A.V. Dub, JSC SPA «CNIITMASH

Development of Components for Recovery Annealing
of VVER-1000 Reactor Vessel Welds
2010
Development of technical task
Development of technical
proposal
Development of draft project of
heating device
2011
Development of design, manufacturing and
testing of pilot sensors for monitoring and
registration of thermal mode.
Development of system РКД for automatic
control, monitoring and registration of
thermal mode.
Preparation of production, manufacturing
and testing of pilot heating panels.
Manufacturing of heating device mock-up
and performing experiments with this mockup.
Development of RKD for heating device
1
Technical Task on Installation and Main Technical Decisions




Heating of reactor vessel welds №3,4 at a rate of 20 ОС /hour maximum from the ambient
temperature to 570ОС;
Exposure at temperature 570ОС , duration 120-150 hours;
Cooling from 570ОС to 100ОС at an average rate 7ОС /hour
Maldistribution of temperature in weld volume + 15ОС maximum
2
The scheme of double-side heating (heating of internal and external surface of vessel)
The scheme of one-side heating of internal vessel side with well-done heat insulation of external
surface (heating of internal and external surface of vessel)
Installation of thermal insulation in hard- to- access places is a difficult task but a real one.
Weld № 4 is located close to the reactor support, there is no practical possibility to install external
insulation in this place that additionally increases heat flow and creates a risk of support concrete
heating higher than permissible temperature.
Due to complicated reactor vessel configuration significant heat losses must be compensated with
a very limited height of thermal area.
Heating with process gap 380 (it was 250)
To reduce mutual influence of thermal area there are flexible metal thermal screens to be installed.
3
Calculated Validation of Adopted Technical Decisions



mathematical model of multi-link system of thermal-technically massive and thin bodies
considering heat exchange with irradiation, heat conductivity and convection between
them
set of programs (2-D and 3-D) providing for simulation of stationary and nonstationary thermal processes during recovery annealing of VVER-1000 reactor vessel
considering specific features of reactor vessel design, reactor pit and heating device
non-stationary calculations with 2-D model of heating device proved correctness of
heating device scheme selected and demonstrated that design decisions provide for the
following requirements of the technical task:
•reactor vessel heating with the rate of 20 ОС/hour up to 570 ОС;
• exposure during 100 and more hours at this temperature;
• temperature variation along reactor vessel during exposure period
close to welds being thermally processes (± 100 mm by height from
middle weld line) is within 19 ОС.
4
The Area of Weld №4 being Thermally Processes
Temperature fields of the vessel during annealing
• Reactor vessel; 2- heating device; 3- weld № 4; 4- external heat
insulation; 5- supporting ring; 6- supporting frame
5
°C
°C
519
519
486
486
454
454
421
421
389
389
356
356
323
323
291
291
258
258
226
226
193
193
161
161
128
95
63
30
128
95
63
30
Температурное поле части фермы опорной
Temperature field of supporting frame
The temperature of adjacent to the
reactor elements of supporting frame
(about 140mm thickness) can reach 500430 ОС (regulated temperature – 430 ОС)
under conditions adopted for 3D model
calculations
6
Experimental Support to Validate Technical Decisions
Bench for Thermal Testing
1– body;
2- heating panels;
3- heating insulation;
4- reactor vessel imitator;
5- regulating thermo couples;
6- control thermocouples;
7- thermal screens
7
Heating panels
8
Installation of heating panels during installation of bench
9
Hoist model in initial and lifted position
10
1. Experimental stability checking of automatic temperature control system and determination of mutual
influence rate for thermal areas
Provides for stable system operation, mutual influence of thermal areas does not impact on
control quality, dynamic settings of temperature PID regulators are determined
2. Comparative testing of two variants for heating panel design
A panel with zigzag heater made of resistance alloy 550х400 size is the most reliable
3. Checking of compliance between contact type thermal couple indications and real temperatures of reactor
vessel surface
Thermal couples provided for compliance of indications and actual temperature of the surface
being measured with error maximum 2ОС
4. Checking availability of the main device for installation of external heat insulation of reactor
vessel (scaled 1:3)
Testing of hoist model proved availability of design developed and allowed for
correcting the choice of materials for specific details of the device модели
11
Heating device
1) Heating device is designed for recovery of metal mechanical
properties in welds №3 и №4 of VVER-1000 reactor vessel
after multiple application at NPP ( must be decontaminated)
Installed capacity, кВА…………………max. 1000
Voltage, V, Hz………………………..... 380/220, 50
Heater voltage, V
………… 36,6
Current at heaters, А………………
364
Number of heaters, pcs.……………… 108
Number of heating areas, pcs. ………18
Connection of heaters in the area
serial
Size of heating unit, mm:
Diameter……………………………………max 3830
Height ………………………………………10900
Weight, kg…………………………………32000
12
2) Heating device contains a lid of
biological protection and two heater units
connected with a bar with membrane installed
on it linked with a curtain and a draw bar.
3) There are 54 heaters in each unit,
108 in two. They create six heating rings by
their height, 18 in each of the ring.
4) Heating unit contains 18
independent thermal areas, 9 areas for each
weld. Three annular heating areas with six
heaters in each of the area
5) Heaters of each area are connected
to the independent supply source with the help
of supplies laid along the bar to the external
surface of the lid.
6) Each area is supplied with thermal
couples in the form of double-arm lever
13
Heating device in
reactor vessel
14
External Heat insulation, Tools for its
Installation
Thirteen vertical «straps» of heat insulation
(metal box filled with heat insulation material).
Thirteen hoists in the form of telescopic fourway screw jack with two telescopic columns.
On upper surface – soft heat insulation filling
the volume between the reactor vessel and
concrete horn of reactor pit support part.
Powered truck with four grips (from tilting) and
rotary frame.
Lifting tongs to move hoists, driving roller bed
on which a strap of heat insulation is laid and a
rotary drive with a gear.
The system of external heat insulation in working position
•
1- rails, 2- powered truck, 3- telescopic hoists,4- heat insulation.
15
Electric Equipment and Tools for Automatic Control
and Registration of Anneal Main Parameters
Electric power supply to heating elements
Automatic control of thermal processing according to a temperature-time
program set by an operator
Collection of information on temperature state of reactor vessel and reactor
room
Visual presentation of thermal processing
Registration of process parameters in paper chart
Archiving and storage of process parameters




