SETTING-UP OF SMR IN A DEVELOPING XA9846711 COUNTRY - INDIAN EXPERIENCE

C.N. BAP AT, P.D. SHARMA Nuclear Power Corporation of , Anushaktinagar, India

Abstract

India envisaged a 3 stage Nuclear Power Programme on long term basis with a view to make use of large deposits of Thorium. The first stage involved Pressurized Heavy Water Reactors (PHWRs) based on natural uranium. First two PHWRs in 220 MWe range were set-up under collaboration with Canadians and subsequent were set-up and operated with totally developed indigenous technology. The designs for 220 MWe & 500 MWe PHWRs are ready. The size of reactors, coming under Small & Medium Reactor Categories, is ideal for a developing country from indigenisation of technology, synchronizing with grid and financing point of view. The paper gives Indian approach and experience gained in setting-up series of PHWRs in SMR range in India.

1. INTRODUCTION The setting-up of Nuclear Power Plants (NPPs) in India is entrusted to Nuclear Power Corporation of India Ltd. (NPCIL). This is Govt. of India owned company set-up in Sept., 1987 to give impetus to Nuclear Power Programme in India. The corporation is sole organization that is responsible for design, engineering, procurement of equipment/components, site construction, commissioning, operation and maintenance of Nuclear Power Plants. The Nuclear Power Production in India started way back in mid 60' s when two Boiling Water Reactor type Nuclear Power Plants of 200 MWe capacity were set-up at Tarapur on 'Turn-key' basis from USA. Around that time. Dr. Homi Bhabha, along with energy planners, assessed the potential of nuclear power vis-a-vis available resources in natural uranium and abundant thorium reserves. As a result, long range nuclear power programme comprising three distinct and basic stages was evolved. The three stages were : I Setting-up of small/medium range Pressurized Heavy Water Reactors {PHWRs) based on natural uranium and heavy water. This stage yields plutonium which is to be used for next stage. II Setting-up of Fast Breeder Reactors (FBRs) based on natural uranium - plutonium fuel with depleted uranium and thorium used as blanket that gets converted into plutonium and Uranium-233 which can be used in third stage i.e.

127 Ill Setting-up of Uranium-233 thorium based Fast Breeder Reactors. The reactor generates more fissile material from thorium than is consumed in terms of Uranium-233. This stage thus provides abundant and continual source for power production.

2. APPROACH Thus it was very clear in the beginning that future of lies in PHWR technology and therefore after setting-up two BWRs at Tarapur, the focus was shifted to PHWRs and accordingly all the efforts were directed towards acquiring and absorbing PHWR technology from the leader viz. Atomic Energy of Canada Limited (AECL). Accordingly collaboration agreement was reached between AECL and Department of Atomic Energy (DAE). As a result, two units at Rajasthan viz. RAPS-1 and RAPS-2, each 220 MWe PHWR, were set-up in the joint collaboration. Indians were trained in Canada on Douglas Point Generating Station and were also involved in certain design and engineering activities. For the first unit of Rajasthan Atomic Power Plant, the design, engineering and supply of major equipment was from Canada, while site construction, commissioning and operation was done by Indians under supervision of AECL. The second unit though constructed under supervision of Canadians, was commissioned, operated and maintained by only Indians. Some of the equipment were also manufactured indigenously. Then on, there was never looking back and Indians took on responsibility of design, engineering, operations and maintenance for series of PHWRs. As of now there are 8 PHWRs of 220 MWe capacity which are being operated and maintained at various locations in the country. Four more units of 220 MWe PHWRs are under construction. Four units of 220 MWe are in future plan at identified sites. Two units of 500 MWe PHWR have been designed and long delivery items have already been procured. The units are likely to be launched shortly. Thus it can be seen that India has fully developed technology to design, construct, operate and maintain PHWRs in SMR range. The two PHWR types - PHWR-220 and PHWR-500 - have already been shortlisted by IAEA in 'detailed design stage' category.

3. PROSPECTS FOR FUTURE In addition, a 100 MWth reactor set-up mainly for isotope production and R&D work has been designed, constructed, operated and maintained by Bhabha Atomic Research Centre (BARC), Mumbai. One Fast Breeder Test Reactor (FBTR) at Kalpakkam is under commissioning trials. This is 14 MWe test reactor being connected to the grid in very near future. Work is in progress for design of 500 MWe Prototype Fast Breeder Reactor (PFBR) on the basis of experience gained from FBTR. Design of Advanced Heavy Water Reactor (AHWR) is also in progress at BARC and these reactors would also be in a state of readiness within next five years. Thus a beginning is already made in second stage of Nuclear Power Programme after successfully acquiring technology for implementing first stage of the Programme.

