2012 Year Fourth Module

Capacity Building Program on Nuclear Safety for Egyptian Nuclear Regulators

WonHyo YOON
Inspection Advisor
KINS
March 14, 2012
Fuel Handling & Transfer System
Table of Contents
Abbreviations & Acronyms
I. Introduction
II. Design Bases
III. Major Components
IV. Operation during Normal Refueling Outage
V. Inspection & Testing Requirements
VI. Summary
2
Abbreviations & Acronyms
3
ALARA
CB
CEA
CVCS
FHS
RCS
RHR
FA
SFA
FB
GDC
RCCA
RV
Rx
T/S
As Low As Reasonably Achievable
Containment Building
Control Element Assembly
Chemical & Volume Control System
Fuel Handling System
Reactor Coolant System
Residual Heat Removal
Fuel Assembly
Spent Fuel Assembly
Fuel Building
General Design Criteria
Rod Cluster Control Assembly
Reactor Vessel
Reactor
Technical Specification
I. Introduction 1/3
The basic function of the FHS
To remove SFA from the Rx and,
To replace them with new FA on a schedule determined by the
fuel management program.
FHS is designed also to function
To receive and store new FA
To store and ship SFA, and
To remove and replace control element assemblies.
4
I. Introduction 2/3
FHS consists of the equipment, tools and procedures for
refueling the Rx
Providing for safe and rapid handling and storage of FA.
Foremost requirements in the design of FHS: Refueling
should be accomplished with
Maximum safety,
A minimum probability of mishandling
Thereby avoiding damage to the FA and Rx components,
ALARA radiation exposures, and
Efficiency of equipment and procedures to reduce Rx downtime.
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I. Introduction 3/3
In addition, detail designs are such that
Positive grappling is provided
For all handling devices,
Interlocks are used
To ensure the correct sequential operation of the system,
Travel and load limits are provided
To ensure safe design conditions are not exceeded, and
Either procedural or equipment backup is provided
In the event of a failure.
Where practical, the equipment contains devices which will function to
bring the operation to a safe condition in the event of a failure.
Visibility is maximized and readout equipment is provided to allow the
most intelligent operation of the equipment.
6
Overview of Fuel Handling & Transfer System
7
Containment & Fuel Handling Area Layout
8

C
C
C

C O
O
O O
O
O
O
O
O
New Fuel Elevator CFuel Handling Machine
CFuel Building Crane Fuel Transfer System
CRefueling Machine CCEA Elevator
CUpender RB Polar Crane
CEA Change Platform
CCEA Elevator
CUpender
RB Polar Crane
CEA Change Platform
O New Fuel Storage OSpent Fuel Pool
O New Fuel Shipping Container Unloading Area
O Cask Loading Pit ODecontamination Pit O Fuel Transfer Canal
ORefueling Canal O Refueling Cavity) OReactor Core
9

