Boiling Water

Reactor Basics
Larry Nelson
November 2008

GE Global Research

Overview
z
z
z
z
z
z

Big Picture - BWR Plants

Major Components
BWR Evolution
BWR Features vs. PWR
Features
Electrochemical Potential
(ECP) Concept
ECP Monitoring &
NobleChemTM

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The Big Picture

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Primary Containment

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BWR Power Cycle

NUCLEAR STEAM SUPPLY
SYSTEM (NSSS)

BALANCE OF
PLANT (BOP)

Moisture Separator
and Reheater

Steam
Reactor
Vessel

Turbine

Generator
HP

LP

LP

Separators
and Dryers
Condenser

Feedwater

Extraction Steam

Core
Demineralizers
Recirc
Pump

Recirc
Pump

Extraction Steam

Feed
Pumps

Heaters

Condensate
Pumps
Drain
Pumps

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Heaters

ABWR Power Cycle

NUCLEAR STEAM SUPPLY
SYSTEM (NSSS)

BALANCE OF
PLANT (BOP)

Reactor
Vessel
Moisture
Separator
Reheater

Main
Steam

Low
Pressure
Turbine

Generator

Feedwater

Suppression
Pool

High
Pressure
Turbine

Condenser

Feedwater
Pump

Offgas
System

CP

High Pressure
Feedwater Heater

Stack

Low Pressure
Feedwater Heaters

Steam Jet
Air Ejector

Gland Steam
Condenser
CBP
Condenser

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Condensate
Purification
System

BWR Major
Components

BWR Jet Pump

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Provide core flow to control

reactor power which yields
higher power level without
increasing the Rx size
Provide part of the boundary
required to maintain 2/3 core
height following a
recirculation line break event
8

Lower Plenum
z
z
z
z
z
z
z

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CRD Guide Tubes

CRBs
CRD housings
Stub Tubes
In-core Housings
Guide Tubes
Flux monitor dry tubes

BWR Core Shroud

Shroud
and Sep
Core Spray
Spargers

hroud
abilizer
yp of 4)

Ecentric
Aligner

Top
Guide

Core Plate

Stud
(Typical)

Ecentric
Aligner

Cor
Shro

Core
Shroud

Stainless Steel Cylinder

z Surrounds the Core
z

Separates upward flow through the core

from downward flow in the downcomer

annulus
Provides a 2/3 core height floodable
volume
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Fuel Assembly & Control Blade

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Steam Separator
Wet
Steam
Ret
W

ing
r

Turning vanes
impart rotation to
the steam/water
mixture causing the
liquid to be thrown
to the outside
z 163 standpipes
z

T
(

To
ecirc

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Stan

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Steam Dryer
Provides Qsteam dryer =
99.9% to the Main
Turbine
z Wet steam is forced
horizontally through
dryer panels
Forced to make a
series of rapid
changes in direction
Moisture is thrown
to the outside
z

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Initial power uprate

plants experiences
FIV minimized by
design improvements

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BWR Evolution

BWR Reactor Evolution

Dresden 1
KRB

Oyster Creek

Dresden 2
ABWR
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ESBWR
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BWR Development
VBWR (Vallecitos Boiling Water Reactor)
1st General Electric BWR power plant
Built in 1957 (near San Jose, California)
1st commercial BWR; 5 MWe supplied to Pacific

Gas & Electric grid (through 1963)

1000 psig (66.7 atm) operating pressure

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BWR Development
BWR1
z

Introduced in 1955

BWR2
z

Introduced in 1963

1st commercial plant in 1960 z 3 plants

(Dresden 1)
z Characteristics:
z 8 plants
Internal steam separation
Low power density core
z Characteristics:
5 Recirculation loops
External or Internal steam
Flow control load following
separation
Low power density core
z

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BWR Development
BWR3

BWR4

Introduced in 1965

Introduced in 1966

First Jet Pump application

Increased power density

9 plants
Characteristics:
Low power density core
Internal Jet Pumps
2 Recirculation loops