128 4. RESEARCH AND DEVELOPMENT (R&D) Self reliance being one of the prominent ingredient of the Nuclear Power Programme, efforts were simultaneously made to establish strong R&D base and training programme for which BARC and other sister organizations under DAE were set-up. The various DAE units engaged in various aspects of supporting Nuclear Power Programme are given below :

4.1. (IRE) Mining of Rare Earth elements.

4.2. Uranium Corporation of India Ltd. (UCIL) Mining of Natural Uranium. 4.3. (NFC) Fabrication of fuel elements and fuel bundles, manufacturing of coolant tubes (pressure tubes), calandria tubes etc. 4.4. Heavy Water Board (HWB) Production of Heavy Water. 4.5. Electronics Corporation of India Ltd.(ECIL) Reactor control and instrumentation, consoles,software development & simulators.

4.5. Bhabha Atomic Research Centre (BARC) This is basic R&D establishment which, interalia, develops basic engineering concepts and technologies required for Nuclear Power Programme implementation. The basic research and development work is then transferred, as part of Technology Transfer, to either above mentioned sister organizations or industries for large scale production on commercially competitive manner.

The BARC is also providing one year Nuclear Orientation Training Course to fresh engineering & science graduates since 1957. Total capabilities exist in complete nuclear fuel cycle including waste management and reprocessing.

5. MANUFACTURING CAPABILITIES

The equipment manufacturing in the country started right from second PHWR (Viz .RAPS-2) itself and as of now, following organizations in Public & Private sector have developed capabilities to manufacture equipment and components as given below :

5.1. Bharat Heavy Electricals Limited (BHEL)

Balance Of Plant (BOP) i.e. secondary side equipment including Turbine - Generator sets, condensers

129 etc.. Steam Generators, Pressure Vessels/Tanks, Heavy Water Heat Exchangers, Electrical Motors. 5.2. Bharat Heavy Plate & Vessels Ltd. (BHPV) Pressure Vessels/Tanks, Main Air-Locks, Heavy Water Heat Exchangers, Condensers, etc.

5.3. Bharat Pumps & Compressors Ltd. (BPCL) Centrifugal and recipocating pumps and compressors in medium range. 5.4. National Government Electrical Factory (NGEF) Motors in all size ranges including for Primary Coolant Pumps. 5.5. Larsen & Toubro Ltd. (L&T) Steam Generators, Calandria, End Shields, Pressure Vessels/Tanks, Heavy Water Heat Exchangers, etc. 5.6. Walchandnagar Industries Limited (WIL) Calandria, End Shields, Heavy Water Heat Exchangers, Pressure Vessels/Tanks,etc. 5.7. Kirloskar Brothers Limited (KBL) Electrical Motors in medium range centrifugal pumps-mech. seal type and canned type.

5.8. KSB Pumps Ltd.

Manufacturing Primary Coolant Pumps.

5.9. Machine Tools Aids and Reconditioning (MTAR)

Precision Machinery and Manufacturing of intricate components.

5.10. Hindustan Construction Company Ltd.(HCCL), Presteel & Elecon Construction Company (ECC)

Civil construction including containment building.

Many of above manufactures have acquired or in process of acquiring ISO-9000 certification.

6. CONSULTANCY

In addition to above mentioned equipment/ component manufacturers, there are number of consultancy organizations in the country which render assistance in design and detailed analysis work required to validate the design or provide Safety Analysis for Licensing purposes. Some of the

130 major organizations engaged are within DAE while others are in educational and industrial sectors.

7. TRAINING

The plant personnel operating and maintaining the Nuclear Power Stations are given thorough training at Nuclear Training Centres located near Rajasthan Atomic Power Station (RAPS). They are selected on the basis of minimum required educational qualification. First operators have minimum graduation (degree) qualifications. The training consists of lectures, plant walk through, check lists, emergency procedures and simulators before they are given independent responsibility to operate and maintain the nuclear power station. The training includes retraining at periodic intervals.

