SYSTEM NOTES PART – II

INDEX

Sr. No. Topic Page No.

1. Clean-up Demineraliser System 03

2. Biological Shield Cooling Water System 08

3. Fuel Pool Cooling & Filtering System 11

4. Reactor Protection System 16

5. Auto Blow Down System 27

6. Core Spray & Post Incident System 28

7. Shutdown Cooling and Head Spray System 34

8. Containment and Containment Isolation 38

9. 120V AC Power Supply 46

10. Station Transformers and Electrical Distribution at TAPS 51

11. 48V DC Neutron Monitoring Power Supply System 68

12. 250V DC System 72

13. 220 KV and 33 KV Switchyard 76

14. Emergency Diesel Generators 98

15. Station Blackout Diesel Generator 111

16. Air Compressor 116

17. Basic Electricity 125

18. Portable Fire Extinguishers 136

19. Liquid Fire Protection System at TAPS 144

20. Cardox System 148

21. Protective Coating and Colour Codes 157

22. Refueling Operation 163

23. Acid and Caustic System 171

24. Radwaste System 174

25. Diesel Oil Storage and Supply System 184

26. Neutron Monitoring System 188

27. Supplementary Control Room 200

28. Chillers And CTPH 203

29. AFR Fuel Pool Cooling and Polishing System 217

 Cleanup Demineraliser System
The purpose of cleanup demineralizer system is to maintain high
reactor water purity in order to,

i) Minimize the deposition of water impurities on fuel surfaces in

reactor core, thus minimizing reduction in heat transfer due to
deposition of impurities.

ii) Minimize secondary sources of beta and gamma radiation by

removing the corrosion products, fission products and
impurities from primary system.

In addition, the cleanup system provides the only route for

removing water from primary system during startup and shutting of the
reactor. The cleanup system takes water from primary system, purifies it and
delivers back to the primary system. It is always kept in service, irrespective
of mode of reactor operation.

The system consists of C.U. auxiliary pump, regenerative heat

exchangers, non-regenerative heat exchangers, pressure reducing station,
demineralizer and its post strainer, recirculation pumps, flow control station,
reject control station, motor operated isolation valves, piping and
instrumentation.

The C.U. auxiliary pump (1ND05) develops 7.7 Kg/cm2 pressure at

system rated flow of 1100 lpm and is driven by 30 H.P. motor. The pump
has mechanical seal. Seal cooling is provided by RBCW system. Pressure
switch (PS-1IJ14) on pump suction is provided to give low suction pressure
alarm at 0.7 Kg/cm2 and to trip the pump at 0.35 Kg/cm2. Temperature
switch TIS-1IJ19 is provided to trip the C.U. system if seal cooling water
temperature exceeds 82oC. When the reactor pressure is below 2 Kg/cm2,
(i.e. during shutdown and refueling outage), the C.U. aux. Pump alone is
sufficient to overcome pressure drop in C.U. system and can pump water
back to reactor. It is not necessary to run C.U. recirculation pumps during
above conditions.

When the reactor pressure is between 2 to 10 Kg/cm2 the C.U. aux.

Pump is kept in service to provide sufficient suction pressure to C.U.
recirculation pumps. C.U. aux. Pump and C.U. recirc. pumps run in series
during this period. When the reactor pressure is above 10 Kg/cm2, the C.U.
aux. Pump is stopped and isolated.

The water coming from reactor is cooled before it is processed by

demineralizer because demineralizer resins can not withstand high
temperatures. The water is cooled down to 49oC by regenerative and non
regenerative heat exchangers. The regenerative heat exchangers (1ND03A,
B and C) provide first stage of temperature reduction to reactor water. The
water coming from reactor flows through the tubes of regenerative heat
exchangers and is cooled by system water returning back to reactor flowing
through shells of regenerative heat exchangers. The regenerative heat
exchangers thus recover about 75% of heat of reactor water going to C.U.
system. The non-regenerative heat exchangers (1ND04 A/B) provide final
stage of temperature reduction of reactor water. The water coming from
regenerative heat exchanger flows through tubes of non-regenerative heat
exchangers, RBCW system water flowing through shell of heat exchangers.
A temperature switch TIS-1IJ36 is provided on reactor water outlet of non-
regenerative heat exchangers to give alarm if water temperature reaches
60oC and trip the C.U. system at 65oC.

The pressure reduction station is provided to reduce the reactor water

pressure to 7 Kg/cm2. This pressure reduction is necessary as demineralizer
in the system is designed for low pressure. The pressure reducing station
consists of PIT-1IJ42, PIC-1IJ41 and PCV-1ND11. It is set to maintain
downstream pressure of 6 to 7 Kg/cm2. Pressure switch PS-1IJ30A is
provided to give alarm if the pressure reaches to 7.5 Kg/cm2 and trip the
system at 8.75 Kg/cm2.A manual bypass valve is provided for PCV-1ND11.
This bypass is opened when reactor is at very low pressure.
 The demineralizer (1ND01) is provided in system to remove soluble
impurities from the reactor water. It can also remove insoluble impurities by
filtering action. The demineralizer is a mixed ion exchange bed containing
cation and anion resins in ratio of 2:1. The resin ratio of 2:3 is also used now
a days as it is expected to increase life of demin. bed. Once depleted, the
resins become highly radioactive. These are transferred to spent resin storage
tank and freshly regenerated resins are transferred to C.U. demin. bed. A
post strainer is provided after demineralizer to prevent any resin particles
from reaching reactor.

Differential pressure switch 1IJ15A is provided to give high

differential pressure alarm for demineralizer and 1IJ15B for high differential
pressure for post strainer. A bypass line is provided for demineralizer but
demineralizer is never bypassed when the system is in normal operation.

C.U. recirculation pumps are provided to bring up the pressure of

clean up return water so that it can be pumped back to reactor. Three half
capacity C.U. recirc. pumps are provided for each unit. Normally two pumps
are running. Pressure switch 1IJ30B on pump’s suction header is provided to
give low suction pressure alarm at 1.5 Kg/cm2 and to trip the pumps at
0.75 Kg/cm2. Each pump has a temperature switch on discharge which trips
the pump on high discharge temperature of 200oF (93oC). Also, each pump
is protected against overheating by providing minimum recirculation flow
lines. A surge tank with nitrogen cushion is provided on suction header of
pumps to damp pressure variations.