ШУ – control cabinet; ШС1 ÷ ШС7 – power supply cabinets (ШС7 – back-up);
ШРП – supply distribution cabinet; ШВП – supply input cabinet;
ПУ – control board – main and back-up
ПР1 ÷ ПР3 (ПР3 – back-up) – registration boards.


16
Functional scheme of control system for thermal processing
of VVER-1000 reactor vessel welds
ШС7
ШС2
ШС1
CS DPL02D
CS
DPL STATUS
L ACTIVE
CPU STATUS
R ACTIVE
CPU STATUS
LEFT CPU
USE
NO USE
CS
POWER
Port 1
1
62
7
83
94
5
1
62
7
83
94
5
Port 2
Port 2
1
62
7
3
8
94
5
1
62
7
3
8
94
5
POWER
Устройство
защиты
RUN
RUN
ERR/ALM
ERR/ALM
INH
BKUP
INH
BKUP
PRPHL
COMM
PRPHL
COMM
PROGRAMMABLE
PROGRAMMABLE
CONTROLLER
CONTROLLER
OPEN
OPEN
MCPWR
BUZY
MCPWR
BUZY
OPEN
OPEN
PERIPHERAL
PERIPHERAL
PORT
PORT
OMRON
SYSMAC
L2/N
RIGHT CPU
Port 1
USE
NO USE
DPL SW
ON OFF
SPLDPL
ON ACT.ACT.
INIT. LEFT
RIGHT
SW
ON
DPL
Возможность
переноса CSV-файлов
на флешь карте
PRPHL
COMM
A39512
RSV
L2/N
L1
L1
Vol.sel.
Vol.sel.
Vol.sel.
Vol.sel.
LG
LG
GR
RUN
output
RUN
output
GR
RUN
output
RUN
output
I> I> I>
USE
NO USE
Программируемый контроллер
Рейка2
II102D
DRM21
II102D
DRM21
DRM21
DRM21
POWER
OUT
IN
OUT
L2/N
1 DRO
2 DR1
3 ESTP
4 RSV
612
7
3
8
945
Port 2
5
V+
CAN-H 4
DRAIN 3
CAN-L 2
1
V-
612
7
843
95
Возможность
переноса CSV-файлов
на флешь карте
1 DRO
2 DR1
3 ESTP
4 RSV
5
V+
CAN-H 4
DRAIN 3
CAN-L 2
1
V-
1 DRO
2 DR1
3 ESTP
4 RSV
5
V+
CAN-H 4
DRAIN 3
CAN-L 2
1
V-
1 DRO
2 DR1
3 ESTP
4 RSV
5
V+
CAN-H 4
DRAIN 3
CAN-L 2
1
V-
L1
Vol.sel.
Vol.sel.
Vol.sel.
LG
LG
GR
RUN
output
RUN
output
GR
RUN
output
RUN
output
DRM21
II102D
DRM21
IN
OUT
L2/N
ПУ
5
V+
CAN-H 4
DRAIN 3
CAN-L 2
1
V-
1 DRO
2 DR1
3 ESTP
4 RSV
5
V+
CAN-H 4
DRAIN 3
CAN-L 2
1
V-
1 DRO
2 DR1
3 ESTP
4 RSV
ПР1
Бумажный
самописец ,
осн.
С еть DeviceN et 3
5kVA
С еть DeviceN et 2
С еть DeviceNet 1
ИБП
....
Сеть1 RS-485
A3B3 A3B3 B3A3
Регулятор
мощности
A5B5 A5B5 A5B5 A5B5 A5B5
A6B6 A6B6 A6B6 A6B6 A6B6
I> I> I>
5
V+
CAN-H 4
DRAIN 3
CAN-L 2
1
V-
L2/N
L1
Vol.sel.
Vol.sel.
Vol.sel.
LG
LG
GR
RUN
output
RUN
output
GR
RUN
output
RUN
output
Температура нагревателей
18 сигналов
Температурные модули сети
Device-Net
OMRON
,
Температура зон ,
18 осн . сигналов
Температура зон ,
18 дубл . сигналов
до 20 станционных
датчиков температуры
180мм,12канал
ов
Тепловые
зоны 1-го шва
ПР2
ШС2
ШС3
180мм,12канал
ов
ПР3
ШС4
ШС5
ШС6
Резерв
Бумажный
самописец ,
рез.
180мм,12канал
ов
1
2
3
4
5
6
7
8
9
.....
Бумажный
самописец ,
осн.
ПК - Персональный компьютер
ПУ - Пульт управления
ШУ- Шкаф управления
ШС- Шкаф силовой
ПР - Пульт регистратора
ШВП- Шкаф вводного питания
ШРП - Шкаф распределения питания
ИБП - Источник бесперебойного питания
I> I> I>
A3B3 A3B3
A4B4 A4B4 A4B4 A4B4 A4B4
POWER
L1
Vol.sel.
Сеть3 RS-485
Сеть2 RS-485
A1B1 A1B1 A1B1 A1B1 A1B1
A2B2 A2B2 A2B2 A2B2 A2B2
+V
-V
+V
-V
IN
1 DRO
2 DR1
3 ESTP
4 RSV
Сеть4 RS-485
P1195 P1196 P1199 P1202 P1189
5
4 V+
3CAN-H
DRAIN
2
1CAN-L
V-
DRM21
POWER
OUT
15 "
рез .
...
L2/N
L1