The design, manufacturing, operation and maintenance of nuclear power station by highly skilled and professional personnel is demonstrated by the fact that in approx. 121 reactor years of operation, no accident of radiological nature and above level 3 of the International Nuclear Event Scale (INES) has taken place. Nevertheless accidents of non radiological consequences have taken place but they have been handled quite effectively; without allowing them to escalate into serious ones. Engineering challenges posed due to equipment mal-function, mechanical fault, operator error or natural events have been successfully tackled within the resources and infrastructure facilities available indigenously. Some of such situations have been : inadvertent dousing, end shield brittleness, coolant channel inspection, fire in turbine building, flooding of plant site etc.

8. DESIGN FEATURES The standard designs now available in India are 220 MWe PHWRs and 500 MWe PHWRs. This size range is ideally suited for Indian conditions viz. strength of the power distribution grid, evolving manufacturing facilities and limited availability of funds and could be prevalent in many developing countries. The salient features of the two nuclear power plants are given below :

Parameters 220 MWe PHWR 500 MWe PHWR (1) Core Horizontal Pressure 306 nos. 392 nos. Tubes

Pitch 229 mm 286 mm Fuel Bundle 19 Elements 37 Elements No. of Fuel Bundles/Channel 12 13 Thermal Power 770 MW 1736 MW Av. no. of fuel Bundles 8 14 replaced per full power day

131 Parameters 220 MWe PHWR 500 MWe PHWR

Weight of all fuel bundles 60 121 Tonnes

(2) Primary Coolant Circuit Single Loop Two Loops

Primary Coolant Pumps 4 4 Steam Generators 4 4 Reactor Headers 4 8

(3) Total Heavy Water Requirement 250 Te 500 Te

(4) Containment : RCC double with Yes Yes suppression pool

(5) Shutdown provisions PSS + SSS PSS + SSS PSS - Primary Shutdown Systeir. SSS - Secondary Shutdown System

(6) Engineered Safety Feature Provided Provided

(7) Capability to cope with Provided Provided Station Black Out

(8) Spent Fuel Storage Bay 10 Years + 10 Years + 1 Core Unload 1 Core Unload

(9) Waste Management at Site at Site

(10) Construction Period < 7 Years approx. 7.5 Years

9. CONSTRUCTION SCHEDULE The construction experience with regard to various 220 MWe PHWRs in terms of construction period is given below :

20 I INOIGENISflTION PHflSE 5IGNIFICHNT DESIGN IMPROVEMENTS 15 CONSOLIDATION 8. COLLRBORflTION STflNDflRDISflTION in 10 a: cr UJ TURNKEY

0

FIG. I. Trend in schedules Indian nuclear power projects

132 It is seen that the project schedules have extended beyond expectations, however, for each case there were valid reasons in terms of either component availability or manufacturing troubles faced during the process of learning. The manufacturer's capability and technical requirements have to be continuously assessed and alternative solution to be found out which help manufacturer to overcome his difficulty but do not comprise on technical and safety requirements. The NPPs could also not be standardized in order to progressively accommodate evolutionary designs and evolving safety requirements. Thus each subsequent project itself presented challenges in newer areas; however, now there is semblance of standardization with respect to 220 MWe PHWRs. Manufacturers have also developed and acquired 'state-of-the-art' technology that is commercially competitive. In most of the cases there are more than one manufacturers and that encourages competition. On the basis of this strength a construction schedule of less than 7 years is very much realistic for 220 MWe PHWR. Extrapolation of this and experience gained in procurement and manufacturing of some of capital equipment for 500 MWe PHWR also indicate schedule of construction around 7.5 years provided unhindered cash flow requirements are met and lead tiwe to complete site specific design details is available.

10. FINANCING AND CONTRACTUAL AGREEMENTS At a time when technological capabilities were fully demonstrated, the resource crunch-typical to a developing country has started affecting schedules. Initially, i.e., upto September, 1987, the funding of Nuclear Power Plants was done by the Government and funds required on yearly basis were made available from National Budget. However, subsequent to formation of NPCIL in '87, the Governmental support started receding with every passing year. The rationale behind this was to give impetus to the Nuclear Power Programme Implementation in India and also to allow NPCIL to effectively generate its own resources from operation of existing Nuclear Power Stations in competitive manner- Initially the Government proposed 1:1 Debt. Equity ratio for funds, but later on this ratio is also gradually changing. This forces NPCIL to borrow funds from free market at market rate to meet costs of new projects under construction. Thus the financing principles and assumptions very much dictate Unit Energy Cost and cost per MW of installed capacity. The utilization of generation surplus and market borrowing is flexible option in changing market economy.