CLEAN UP RECIRCULATION PUMPS DETAILS

Flow No.of
Pump H.P. Make Lubrication
(lpm) Stages
1ND06A 220 550 Sulzer 10 Oiler lubrication

1ND06B 175 450 Pacific 12 Shaft driven oil pump

1ND06C 220 450 KSB 7 Separate oil pumps

2ND06A 220 450 KSB 7 Separate oil pumps

2ND06B Pump is not presently available

2ND06C 220 450 KSB 7 Separate oil pumps

Two lines branch-off from discharge header of C.U. recirculation

pumps, namely the return water line and reject water line. The return water
flow goes back to reactor through flow control valve FCV-1ND12 and shell
side of regenerative heat exchangers. The flow controller FCV-1ND12
automatically controls the return flow at the set value.

The reject line provides the facility to reject water from primary
system to either radwaste system or to main condenser. The reject flow is
controlled by manually operating the reject valve FCV-1ND22. The reject
CV closes automatically if there is high pressure in reject line towards
radwaste or if there is high vacuum in reject line towards condenser.

The system has four automatic motor operated valves (MOVs-1396,

1397, 1398 and 1382) on C.U. outlet and return lines. MOVs-1397 and 1398
are D.C. operated. All the four MOVs go close automatically and isolate the
C.U. system from reactor in case the reactor scrams on low water level. The
clean up system trips automatically on following signals.

1) Filter inlet high temperature.

2) Filter inlet high pressure.
3) Aux. Pump seal cooling water high temperature.
4) Poison injection.
5) Reactor water low level.
 Tripping of system on any of the parameters from Sr. no 1 to 4
will result in tripping of running pumps and closure of MOVs-1396 and
1382. Tripping of the system on reactor low level will cause closure of MO-
1397 and MO-1398 also in addition to the above.

A conductivity cell and pH cell is provided on sample line before the

filters. These instruments continuously monitor the conductivity and pH of
reactor water. Another conductivity cell is provided on outlet of
demineralizer to monitor the performance of demineralizer.

DRG 130A
Biological Shield Cooling Water System

Biological shield is provided for attenuation of nuclear radiation

emitted from the reactor; so as to reduce the exposure of persons to the
radiation. Most important radiation considered in the design of biological
shield is gamma rays and neutrons because they are most penetrating.
BSCW system is provided to protect the shield from damage due to heat
liberated upon absorption of radiation. The purpose of the system is to keep
the shield temperature below 150 oF (65 oC) and to limit the temperature
gradient between inner surface and outer surface of shield to 10 oF (5.5 oC).
The BSCW system is a closed loop system consisting of biological shield of
the reactor with cooling water tubes embedded into it. Three cooling water
pumps (1P27, P27 and 2P27). Three heat exchangers (1E20, E20 and 2E20),
two surge tanks (1T31/ 2T31), two chemical feeders (1T70 /2T70), piping
instrumentation and controls.

Each reactor has a concrete biological shield of about 5 feet thickness.

The shield is divided into two parts by a bond retainer; so as to prevent a
thorough propagation of crack in the shield. The inner shield is about 13
inch thick. 200 stainless steel cooling water tubes of ½ inch dia. each are
embedded vertically in the inner shield and are evenly dispersed in the circle
of about 7 ft.7 inch radius. The tubes are divided into four groups of 50 tubes
each. The alternate tubes from each group are connected to concentric
distribution sub-headers at each end. Out of each pair of sub-headers one is
initially connected to the main inlet and outlet headers to keep them in
service. Other is a spare one and is kept capped. These spare group headers
can be connected into service if the one in the service develops some
problem.

The pumps, heat exchangers and chemical feeders are located in

reactor building at 160 ft. elevation. Surge tanks are located in same building
at 180 ft. elevation. Each pump is rated for 50 gpm and is driven by 3 H.P.
motor. P-27 is a spare pump which can be used for either unit. E-20 is a
spare heat exchanger which can be used for either unit.

The system is initially filled by demin. water through the 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 feeders are
provided to feed a potassium dichromate and caustic soda.

Potassium dichromate is added to inhibit corrosion while caustic soda

is added to control pH of the system water. Chemicals are added to the
system after weekly analysis of the system water.

During normal operation, the BSCW pump runs continuously and

circulates 50 gpm flow through the heat exchanger tubes and the tubes in the
biological shield. The RBCW flows through the shell side of the heat
exchanger and cools the shield cooling water. The shield temperature is
controlled by controlling flow of RBCW by means of CV-1777 and 2777.
Six temperature sensors are located in the biological shield and one sensor is
located in the drywell for sensing ambient temperature. Combined signal
from these temperature sensors is used to automatically position the
CV-1777/2777 to control shield temperature at 125oF (51.7 oC).
DRG 132A
 Fuel Pool Cooling and Filtering System
The irradiated fuel bundles removed from reactor are stored in fuel
pools till their shipment to AFR Plant. The fuel pools are always filled with
water. The water provides the shielding and cooling for irradiated fuel
bundles. There are two fuel pools (Fuel Pool No.1 and Fuel Pool No.2)
interconnected with gates. Also the fuel pool No.1 is connected with reactor
cavity No.1 and fuel pool No.2 is connected with reactor cavity No.2 by two
gates in series. During normal operation of units, the gates between reactor
cavity and fuel pool are in position. A drain line with flow switch is
provided from space between two gates to monitor the fuel pool gate
leakage. During refueling the reactor cavity is also filled with water and
gates between fuel pool and reactor cavity are removed to facilitate fuel
movement to and from reactor vessel. The fuel pools and reactor cavities
have stainless steel liners to prevent water leakage. No drains are provided at
fuel pool bottom to prevent inadvertent draining of fuel pools. The gates are
designed such that even if pool should drain through a gate, there will be
sufficient water level above fuel to provide adequate shielding and cooling.

The purpose of fuel pool cooling and filtering system is,

a) To remove the decay heat generated by irradiated fuel stored in

fuel pools and maintains water temperature to about 50oC to
assure no steaming and adequate visibility.

b) To provide for filling and draining of reactor cavity and

equipment storage pool during refueling.

c) To maintain water clarity in pools and reactor cavity during

refueling works. The system is common for both units.

The system consists of skimmers, surge tanks, pumps, heat

exchangers, filters, return line diffusers, piping, instrumentation and controls
etc.
 The skimmers are provided at normal water level surface of the pool,
reactor cavity and equipment storage pool to remove dust and debris from
water surface.

The water from pool, cavity and equipment storage pool overflows to
fuel pool surge tank through skimmers. The pool skimmer serves as the level
control and overflow weir from pool to surge tank. The normal overflow
level is adjusted to 199 ft. elevation.