25 Plants
Characteristics:
High power density core
Mark I or II containment

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BWR Development
BWR5

BWR6

Introduced in 1969
z Improved safeguards (ECCS)
z Recirculation flow control
valves
z 8 plants

Characteristics:
Valve flow control load

Introduced in 1972
z Added fuel bundles; increased
output; Improved fuel safety
margins
z Improved Recirc system
performance
z 8 plants

z Characteristics:
following
Valve flow control
ECCS injects into core shroud
8 x 8 fuel bundle

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BWR Development
ABWR

ESBWR

Introduced in 1991
z Currently in licensing and design
z Blend of best features:
z Characteristics:
operating BWRs, available new
Passive Safety
technologies, & modular
Natural Circulation; No Recirc
construction techniques
Loops or Pumps
z 4 plants
Safety improvements (reduced
z Characteristics:
core damage frequency)
Safety improvements
Design life 60 years
(reduced core damage
Larger Main Generator (~1600
frequency)
MWe)
Design life 60 years
No external Recirc Loops;
Reactor Internal Pumps
z

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Operating Parameters for Selected BWRs

Parameter

BWR/4
(Browns Ferry 3)

BWR/6
(Grand Gulf 1)

ABWR

ESBWR

3293/1098

3900/1360

3926/1350

4500/1590

21.9/6.4

21.8/6.4

21.1/7.1

27.6/7.1

Fuel Bundles (number)

764

800

872

1132

Active Fuel height (m)

3.7

3.7

3.7

3.0

Power density (kW/l)

50

54.2

51

54

Recirculation pumps

2 (large)

2 (large)

10

zero

Number of CRDs / type

185/LP

193/LP

205/FM

269/FM

Safety system pumps

18

zero

Safety Diesel Generator

zero

Core damage freq./yr

1E-5

1E-6

1E-7

1E-8

Safety Bldg Vol (m3/MWe)

120

170

180

135

Power (MWt / MWe)

Vessel height / diameter (m)

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ESBWR Reactor Pressure Vessel

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ESBWR Passive Safety

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ESBWR Gravity Driven Cooling System

Simple design
Simple analyses
Extensive testing
Large safety margins
Before

After

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Gravity driven flow keeps core covered

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BWR vs. PWR

BWR and PWR the main differences

Pressurized Water Reactor

Boiling Water Reactor

Pressurizer

Pressure/Temperature

Chemical &
Volume Control

Reactor
Pressure
Vessel
T/G

T/G

Turbine
Generator

Turbine
Generator
Steam Generator

Reactor
Pressure
Vessel

Condenser

Condenser

2 loops
heat balance/
heat transfer

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1 loop
heat balance/
heat transfer

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Principle of Steam Generation

BWR

PWR

z RPV Pressure ~7 MPa (1020

z RPV Pressure ~15 MPa (~2240

psig)
z RPV Temperature 288 oC
(550 F)
z Steam Generated in RPV
(with Separator & Dryer)
z Bulk Boiling Allowed in RPV

psig)
z RPV Temperature 326 oC (~618
F)
z Steam Generated in Steam
Generator (via Second Loop)
z No Bulk Boiling in RPV

BWR
BWRhas
hasLower
LowerRPV
RPVPressure
Pressureand
andSimplified
SimplifiedSteam
SteamCycle
Cycle
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Major NSSS Components

BWR
z RPV (with Dryer & Separator)
z No Steam Generator
z No

Pressurizer
z Natural Circulation (ESBWR)
z RPV mounted pumps (ABWR)
z Bottom Entry Control Rod Drives

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PWR
z RPV
z 2 - 4 Steam Generators
z 1 Pressurizer
z Reactor Coolant Pumps

outside of RPV
z Top Entry Control Rod
Clusters

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Electrochemical Potential
(ECP) Concept

Stress Corrosion Cracking History in BWRs

# of BWRs

Operating BWRs
N. America Europe Asia
GE
34
4
11
Non-GE
0
16
21
80,000 MWe installed
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Total
49
38