India has not yet offered Nuclear Power Plant package to any other country and therefore, contractual agreements are not existing. The previous contractual agreements in nuclear field were in sixties but those were as buyer country and not as supplier country.

The pricing of nuclear power plant within home country and for export model is not identical . This is so because the taxation and duties levied are different. There are concessions available for export items and these change to

133 • OPERATING • UNOER CONSTRUCTION I TO BE LRUNCHED

NflRORfl • 2x220 MVe RflJflSTHRN • 1x100, 1x200 MVe • 2x220 MVe

KRKRflPflR • 2x220 MVe TflRflPUR • 2x160 MWe a 2x500 MWe

KfllGfl ,•2x220 MWe MflORflS • 2x220 MVe

NUCLEAR POWER PROGRAMME IN INDIA PRESENT STATUS

some extent with time. It is, therefore, not quite appropriate to project the figures but can be at best taken as indicative. These figures will emerge only at the time of negotiations taking place and the prevailing economic scenario.

As on date NPCIL is not able to finance any Nuclear Power Plant outside India. Various financial options which could be available at the time of negotiations are :

Financing by buyer country within its resources.

Financial assistance from world financing organizations.

Supplier's credit for the equipments/components manufactured by the supplier (i.e. manufacturer in this case).

134 MILESTONES

RPRIL 15, 1948 i flTOMIC ENERGY RCT 15 РЯ55Е0 RUGU5T 10, 1948 i flTOMIC ENERGY COMMISSION 15 5ET-UP

RUGU5T 03, 1954 i DEPflRTMENT OF RTOMIC ENERGY 15 CRERTED

RUGU5T 01, 1955 THORIUM PLRNT HT TROMBRY GOES INTO PRODUCTION

RUGU5T 04, 1956 i RPSflRfl REflCTOR - THE FIRST IN flSIfl - GOES CRITICflL

JRN. 20, 1957 i flTOMIC ENERGY ESTRBLISHMENT, TROMBflY NOW (BflRC) INRUGURflTED

JflN. 30,-1959 i URflNIUM METRL PLflNT RT TROMBflY PRODUCES NUCLERR GRRDE URflNIUM

OCT., 1969 : TRRRPUR flTOMIC POWER STflTION ( BWR ) COMMERCIRL OPERRTION

DEC, 1973 « RflJRSTHRN flTOMIC POWER STflTION ( PHWR ) COMMERCIflL OPERflTION

NOV. 19, 1982 i POWER REflCTOR FUEL REPROCESSING PLflNT flT TflRflPUR REPROCESSES URflNIUM OXIDE FUEL

MflRCH 04, 1985 i WflSTE IMMOBILISflTION PLflNT flT TflRflPUR IS COMMISSIONED.

135 DESIGN FEATURES - 220 MWe PHWR

1. CORE i HORIZONTAL PRESSURE 306 Nos. TUBES PITCH 229 mm No. FUEL BUNDLE 19 ELEMENTS No.OF FUEL BUNDLES/CHfiNNEL 12 THERMflL POWER 770 MW flv.No.OF FUEL BUNDLES 8 REPLflCED PER FULL POWER DRY

WEIGHT OF flLL FUEL 60 BUNDLES TONNES

2. PRIMflRY COOLflNT CIRCUIT SINGLE LOOP PRIflMRY COOLflNT PUMPS 4

5TERM GENERflTORS 4

REflCTOR HEflDERS 4

3. TOTflL HEflVY WflTER REQUIREMENT 250 Te 4. CONTfllNMENT i RCC DOUBLE WITH YES SUPPRESSION POOL 5. SHUTDOWN PROVISIONS PSS + SSS PSS - PRIMflRY SHUTDOWN SY5TEM SSS - SECONDflRY SHUTDOWN SYSTEM 6. ENGINEERED SflFETY FEflTURE PROVIDED 7. CflPflBILITY TO COPE WITH PROVIDED STflTION BLflCK OUT 8. SPENT FUEL STORflGE BflY 10 YEflRS + 1 CORE UNLORO 9. WflSTE MFlNflGEMENT flT SITE