The surge tank serves several functions such as:

i) Provides adequate suction head to pumps.

ii) Provides sufficient capacity for evaporation losses for one week
operation.

iii) Provides storage to compensate for pool water displacement

due to insertion and removal of large objects such as shipping
cask.

There are two interconnected Surge tanks each with capacity of

about 13250 liters(3500 gallons) capacity. Level instruments are provided on
surge tank to:

i) Monitor the level continuously.

ii) To give surge tank high-low level alarms.
iii) To trip pumps on very low level in surge tank.

Two full capacity pumps, each rated for 30 lps. (500 gpm) flow
are provided for recirculating the water through filters and plate type heat
exchangers. The pumps can take suction from surge tank, reactor cavity or
equipment storage pool and deliver to cavity or fuel pool depending on
specific mode of operation.
 Both the plate type heat exchangers (NUO3A, B) are normally
kept in service with one pump running. Two pressure pre-coat type filters
are provided to maintain water clarity and quality. Each filter is rated for 19
lps (300 gpm) flow and normally both filters are in service. The system
operates at reduced capacity when one filter is being back washed and pre-
coated. Different pre-coat materials like Powdex , Ecodex resins and Solca-
floc are used to pre-coat fuel pool filters. Solca-floc (Fine Cellulose Powder)
removes only insoluble impurities. While Powdex and Ecodex resins remove
soluble impurities and maintain the fuel pool water quality.

A provision has been made to use radwaste demineralizer for

polishing fuel pool system water if need arises.

The outlet from filter/demineralizer is returned to cavity or fuel

pool through diffusers. Diffusers are provided to minimize turbulence and
thus improve visibility.

During normal operations the water is returned to the bottom of

fuel pools on the opposite side from the over flow to maximize the
circulation and minimize stratification of temperature or contamination. An
open vent line provided at highest point on return lines to prevent siphoning
of fuel pool water in case of abnormal conditions like pump trip, line rupture
etc.

During refueling the majority of water is returned to cavity and

part of it to fuel pools. Make up to the fuel pool surge tank is made up by
condensate water through CV-825 or from demin. water hose station at 200
ft. elevation reactor building. During refueling operation, for filling the
reactor cavity and equipment pool water is supplied from condensate storage
tanks (T1A/B) and is pumped to the fuel pool cooling system by condensate
service pumps (P-6 A, B, C).
DRG 135A
DRG 135B
 Reactor Protection System

The Reactor Protection System (RPS) is provided to place the reactor

in safe shutdown condition by rapidly inserting all the control rods
simultaneously (i.e. Scram) in the event that operating conditions approach
unsafe limits. In addition to rapid insertion of all control rods, this system
also initiates appropriate corrective actions to mitigate the consequences of
the event. The reactor protection system is initiated by devices which are
provided to monitor selected plant operating parameters and trip when
parameters approach unsafe limits. The important features of reactor
protection system are:

1) The system is designed to be fully automatic to eliminate

necessity of any operator’s action in the event of disturbance.

2) The system is designed for reliability so that continuous and

safe operation of reactor is assured, i.e.

a) The system is designed to scram the reactor during unsafe

conditions and to avoid spurious Scram.

b) The system is designed to accommodate single component

failure.

3) The system is designed such that it can be tested during reactor

operation without jeopardizing safety.

4) The system is designed to be fail safe, i.e. the system is

independent of other plant systems for performing its safety
functions when de-energized.
 The dual channel reactor protection system is provided which
has all the above mentioned features. The system consists of two
independent logic channels called Channel-A and Channel-B. Both logic
channels must trip simultaneously to cause the reactor scram. Tripping of a
single channel A or Channel B does not cause the reactor Scram but, gives
only an alarm. The trip logic of main channel is described as One out of Two
taken twice. This logic is achieved by controlling air supply to Scram inlet
and outlet valves of CRD through two solenoid operated pilot valves NC-14
and NC-15.

Normally both solenoid valves are energized and Scram inlet

and outlet valves are kept closed by air pressure. NC-14 solenoids are
supplied by Ch. A and NC-15 solenoids are supplied by Ch.B. De-energising
of NC-14 alone or NC-15 alone does not result in interruption of air supply
to scram inlet and outlet valves and venting of air. De-energisation of both
NC-14 and NC-15 causes the Scram valves to open to cause rapid insertion
of control rods.

Each logic channel consists of two logic sub channels. Each logic sub
channel consists of set of relays and relay contacts. The logic sub channels
are not totally independent as they share common power supply and
protective channels. Tripping of either logic sub channel results in tripping
of corresponding logic channel. The trip logic of sub channels is described
as one out of two.

There are minimum two protection channels provided per logic

channel for every plant parameter selected to initiate reactor protection
system. The protection channel consists of components and modules that
generate a trip signal. When protection channel associated with logic A trips,
it trips both sub channels of logic Ch.A. If simultaneously some protection
channel associated with logic Ch.B also trips, it will result in reactor scram.

The power supply to reactor protection system consists of motor

generator sets 1G-3A and 1G-3B for Unit No.1 (2G-3A and 2G-3B for Unit
No.2). 1G-3A supplies to Ch.A and 1G-3B to Ch.B. Each MG set consists
of 415V, 3φ motor of 10 HP, 120V, 1φ generator of 6KVA. The motors are
supplied from 415V Class IV buses. The M-G sets have been provided with
large flywheels to stabilize the output against fluctuations or momentary
interruptions of input supply. Provision is made for supplying one channel
from alternate supply to facilitate maintenance of M-G sets. The alternate
supply is from 415V AC bus through X-23 (X24 for unit 2) transformer.
Only one channel can be taken on alternate supply at a time. Normally
alternate supply is kept selected for Channel-B. If supply to this selected
channel is lost, it automatically gets supply from alternate source. Alternate
supply Change over switch is in Main Control Room and is normally
selected for Channel B.
Reactor Mode Switch:

A key locked switch called reactor mode switch is provided in control

room to select the mode of reactor operation. The mode switch has four
positions namely – SHUTDOWN, REFUEL, START-UP/STAND-BY and
RUN Mode. The reactor protection system functions vary as the selected
operating mode various.

The plant parameters which are monitored by reactor protection

system and used to Scram the reactor auto

matically are describe below:

1) PRM High Flux :

This scram is provided to protect the fuel cladding from

overheating and damage. There are six power range monitors
i.e. PRMs, three in each channel of RPS. The trip occurs when
neutron flux or power exceeds 120% of rated. This protection is
effective in all the four modes.