Repair costs
>$1B / BWR

Stress Corrosion Cracking History

1969
1st detected in sensitized SS
1970s Stainless steel welded
piping
1980s BWR internals
1990s Low stress BWR internals
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Nuclear Chain Reactions on One Slide

HEAT
X

E=mc2

235
U
Etc.

235
U

HEAT

n
n
Moderator

Water
or
Graphite

n
238
U

high energy
neutron

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239
Pu

low energy
neutron

H20

X,Y

H+ + OH-

Radioactive
by-products

e.g. Kr, Cs, I, Ba, Th, Np

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Water Radiolysis Generates Species

Harmful to Materials

H2

H*

n
e

OH*
H2 O

H2 O
+
O2

H2O2

OHHO2
HO2

Commonly
Observed
species

(n,p)
-

N2
NO2NO3-

Oxidant (H2O2 and O2) Generation By Water Radiolysis

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Stress Corrosion Cracking

Environment

Cr depletion occurs
during welding of
stainless steels with high
carbon levels

Stress

Microstructure

Plastic Strain (%)

20

15

1.E-05

Sensitized 304 Stainless Steel

30 MPam, 288C Water
0.06-0.4 S/cm, 0-25 ppb SO4
SKI Round Robin Data
filled triangle = constant load
open squares = "gentle" cyclic

1.E-06

0
-25

-20

-15

-10

-5

10

15

20

25

Relative Distance From Weld Fusion Line (mm)

Crack Growth Rate, mm/s

10

316L (A14128, square )

304L (Grand Gulf, circle )
non-sensitized SS
50%RA 140 C (black )
10%RA 140C (grey )
1.E-07

CW A600
42.5
28.3

14.2
in/h

CW A600

GE PLEDGE
Predictions
30 MPam
Sens SS

0.5

2000 ppb O2
Ann. 304SS
200 ppb O2

0.25

Weld
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2000 ppb O2

25

200 ppb O2

GE1 Scan B 600A

GE1 Scan D 600A
GE2 Scan C 600A
GE2 Scan D 600A
GE3 Scan D 600A
GE3 Scan C 600A
GE8 Scan C 400A
GE8 Scan D 400A
GE9 Scan D 300A
GE9 Scan C 300A
GE4 Scan C 600A
GE4 Scan D 600A

500 ppb O2

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Outside

Plastic strain occurs during

welding and leads to cracking in
stainless steels with low carbon
(L-grade SS)

1.E-08

0.1
0.06 S/cm
GE PLEDGE Predictions for Unsensitized
Stainless Steel (upper curve for 20% CW)
1.E-09
-0.6

-0.5

-0.4

-0.3

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

Corrosion Potential, Vshe

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Stress Corrosion Cracking Prediction & Application

Complex phenomenon must be
understood mechanistically as
crack tip system processes

LAB
Lab understanding &
data must be verified
by plant data before
use in BWR prediction

PLANT

PREDICTION
Insights yield
novel technology
like NobleChem
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Stress Corrosion Cracking Mitigation

Radiation Field Response

Crack Growth Response

Main Steam Radiation Field

Normalized Main Steam Line Activity

Low
Hydrogen
Moderate
Hydrogen

High
Hydrogen

Feedwater Hydrogen Concentration (PPM)

High crack growth rates at high corrosion potential (ECP)

ECP is a dominant variable effecting SCC response

Hydrogen injection results in an increase in main steam line

radiation fields

NobleChem Basics

Electro Chemical Potential (ECP)

Response
ECP, mV (SHE)

200

NWC In-core
NWC - Piping

0
- 200
- 400

HWC

NobleChem

- 600
0.5

1.0

1.5

//
2.0

With excess H2, O2 is consumed & its level at the surface is zero

H2 + O2 reaction is catalyzed with NobleChem particles

Hydrogen added is more effective lower radiation fields

Hydrogen Injection Rate (ppm)