10. CONSTRUCTION PERIOD < 7 YEflRS

136 DESIGN FEATURES - 500 MWe PHWR

i. CORE > HORIZONTHL PRESSURE 392 Nos. TUBES PITCH 286 mm No. FUEL BUNDLE 37 ELEMENTS No.OF FUEL BUNDLES/CHflNNEL 13 THERMRL POWER 1736 MW flv.No.OF FUEL BUNDLES 14 REPLRCED PER FULL POWER DRY WEIGHT OF FILL FUEL 12 BUNDLES TONNES 2. PRIMflRY COOLRNT CIRCUIT TWO LOOPS PRIflMRY COOLRNT PUMPS 4 5TERM GENERRTORS 4 REflCTOR HERDERS 6 3. TOTRL HERVY WRTER REQUIREMENT 500 Te 4. CONTRINMENT i RCC DOUBLE WITH YES SUPPRESSION POOL 5. SHUTDOWN PROVISIONS PSS + 555 PSS - PRIMflRY SHUTDOWN SYSTEM SS5 - SECONDARY SHUTDOWN SYSTEM 6. ENGINEERED SflFETY FEflTURE PROVIDED 7. CRPflBILITY TO COPE WITH PROVIDED STRTION BLRCK OUT 8. SPENT FUEL STORRGE BRY 10 YERR5 + 1 CORE UNLORD 9. WRSTE MRNRGEMENT RT SITE 10. CONSTRUCTION PERIOD RPPR0X.7.5YERRS

137 INDIAN NUCLEAR POWER PROGRAMME

UNIT CflPflCITY REMARKS

TRRRPUR-U2 2 x 160 COMMERCIflL OCT '69

RflJflSTHflN-1 100 —— DEC '73 RFIJFI5THflN-2 200 -.— RPR '81

MRDRR5-U2 2 x 220 ——JRN'84&MRR '86 NflRORfl-18,2 2 x 220 —— JRN'918JUL '92 KRKRRPRR-1&2 2 x 220 —— MflY'93&FEB '95 RRJfl5THFiN-3&4 2 x 220 CRITICflLITY BY KFIIGR-1&2 2 x 220 CRITICflLITY BY

TRRRPUR-3&4 2 x 500 LflUNCH BY

KflPP I & II

DEGREE OF 1NDIGENISATI0N IN NUCLEAR POWER PROJECTS

138 POTENTIAL DESIGN

D DHRUVR 100 MWe

D FR5T BREEDER TEST REfiCTOR 14 MWe

D PROTOTYPE FR5T BREEDER REflCTOR 500 MWe

D flDVRNCED HERVY WRTER RERCTOR 220 MWe

Deferred payments towards expenses incurred by NPCIL and its sister organizations. Market borrowing from financial institutions.

These options very much depend on credit rating of and soundness of economy in the buyer country. 11. LICENCING AND PUBLIC ACCEPTANCE The need to separate the organization engaged in Nuclear Power Programme and the organization that is custodian of nuclear safety and has Licencing Authority was recognized and accordingly Atomic Energy Regulatory Board (AERB) was constituted in 1983. This body is totally independent from all other sister organizations of DAE and NPCIL. With growing concern for nuclear safety world over and in post TMI and Chernobyl accidents, the responsibility and accountability to Public (of AERB) has tremendously increased in recent past and emphasis on thorough safety analysis and documentation has increased. Some of the delays are attributable to preparation and approval of Safety Reports and documents.

Public acceptance of nuclear power is dependent on accident free operation of nuclear power plants and right kind of communication between NPCIL and general public. In recognition of this fact, NPCIL formed separate directorate for Environment and Public Awareness in 1988. This directorate liaise with educational institution and organizes regular exhibition, seminars, press briefings and topical discussions on environment friendly and benign generation of nuclear power.

12. SUMMARY

To sum-up, India has acquired total capabilities in setting-up SMR in developing country. The size of reactor very well matches with connecting grids and indigenous manufacturing capabilities. The NPPs are capital cost intensive units and require matching financial resources. The energy needs of the country on long term basis vis-a-vis

139 available resources have to be properly assessed. Induction of Nuclear Power Programme with a view of indigenization needs proper evaluation in terms of setting-up of large infrastructural facilities and available financial resources. Once committed it is most expensive to abandon a Nuclear Power Programme for any reason whatsoever.

140