2) IRM High Flux:

This scram is also provided to protect the fuel cladding from

overheating and damage. This protection is effective for reactor
in all four modes. The protection is bypassed if PRM readings
are on scale when the reactor mode switch is in “RUN” mode.
There are four intermediate power range monitors i.e. IRMs
 two in each channel of RPS. The trip occurs when neutron flux
or power exceeds 12% of rated.

3) Reactor Low Water Level:

This scram is also provided to protect the fuel cladding from

overheating and damage. There are four level switches, two in
each channel of RPS. The trip occurs when the water level in
reactor decreases to 107 inch (271.8 cms) above the top of
reactor core. The low level reactor scram also causes isolation
of reactor primary system so that there is no further loss of
water from the reactor.

4) Primary Steam Line Low Pressure:

This scram is also provided to protect fuel cladding from

overheating in case of high power operation at low reactor
pressure. There are four pressure switches, two in each channel
of RPS. The trip occurs when steam line pressure drops to 850
psig. (59.76 Kg/cm2). This protection is effective only when the
reactor mode switch is in “RUN” mode. The low pressure
scram also causes closure of primary steam isolation valves.

5) Reactor Recirc. Loop MOVs Closure:

This scram is also provided to protect fuel cladding from

overheating and damage in case the core coolant recirculation
path is lost. The position switches are mounted on stems of
recirc. loop MOVs to monitor their positions. The trip occurs
when MOVs of both recirculation loops get closed to the preset
extent. This protection is bypassed when the reactor mode
switch is in “REFUEL” mode.
6) Reactor High Pressure:

This scram is provided to protect reactor primary coolant

system from excessive pressure. There are four pressure
switches, two in each channel of RPS. The trip occurs when
reactor pressure exceeds 1050 psi. (73.8 Kg/cm2). The reactor
high pressure scram brings emergency condenser in service if
pressure continues to be higher than 1050 psi for more than 10
seconds.

7) Drywell High Pressure:

This scram is provided to protect the drywell from excessive

pressure. There are four pressure switches, two in each channel
of RPS. The trip occurs when the drywell pressure exceeds 1.5
psig. (0.105 Kg/cm2). The drywell high pressure scram also
cause isolation of the primary containment.

8) Primary Steam line High Radiation :

This scram is provided to prevent escape of fission

products from reactor to outside the containment in case of
gross fuel failure. There are four radiation monitors, two in each
channel of RPS. Trip occurs when radiation level in steam lines
rises to 10 R/hr. The high radiation scram also causes closure of
primary steam line isolation valves.

9) Primary Steam Line Isolation Valves Closure :

This scram is provided to anticipate the reactor high

pressure scram due to closure of PSIVs and scram reactor in
advance so that the pressure transient is less severe. Position
switches are mounted on stems of PSIVs to monitor their
 position. The trip occurs when one of the two PSIVs on each
line go close by 10% of stroke. This scram is bypassed in
“REFUEL” mode. It is also bypassed in start-up/standby mode
subject to some other condition.

10) Condenser low vacuum :

This scram is provided to protect the main condenser in

case the vacuum is lost. There are four vacuum switches, two in
each channel of RPS. The trip occurs when the condenser
vacuum drops to 23 inch Hg. (58.5 cms Hg.). This scram is
bypassed till reactor pressure is below 600 psi (42.2 Kg/cm2).

11) Scram Dump Tank High Level :

This scram is provided to assure that sufficient free

volume is available in scram dump tank all the while to
accommodate a full scram. There are four level switches, two in
each channel of RPS. The trip occurs when 100 gallons (379
liters) of free volume is left in the scram dump tank. Provision
is made to bypass this scram protection manually.

Apart from automatic scram signals listed above, the reactor scram
takes place due to following:

a) Reactor mode switch in “SHUTDOWN” mode.

b) Manual scram push button.
c) Manual “SCRAM and ISOLATION” control switch.
d) Loss of A.C. power to RPS.
e) Loss of instrument air supply.

To assure the reliability of reactor protection system, all scram sensors

are tested periodically as a part of mandatory requirement.
DRG 141A
DRG 141B

DRG 141C
DRG 141D

DRG 141E
 Auto-Blow Down System

The core spray system provided at TAPS is of low pressure design. It

can not inject water into reactor vessel unless the reactor vessel pressure is
less than 200 psig. The system provides protection and prevents damage to
cladding for breaks of size not greater than 0.1 Sq.ft. The breaks of size
above 0.1 Sq.ft. will depressurize the reactor and bring the core spray system
in service within stipulated time to maintain uninterrupted cooling of fuel.
However, if the break size is below 0.1 Sq.ft. and also the normal source of
feed water is not available it can lead to uncovering of reactor core, as
reactor will not get depressurized in time to make core spray effective. The
auto blow-down or auto depressurization system is provided to make the
core spray system effective under such circumstances of small breaks by
depressurizing the reactor rapidly so that core spray system becomes
effective.

The system consists of three air operated reactor relief valves

1NR28A, 1NR28B and 1NR28E and associated instruments and electrical
circuitry.

The operation of system is automatic. Following signals are used in

circuitry to initiate auto blow-down.

1) Reactor Water Low Level.

2) Reactor Water Low-Low Level.
3) Drywell High Pressure.
4) Primary Feed Water Low Flow.

When all the four signals coincide, all the three relief valves will open
automatically after a time delay of 120 seconds and depressurize the reactor
by venting steam to suppression pool. The time delay of 120 seconds is
provided for operators action to bring up the reactor water level. The auto-
blow down system can be reset manually, if the reactor water level can be
brought up within this 120 seconds period.
Core Spray and Post Incident System
Among the features which differentiate the nuclear reactor from
conventional boiler are the radioactivity and the decay heat. The heat
liberation from irradiated nuclear fuel continues indefinitely due to decay of
fission products even after the reactor is shutdown. If no means are provided
for removal of this decay heat, fuel failure and damage to the fuel cladding
can occur due to overheating of cladding. Once the cladding fails, the
radioactive fission products get released from fuel to primary system and
even may get released to environment.

For this reason the uninterrupted cooling of reactor core must be

maintained under all circumstances and an alternate and independent core
cooling system must be provided to maintain core cooling under accident
conditions like loss of coolant accident (LOCA). The core spray and
containment cooling system is provided as a last resort to maintain reactor
core cooling.

The core spray system is designed to maintain uninterrupted core

cooling even at the time of maximum credible accident (MCA), to assure
that:

1) The damage to fuel cladding and consequent release of fission

products will not be extensive.
2) The generation of hydrogen by chemical reaction between
water and zircaloy cladding at elevated temperature will be
insignificant to cause additional potential hazard due to
combustion of hydrogen.

