization of poison
solution into pipe lines.

All drains and vents from poison system are routed to a portable container.
The solution coming into container is disposed off separately to eliminate its
mixing with other plant drains and possible entrance into primary system.

Two control switches are provided in control room which must be operated
simultaneously to initiate poison injection into reactor. This provision prevents
inadvertent injection of poison.
DRG 125A
DRG 125B