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ECP Monitoring &

NobleChem
TM

BWR ECP Monitoring Locations

Modified LPRM Assembly
for Bottom-of-Core ECP Monitoring
(3 ECP Sensors)

Full Function
Data Acquisition
System
Air Conditioner

Recirculation\Decon Flange
Assembly (4 ECP Sensors)

Multiplexer

Personal Computer

Digital Multimeter
Deskjet Printer
AC Line
Conditioner

Modified LPRM Assembly

for Lower Plenum
ECP Monitoring
(2 or 3 ECP Sensors)

Drywell

Multimeter/
Multiplexer

Core
Plate
EDM one new
hole in Guide
Tube

Simplified
Data Acquisition
System

Personal
Computer

Drain Line Flange Assembly

(4 ECP Sensors)

Inlet to LPRM
(ECP sensors
inside and
above)

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Lower Plenum ECP Monitoring

High
Temperature
Prefilm (in
laboratory)

Fe/Fe3O4

Platinum
Noble Metal
Treated SS
Electrode

Core
Plate
2.75 in.
(70 mm)

Inlet Cooling Holes in

LPRM Cover Tube

Lower Cooling Holes in

LPRM Cover Tube, ECP
Sensors Inside and Above
Holes
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1/2 diameter Inlet

Cooling Hole in In
Core Monitor
Housing
Local Power Range
Monitor Assembly
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Bottom Plenum ECP Response

Lower Plenum ECP

200

100

HWC is Effective
In Mitigating IGSCC
ButLower Plenum
Requires More H2

Middle

ECP (mV SHE)

Bottom

-100

-200

IGSCC Mitigation Potential

-230 mV(SHE)

-300

Core Plate
ECP

-400

-500
0

0.5

1.5

2.5

FEEDWATER HYDROGEN (ppm)

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Basis for NobleChem Technology

TM

1.0

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2.0

(ppm)

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HWC vs. NobleChem Technology

TM

200
TM

Before NobleChem - 1994

ECP mV(SHE)

TM

After NobleChem - 1999

-230 mV(SHE)

-200

IGSCC Mitigation
-400

-600
0

0.4

0.8

1.2

1.6

Feedwater H2 (ppm)

BWR/4 Low ECP After NobleChemTM and Low Hydrogen

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ECP Reduction With NobleChem

TM

300

200

100

Non-NobleChem Plant Data

ECP mV(SHE)

-100

Upper Core - UC

-200

-230 mV(SHE)

-300
Lower Core - LC
-400
Lower Plenum - LP
-500

NobleChem Plant Data

for UC, LC, LP, RRS

RRS

-600
0

0.5

1.5

2.5

Feedwater Hydrogen, ppm

Provides Low ECPs At All Internal Locations

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Noble Metal Distribution After On-Line

Application

Pt PARTICLE SIZE DISTRIBUTION

(based on number)
100%

S TATI STICS
M ean :
6.1
Std . De v. :
2.3
Minim um :
2.1
Ma xim um :
2 1.8
O bject Co unt : 17 331
(b ased on num b er)

25%

20%

90%

nm
nm
nm
nm

80%
70%
60%
50%

15%

40%
10%

30%

Cumulative Number

Relative Number Frequency

30%

20%

5%

10%
0%

100 nm

0%
0.5

1.5

2.5

3.5

4.5

5.5

6.5

7.5

8.5

9.5

10.5 11.5 12.5 13.5 14.5 15.5 16.5 17.5 18.5 19.5

Particle Diameter (nm)

Nano-particle Pt Generation By On-Line NobleChemTM

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Summary

Reactor operation at low ECP is essential for minimizing component

degradation in all BWR designs including the ESBWR
z ESBWR is GEHs latest evolution in BWR design
4500 MWt/~1575MWe
Natural circulation
Passive safety features
Significant simplification
z ESBWR is under licensing review by USNRC
z ESBWR chosen by NuStart, Dominion and Exelon as reference design
z

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