The Post Incident system is designed to remove the heat energy

released into containment during the accident and after the accident. The
system is also known as containment cooling system. This system by
cooling and depressurizing the containment:

1) Protects the containment from overstressing.

2) Minimizes the driving force for leakage of fission products
from the containment.
 As the core spray and post incident system is last resort for
cooling the reactor core, the system is designed to be highly reliable,
independent
and fully automatic in operation. The reliability is achieved by providing
redundant equipment and power supply from emergency buses and D.C.
sources. The reliability is maintained by periodic testing of components.

The system provided is common for both the units. The

majority of system equipments are located in containment cooling building.
The system is designed to handle the incident in only one unit at a time. In
case the incident occurs on one of the units requiring core spray and post
incident system, the other unit will be shutdown and depressurized to
maintain it in safe condition. As the heat removed from core has to be
ultimately transferred out of containment, the core spray and post incident
system are designed to operate simultaneously. All core spray and post
incident pumps have a common suction header. The suction header is
connected with drywell and suppression pool of each unit by MOVs.
Strainers are provided at outlet from each unit’s suppression pool and
drywell.

The MOVs are also provided on pumps discharges for directing

flow to each of the reactor, drywell and common chamber. In case of an
incident the MOVs associated with affected unit open automatically and
spray water into its reactor vessel, drywell and common chamber. The core
spray system and post incident system are described below separately for
convenience.

Core Spray System:

The core spray system is designed to spray the water directly

over the fuel assemblies in case of loss of coolant accident (LOCA). The
system consists of two, fully independent, full capacity core spray loops
physically separated from each other to the extent feasible. A loop selector
switch is provided to select one of the loops for operation and the other loop
remains as stand by. The loop selector switch starts and monitors the
equipments i.e. Pumps and MOVs in selected loop are capable of starting
equipments in standby loop in case of failure of some equipments in the
selected loop.

Each core spray loop consists of pumps, MOVs, piping, spray

headers and instrumentation. Each loop has two pumps of 50% capacity
each. Loop- I has pumps P-25A and P-25B and Loop- II has pumps P-25C
and P-25D. Each pump is rated for 57 LPS (915 GPM) at 158.5 m (520 ft.)
TDH and is driven by 150 HP motor. Core spray loops are interconnected to
increase redundancy of equipment.

The MOVs are provided on suction header and discharge headers of

the pumps. The MOVs for affected unit open automatically. An interlock is
provided which prevents the opening of core spray discharge MOVs until
the reactor pressure is less than 14 Kg/cm2.

Each core spray loop has a spray ring header located inside the
reactor vessel above the reactor core. Each header has 120 nozzles designed
to spray water in fine droplets directly over the fuel bundles. The system has
built in facility to test the freeness of nozzles by admitting good quality
water from condensate service system to the spray headers. Strainers
provided on suction lines from drywells and suppression pools trap the
particles which could cause blocking of spray nozzles.

Four lines branch off from the common discharge header of the
Core spray pumps as given below. Each line is provided with two MOV’s.

1) Unit #1 Core spray Loop-I header with MO-1795 and MO-1312/MO-

1313.
2) Unit #1 Core spray Loop-II header with MO-1606 and MO-1605.
3) Unit #2 Core spray Loop-I header with Mo-2795 and MO-2312/MO-
2313.
4) Unit #2 Core spray Loop-II header with MO-2606 and MO-2605.

Post Incident System:

The post incident system is designed to spray the cool water into the
drywell and common chamber to condense the steam arising from incident
such as break in primary system inside the dry well and transfer the heat to
RBCW system outside the drywell.

The system consists of two independent, full capacity cooling groups.

Each group has two pumps and one heat exchanger discharging into
common outlet header. Pumps P-80A and B are in group I and pumps P-80C
and D are in group II. Each pump is rated for 47 LPS (740 gpm) at 75.25 M
(247 ft.) TDH and is driven by 60 HP motor. Heat exchanger E-22A and
RBCW Outlet MOV-1311 are in loop I and heat exchanger E-22B and
RBCW Outlet MOV-2311 are in loop II.
 The heat exchanger has heat removal capacity of 9.67 Mwt (33
6
x 10 Btu/Hr.) A group selector switch is provided to select one group for
operation and the other group remains on standby. The selector switch starts
and monitors the pumps and MOVs in selected loops and is capable of
starting pumps and opening the MOVs in standby loop in case of failure of
any pump or MOV in the selected loop.

Six lines branch off from common outlet header of the heat
exchangers as given below. Each branch line has a motor operated valve.

1) Drywell Unit #1 spray header I with MOV 1295

2) Drywell Unit #1 spray header II with MOV 1296
3) Drywell Unit #2 spray header I with MOV 2295
4) Drywell Unit #1 spray header II with MOV 2296
5) Common Chamber spray header with MOV 1750
6) Common chamber spray header with MOV 2750

Inside each drywell there are two full capacity spray headers. Each
spray header has 120 nozzles for spraying water uniformly in the drywell. A
selector switch is provided to select one of the headers for operation and the
other header remains on standby. During incident condition the MOV on
selected header will open automatically and the MOV in standby header
will open only if the selected header is not giving required flow. The MOVs
on spray headers to common chamber open irrespective of incident on any
unit. The strainer provided on suction lines from drywells and suppression
pools trap the particles which could cause blocking of nozzles. The nozzles
of drywell spray headers are tested periodically by admitting compressed
air to spray headers.

The operation of entire system is fully automatic. The system is

initiated by any one of the following two limiting conditions on either of the
units:

1) Reactor water low-low level (150 cms. Above the core).

2) Drywell high – high pressure (0.14 Kg/cm2).

There are two independent initiation circuits which get energized on

receipt of any one of the above signals. Once energized, the initiation circuit
carries out all operations like opening of MOVs, starting of pumps,
monitoring of pump and MOVs, starting of standby pumps, opening of
standby MOVs etc. automatically as per pre-determined sequence of
operations. Before normalizing the system, the initiation circuits have to be
reset manually.

The suction MOVs to the post incident cooling pumps change over
from suppression pool of respective unit to the outlet from the drywell of
that unit, as soon as the water level in the drywell reaches particular preset
valve.