Vol.sel.
F1
F2
F3
N
PE
Программируемый контроллер
Рейка3
II102D
15 "
осн .
Сеть DeviceNet 4
POWER
IN
Port 1
Сенсорная
панель
Модули ввода /
вывода
Smartslice
I> I> I>
Программируемый контроллер
Рейка1
OMRON
SYSMAC
.....
ПК
Ethernet
коммутатор
ШВП
A C1 / 80 k W / 36 0 A / 2 2 0 V
Возможность
подключения ПК
ШРП
F1
F2
F3
N
PE
F1
F2
F3
N
PE
I> I> I>
ШУ
Тепловое кольцо
Тепловые
зоны 2-го шва
10
11
12
13
14
15
16
17
18
Attachment 1
17
Conclusions and Results
1.
2.
3.
4.
An annealing facility for №3 and 4 welds of VVER-1000 reactor vessel is
designed.
Working design documents for heating device, control and heating mode
registration systems providing for implementation of this annealing
technology is developed.
Calculated and experimental validation of adopted technical decisions is
made, heating device is being manufactured, auxiliary devices and facilities
are being designed and tested.
The work is being done strictly according to the schedule providing for
readiness of technology and components to first annealing in 2016-2017
(Balakovo NPP, unit №1).
To refine equipment operation modes, specify real bordering conditions and
temperature fields in reactor vessel and bearing structures it is necessary to
perform full-scale experiments for «clean» reactor vessel not intended for
further operation
18
Residual embrittlement of irradiated welds after recovery annealing 565±15оС
/100 h
140
150
ия
оян
сост
о
г
но
учен
120
для
сть
о
м
си
ави
ая з
н
в
и
мат
Нор
100
80
обл
100
Rp0.2, МПа
40
ивн
мат
Нор
50
ост
o
TK, C
60
б
ля о
ть д
с
о
сим
ави
ая з
ния
стоя
о
с
ого
енн
луч
20
0
0
-20
-40
-50
0
10
20
30
22
40
2
Флюенс х10 , нейтрон/м
50
0
10
20
30
22
40
50
2
Флюенс х10 , нейтрон/м
Possibility for almost total recovery of material structure and properties in
VVER reactor vessel as a result of recovery annealing after irradiation within
the range of neutron fluence corresponding to the design one as well as to
prolonged up to 60 years operation period was proved experimentally. This
demonstrates possibility of recovery annealing application to provide
operation of reactor vessels up to 60 years and more.
Continuation of Work on Development of Equipment
Making control and power supply system
Making heating unit
Making external thermal insulation and tools for its installation
Designing and making a стапеля and rigging for installation of heating device before its
loading to the reactor
Programming and debugging of control system
Hot testing, RKD correcting
Experimental- calculated validation of reliability and sufficiency of proposed
technology for recovering annealing of reactor vessel, safety of adopted concept
for annealing of design elements of reactor, reactor pit and other NPP
components.
Possible study of variants for cooling of support structures.
Development of operation documents, POR.
Creation and training of specialists for annealing
20