Process-1
II. Design Bases 1/2
FHS is designed to:
Be operated under a constraint such that only one SFA is
suspended in each building area (containment or fuel handling)
at any one time.
To be consistent with the assumptions of the postulated fuel
handling accident which assumes total mechanical damage to a
single dropped FA.
Support maximum loads under design earthquake conditions.
To prevent fuel damage from an earthquake.
Preserve the integrity of containment (where the system
penetrates containment).
To ensure containment integrity.
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II. Design Bases 2/2
Maintain the minimum required depth of water shielding.
Cranes and hoists used to lift SFAs are required to have limited
maximum lift heights.
To ensure adequate radiation shielding is maintained.
Be operated under a constraint such that a spent fuel shipping
cask drop accident will not cause any fuel damage.
Assured by requiring (via Tech Specs) that all FAs be stored outside
of the exclusion zone during cask handling operations
To prevent the possibility of fuel interaction if a shipping cask is
accidentally dropped.
To prevent fuel damage or an unsafe fuel configuration.
Prevent inadvertent movements following loss of power.
Equipment used to transfer or lift FAs have positive latching devices and
automatic braking devices for this purpose.
To ensure there are no inadvertent movements on loss of power.
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III. Major Components
New Fuel Storage Rack
Reactor Cavity Pool Seal Assembly
Transfer Tube Assembly
Spent Fuel Storage Rack
Others
Refueling Machine
CEA Change Platform
Spent Fuel Handling Machine
New Fuel Elevator
Closure Head Lift Rig
Upper Guide Structure Lift Rig
Fuel Transfer System, Carriage & Upender CB
Hydraulic Power Unit
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New Fuel Storage Rack
A 12 x 12 cavity new fuel storage rack
for storage of 72 new fuel assemblies
welded stainless steel
configuration is similar to the spent fuel
storage rack design.
Cavity blocking devices will be utilized
to affect a storage configuration which
will result in an effective multiplication
factor (K
eff
) within allowable limits
0.98 even if a foam or water mist of
optimum moderator density is
homogenously dispersed inside and/or
outside the stored fuel.
0.95 assuming the storage area is flooded
with un-borated water
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Reactor Cavity Pool Seal Assembly
Spans the annulus between the
RV flange and the refueling pool
floor.
The seal consists of a stainless seal
plate with 2 attached inflatable
elastomer seals.
After installation and testing, the
pool can be filled with water for the
refueling operations.
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Transfer Tube Assembly
Provides the interconnection
between the CB and the FB
pools for underwater passage
of the FA via the fuel transfer
system.
15
Spent Fuel Storage Rack
Minimum storage capacity: 632 FAs
10 batches x 45 FA/batch + 177 FA/core +
5 failed fuel canister
initial U-235 enrichment of FA is 4.3%.
Nine (9) 10 x 12 modules having a
usable total capacity of 678 FA are
provided.
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Other Components
17
Refueling Machine CEA Change Platform Spent Fuel Handling Machine New Fuel Elevator
Closure Head Lift Rig Upper Guide Structure Lift Rig
Fuel Transfer System,
Carriage & Upender CB
Hydraulic Power Unit
IV. Operation during Normal Refueling Outage
Preparation
Rx disassembly
Fuel handling
Rx assembly
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Preparation
RCS clean up and decontamination
Accomplished by CVCS prior to shutdown
In order to minimize the radiation exposure during the refueling,
Containment atmosphere clean up
Accomplished by purge and filtration system
Rx is shutdown and cooled to cold shutdown conditions
A final effective multiplication factor (K
eff
) < 0.95 (all rods in) and
RCS temperature < 140F (MODE 6).
Following a radiation survey, the CB is entered.
At this time, RV water level is lowered to a point slightly below the RV flange.
Then the fuel transfer equipment and manipulator crane are checked for
proper operation.
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Rx Disassembly 1/2
Begins with the removal of the missile shield
All cables, air ducts, and insulation are then removed from the
RV head.
RV stud tensioners are used to de-tension the vessel studs
The refueling cavity is then prepared for flooding by
sealing off the reactor cavity;
checking the underwater lights, tools, and fuel transfer system;
closing the refueling canal drain valves; and
removing the blind flange from the fuel transfer tube.
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Rx Disassembly 2/2
With the refueling cavity prepared for flooding,
RV head is unseated and raised approximately 1 foot above the RV
flange.
Water from the RWST is pumped into the RCS by RHR pumps
Causing the water to overflow into the refueling cavity.
The RV head and the water level in the refueling cavity are raised
simultaneously,
Keeping the water level just below the head.
When the water reaches a safe shielding depth, RV head is taken to
its storage pedestal.
Control rod drive shafts are then disconnected and, with the upper
internals, are removed from the vessel.
FAs and RCCAs are now free from obstructions
Core is ready for refueling.
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Fuel Handling
Fuel handling can start after the reactor has been subcritical for 100 hours
(T/S requirement).
This time allows for the short-lived fission products to decay.
Refueling sequence is started with the manipulator crane.
SFA are removed from the core.
Positions of partially SFAs are changed (fuel shuffle) and
New FAs are added to the core
Reactor Assembly
Achieved, following refueling, by reversing the operations given in Reactor
Disassembly
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V. Inspection & Testing Requirements
Fuel Handling Machine, Refueling Machine, etc.,
Minimum Acceptable Shop Test
Load Test at 125% of Rated Load
Functional and Running Operation
Maintenance and Checkout Test
Visual Inspect(Loose or Foreign Parts, Dirt and Grease)
Proper Lubricant(Wheel, Gear)
Inspect Hoist Cable(Worn, Broken)
Visual Inspect Limit Switch
Check the Functional & Running Operation
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VI. Summary
The basic function of the FHS
To remove SFA from the Rx
To replace them with new FA into the Rx
Preparation, Rx disassembly, Fuel handling, Rx assembly
Design Bases
Support maximum loads under design earthquake conditions
Preserve the integrity of containment
Maintain the minimum required depth of shielding
Backup devices
Positive grappling, interlocks, travel & load limits, procedural or
equipment backup
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Process-2
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The strength of a chain is
in its weakest link!
Thank you for
Your Attention