During refueling shutdown Core spray spargers of both the loops are
tested for nozzles through ness test by actually admitting water through the
spargers. Post incident spray header nozzles in drywell are also tested for
through ness by admitting service air in to the nozzles.
DRG 147A
 Shutdown Cooling and Head Spray System

The purpose of shutdown cooling system is to cool down the reactor

from 150oC to approximately 50oC during shutting down and to maintain
reactor water temperature around 50oC during shutdown period by
continuous removal of decay heat. To meet the requirements of refueling
schedule, the shutdown cooling system is designed to cool down reactor to
60oC within 24 hrs. and to 50oC by 51 hrs. During refueling outage, the
vessel head removal is generally scheduled at 51 hrs. after start of shutdown.
Cooling down to 50oC will preclude uncomfortable working conditions and
facilitate adequate visibility in the reactor water for refueling works. RBCW
system provides the cooling water for heat exchangers.

The system is independent for both the reactors. The shutdown

cooling system of each unit consists of two pumps and one heat exchanger,
motor operated valves, instrumentation and piping etc. One heat exchanger
is spare for both the units.

There are two shutdown cooling pumps for unit #1 1NU0-2A/B are of
75 lps (1200 gpm) each capacity at 55 M (180 ft.) TDH driven by 75 HP
motor. For unit #2 2NU0-2A/B are of 75 lps. each (1200 gpm) capacity at
55 M TDH driven by 100 HP motor. Unit No.1 pumps are supplied from
Class IV power supply where as Unit No.2 pumps are supplied from class III
power supply. The pumps have mechanical seals. RBCW is provided as
cooling water to seal coolers. The pumps are protected against low suction
pressure, low discharge flow and high temperature. The pumps suction
header is connected to reactor recirc. loop B by MOVs and the discharge
header is connected to recirc loop A by MOVs. The pumps take water from
reactor annulus and pump it back to reactor core through heat exchangers.
Usually, it is sufficient to run one pump. The pumps are located at lower
elevation to ensure sufficient NPSH.
 There are three shutdown cooling heat exchangers (1NU01, NU01 and
2NU01). RBCW system provides the cooling water. Reactor water flows
through tube side and RBCW flows through Shell side of the heat
exchanger. Each heat exchanger has heat duty of 1.32 MWt (4.5 x 106
Btu/hr.). Tube side of heat exchanger is designed for 1250 psi. (85 Kg/cm2)
at 350oF (176oC) and the shell side is designed for 150 psi. The heat
exchanger 1NU01 serves for unit#1 and 2NU01serves for unit#2 shutdown
cooling system and NU01 is a spare heat exchanger for both units.

During operation of the system, the reactor water ∆T across heat

exchanger is controlled at about 75oC to avoid thermal stresses at reactor
vessel.

The maximum cooling water temperature i.e. RBCW outlet

temperature is limited to about 80oC due to materials used for valves in
RBCW system. Reactor water outlet from shutdown heat exchanger is
connected to reactor recirc. loop A through MOVs.

There are four MOVs provided for each reactor to connect it to

shutdown cooling system. Two MOVs MO-1393 and MO-1394 are on outlet
line from reactor and two MOVs MO-1392 AND MO-1391 are on the return
line to reactor. One MOV (MOV 1391/2391) on return line is of throttle type
to facilitate control of ∆T and cooling rate. All the four MOVs go close
automatically on reactor low level scram. The MOVs cannot be opened
unless:

i) The reactor level is above low level scram point.

ii) Reactor water temp, is below 170oC.

Interlock (i) Prevents any possible loss of reactor water from shutdown
cooling system during conditions of low level.
Interlocks (ii) Prevents inadvertent valving of shutdown system during
running unit.

The reactor vessel head spray system is provided to spray water and
cool the upper portion of reactor vessel and vessel head at a rate matching
with the rest of the vessel, when shutdown cooling system in service. The
system receives cool water supply from CRD hydraulic system. The spray
nozzles are provided at the top center of reactor vessel head. The head spray
flow is controlled manually by a remotely operated pneumatic throttling
valve. The head spray is started little before the shutdown system is taken in
service. An MOV is provided on head spray line which can be opened only
when the reactor mode switch is in other than “RUN” mode position.
DRG 149A
 Containment and Containment Isolation

The most important consideration about any nuclear plant is the

nuclear safety i.e. protecting the public from excessive exposure to radiation.
The plants are designed carefully to prevent or to keep release of
radioactivity within prescribed safe limits. However, abnormal radioactivity
release to environment can occur under conditions of serious accidents. The
plants are therefore always provided with an independent barrier called as
“Containment” to protect the public from excessive exposure to radiation
during serious accidents.

The containment is the last and most important barrier that prevents
the uncontrolled release of fission products to the environment. The
functions of containment are to,

i) Contain within its bound all the energy released during

accident.
ii) To contain within its bound all the fission products released
during accident.

The containment is designed such that it can do its function

effectively under worst condition like “Loss of Coolant Accident” or
“LOCA”. The sources of energy release during accident condition are:

i) Transient nuclear energy.

ii) Stored energy in the system.
iii) Stored energy in fuel and its decay heat.
iv) Energy released due to chemical reactions.
 The release of fission products occur when fuel cladding fails.
The energy and fission products released in the containment during accident
can safely disposed off in a controlled manner later on.

At TAPS double containment is provided namely primary

containment and secondary containment. The primary containment is of
“Pressure suppression type”. It has sufficient free volume to prevent
abnormal pressure rise during accident condition and has sufficient stored
water to absorb the heat energy released during accident condition. Reactor
building itself provides secondary containment and is common for both the
units.

The primary containment system for each reactor consists of Drywell,

Suppression pool and Common Chamber. Other important equipments in
this system are Drywell to Suppression pool Vent headers, Down comers in
Suppression pool , Vacuum breakers between drywell and suppression pool,
Vacuum breakers between suppression pool and reactor building, Vacuum
breakers between Suppression pool and Common Chamber ,instrumentation
and piping. Common chamber is provided to meet requirement of free
volume. Each suppression pool is connected to common chamber by rupture
diaphragms and also there is a vacuum breaker from each suppression pool
to common chamber. This common chamber serves any of the two units.

The reactor vessel and coolant recirculation system is contained in a

leak tight drywell. The drywell has free volume of 132880 CFT (3762 M3)
and is normally at atmospheric pressure. The drywell is designed for internal
pressure of 45 psig. At 245oF (118.3 oC) and external pressure of 2 psig. at
205 oF (96.1 oC).

The drywell for each reactor consists of a steel cylinder shape

projecting up from a spherical shape. The cylinder is of 7.01 M (23 ft.)
diameter and extends for 9.14 M (30 ft.) beyond the top of sphere, which is
of 19.8 M (65 ft.) dia. The semispherical drywell head is bolted to drywell
flange and has double seals to ensure leak tightness.

The head is removed during refueling to provide access to reactor

vessel. Two equipment hatches are provided for each drywell. The hatch
doors also have double seals.

Provision exists for checking leak tightness of double seals of drywell

head and equipment hatch doors by pressurizing area between seals. A
personnel air lock is also furnished for normal personnel access to the
drywell. The personnel air lock has two gasket doors in series, mechanically
interlocked so that one door cannot be opened unless other door is closed.

Number of leak tight penetrations are provided in the drywell shell to

permit passing various connecting lines, piping, electrical and
instrumentation lines to other areas of plant. The drywell is totally closed
during reactor operation and the drywell atmosphere as well as the
equipments inside drywell is cooled by three drywell cooler fans. The
drywell cooler fans are having cooling coils which are cooled by RBCW.
During shutdown periods, the fresh cold air is supplied to drywell and
exhaust air is led to plant stack.

Individual suppression pools are located adjacent to each drywell.

The suppression pool is a steel lined reinforced concrete structure, partially
filled with water. Individual suppression pool is approximately 26.5 M
(87 ft.) long, 13.25 M (43.5 ft.) wide and 16.25 M (53 ft.) high. It contains
53000 CFT (1500M3) of water for absorbing energy released during accident
and has free volume of 110,000 CFT (3114 M3). Each suppression pool is
designed for internal pressure of 8 psig (0.56 Kg/cm2) at 130 oF and for
external pressure of 1 psig (0.07 Kg/cm2) at ambient temp.
 The drywell and suppression pool are connected by vent system. The
vent system consists of three vent pipes of 9.5 ft. (2.89M) dia each, leaving
from drywell and terminating in a common vent header of 2.89M (9.5ft.)
dia. in the suppression pool. The vent header has 76 down comers of 2 ft.
dia. each terminating under the water in suppression pool. The minimum
submergence provided is 4 ft. During accident condition the steam air
mixture from drywell rushes to suppression pool through vent system and
the steam gets quenched in suppression pool water.

The common chamber is also a steel lined reinforced structure located

above the suppression pools and designed for 8 psig (0.56 Kg/cm2) internal
pressure. It is 178ft (54.25M) long, 43.5ft (13.25M.) wide and 50ft (15.24M)
high. It has free column of 390,000 CFT (11040M3) and can be useful for
either unit. It is normally isolated from each suppression pool by 10 rupture
diaphragms of 4 ft. dia (1.218M). These diaphragms are designed to rupture
when suppression pool pressure is higher than common chamber pressure by
2 to 6 psig (0.14 Kg/cm2 to 0.42 Kg/cm2.). The diaphragms can stand reverse
differential pressure up to 8 psig (0.56 Kg/cm2.).

Vacuum Breakers:

After the incident, the steam in the drywell is condensed and also the
suppression pool water is cooled by operation of core spray and containment
spray systems. The containment system can be subjected to vacuum under
such conditions. It is protected against excessive vacuum by providing three
sets of vacuum breakers as described below:

1) Suppression pool to Drywell vacuum breakers :

These vacuum breakers operate to admit air from

suppression pool to drywell in case the drywell pressure is less
than suppression pool pressure by 0.25 psi. (17.5 cms of water).
 There are 4 vacuum breakers of 60.9 cm (24 inch) size in
parallel to meet the flow requirement. The vacuum breakers are
check-valves adjusted to lift at differential pressure of 0.25 psi.
(17.5 cm. of water).

2) Suppression pool to Common Chamber vacuum breakers:

There is one vacuum breaker from each suppression pool to

common chamber. Each vacuum breaker consists of a check
valve and an air operated valve connected in series. The valves
open when common chamber pressure is less than suppression
pool pressure by 0.25 psi. (17.5 cm. of water).

3) Suppression Pool Reactor building vacuum breakers :

These vacuum breakers admit air from reactor building to

suppression pool in case suppression pool pressure is less than
reactor building pressure by 0.25 psi. (17.5 cms. of water).
There are two vacuum breakers in parallel for each suppression
pool and each vacuum breaker consists of a check-valve and air
operated valves connected in series.

Primary Containment Isolation :

The containment has to be a closed and leak tight system to do its

function of containing the fission products released from reactor in case of
an accident. However in actual practice number of penetrations are
necessary to carry process pipes to and from the containment.

All such pipes are provided with either automatic or remotely

operated isolation valves. These isolation valves go close automatically or
are closed from main control room to ensure integrity of primary
containment in case of accident.
 The secondary containment is provided by reactor building and is
common for both units. It encloses primary containment during normal
operation when drywells are closed and sealed. It provides primary
containment when the unit is shutdown and drywell is open as during
refueling. It is designed to minimize any ground level release of
radioactivity which might result from serious accident.

The reactor building is always maintained at slight negative pressure

and the ventilation exhaust is monitored continuously for radiation before
release to atmosphere through stack. If the exhaust radiation level increases
beyond permissible limit the reactor building is isolated from normal
ventilation system and is put on emergency clean-up ventilation mode.
Under this condition the reactor building exhaust is filtered through HEPA
and CBR filters before releasing through stack. The reactor building
ventilation changes to emergency mode when:

i) Any reactor scrams on drywell high pressure signal.

ii) High radiation of reactor building exhaust.
iii) Loss of normal ventilation system.

Air in leakage into reactor building is controlled by sealed

penetrations and proper access control. All access points to reactor building
have interlocked double door system. The one door cannot be opened unless
other door in series is closed. As per Tech. Spec. allowable leak rate is 6%
of the primary containment volume per day.

Drywell Vol. = V1 = 1,32,800 CFT for TAPS.

Wetwell Vol. = V2 = 1,10,000 CFT for TAPS.

The two volumes are connected by means of vent shaft and

distribution header system via suppression pool water.

Power Station V1/V2 Type of containment

 RAPS ∞ Dry type V1=1.5x106cft
(V2=0)
MAPS 2.4 Vapour Suppression type
NAPP 1.4 Pressure Suppression type
TAPS 1&2 1.2 Pressure Suppression type
TAPS 3&4 0.1 Pressure Suppression type

MAPS is not truely pressure suppression containment but may

be considered as mixture of dry and pressure suppression containment. In
MAPS suppression pool is at basement, filled with 8 ft. of water.

As V1/V2 decreases :

i) % of flashed energy in pool water goes up.

ii) Peak drywell pressure goes up. (Peak DW pressure) also
depends on size of flow path connecting V1 & V2.

TAPS

1) Suppression pool to common chamber diaphragms ruptures

after 1 second. of MCA = Double ended break in recirc piping.
2) Blow down phase = 2 to 4 sec. Cooling of fuel due to flashing.
3) In 12 secs. period cooling due to flashing comes to zero.
4) Complete Reactor vessel blow down takes place, complete
equilibrium is reached in about 25 seconds. Pressure in
Drywell, suppression pool and common chamber stabilizes to
5-6 psig in about 25 seconds.
5) Max. Cladding temp. should not exceed 2050oF (≈ 1120 oC).
6) If core spray does not come in service, max. fuel damage occurs
at about 90 seconds.

Metal water reaction is not significant up to 1000oF but becomes

predominant at 2000 oF.
DRG 155A
 120V AC Power Supply

1) Reactor Safety System:

Identical power supply systems are provided for the safety and
control systems of each reactor. Each system consists of two motor
generator sets with fly wheels and associated switchgear.

The motors are of induction type 10 HP supplied from separate

415 volts MCC buses. Each generator is of 120V AC single phase 50
cycles, having capacity of 6 KVA at 0.65 PF lagging. This is
supplying the load of reactor protection system equipment associated
with one of the protection channels. These MG sets are specially
designed to take care of voltage dips caused to the motor with the help
of flywheels moment of inertia which will take care of the generator
out-put voltage for a period of 5 seconds even if the motor supply is
switched OFF. Control panel for unit #1 M-G sets is provided at cable
spreading room division #1 (service building 118ft. elev.). Control
Panel for unit #2 M-G sets is at a room near B.B #2 (at service bldg.
133 elev.)

The alternate source of power supply to these reactor protection

channels is from X21(X22) transformer through Y01 (Y02) panel
which is fed from emergency bus B-41(B-52).

Operating Philosophy:

During normal operation, each of the motor generator sets will

supply the 120V AC to their respective connected buses. The MG sets
 are started and stopped by control switches located on control and
distribution panel C26 for unit #1 and C30 panel for unit #2.
Ammeters and Volt meters are provided on each of the panels to
indicate output of each generator.

A manual selector switch is provided in control room on

C07(C17) panel for selecting the alternate supply from Y01(Y02) to
one of the protection channels. If the normal supply from MG set to
selected channel fails then the changeover to alternate supply takes

place automatically. The changeover back to normal supply from MG

set requires manual action.

It should be remembered that the protection channel looses

power supply momentarily when changeover from normal to alternate
supply or vice versa takes place.

2) Instrument AC Supply:

A 415/120 volt transformer is provided for each generating unit

to supply power for certain control and instrument systems which
require 120 volts AC and which are not supplied by reactor safety
system MG sets. These transformers are of 30 KVA 3φ 50 c/s. These
transformers are supplied from separate emergency buses of their
respective units (Division 1 and Division 2).

Each transformer supplies a 415/120 volts 3φ, 4 wire instrument

AC panel with single phase feeder breakers.
 The power panel for unit # 1/2 services is designed as Y01/Y02
which are supplied from X21/X22 transformers.

A power panel Y03 of 120V AC is feeding common station

services. This panel is normally fed by Y02 panel and alternate power
is provided from Y01 panel. The other power panel of 120V AC is
designated asY04A and YO4B (Y05A and Y05B) in Division1
(Division 2). Panel Y04A/B (Y05A/B) are normally fed by inverter
DY01A/B (DY02A/B) supplied from 240V DC system and
DYO1C/DYO2C are the spare inverters for YO4A/B and YO5A/B
respectively. The alternate source of power supply to this panel
Y04A/B (Y05A/B) is automatic from a transformer X23 (X24). This
is capable of supplying a load of 7.5 KVA at 120 volts single phase
supply.

Operating Philosophy:

An additional distribution panel is provided for each unit with

feeder circuit for other reactor safety and control systems not supplied
from the MG sets. These panels are designated as Y04A/B for unit #1
(Division1) and Y05A/B for unit #2 systems (Division2).
 Y04A and Y04B are normally supplied from the safety system
inverters DY01A and DY01B respectively. A white indicating light is
provided in the main control room to indicate that the bus is being
supplied from its normal source. An automatic transfer switch is
provided to transfer the bus source to an alternate source during loss
of voltage from the normal source. A yellow indicating light in the
main control room will indicate this transfer. Automatic transfer back
to its normal source is provided upon return of the normal source
voltage.

The alternate source is from the instrument transformer X23

(X24) connected to class III MCC (4l5/120V AC single phase, 7.5
KVA). The alternate source transformer which supplies panel Y04A
and B (Unit l) is fed from MCC B41 and alternate source transformer
which supplies panel Y05A and B (Unit 2) is fed from MCC B52.
Spare inverter DY01C can be taken into service in place of DY01A/B
inverter through manual changeover switch. Similarly Y05A and
Y05B are supplied from the safety system inverters DY02A and
DY02B respectively. Spare inverter DY02C can be taken into service
in place of DY02A/B inverter through a manual changeover switch.
DRG 158A

DRG 158B
 Station Transformers and
Electrical Distribution at TAPS

Main Transformer Unit #1 - X01

The main transformer for unit #1 is an outdoor two winding,

three phase, 50 c/s, 227,000 KVA, 12KV/230 KV (primary winding is
connected delta and secondary winding is connected in star) forced oil to
water cooled transformer. The high voltage winding has two 2 ½% full
capacity taps each above and below rated voltage. The transformer must be
de-energized before changing taps.

The Forced Oil-to-Water (FOW) cooling system consists of six

sets of pumps and heat exchangers and is provided with manual and
automatic controls. Sufficient cooling capacity is provided so that full rated
transformer capability is available with one set out of service. Two 415 volt
feeders from separate motor control centers feed the pumps and are arranged
to switch from one source to the other upon loss of 415 volt power from one
of the sources.

Lightning arresters rated for 192 KV and equipped with discharge

counters are connected to HV terminals and are mounted directly on the
transformers.

There are two current transformers provided on each high voltage

bushing of the main transformer. One set is used for the main transformer
over-current relaying. The other set is not presently used.
 A set of three current transformers on the transformer side of the high
voltage circuit breaker located in the 220 KV switchyard is used for the
overall unit differential relays and the generator, start-up over current relays.

A sudden pressure relay operating from internal cooling oil conditions

provides back up protection.

The transformer is provided with a local annunciator to facilitate the

indication of transformer trouble and initiate the transformer trouble alarm in
the main control room.

Neutral point of the secondary winding of the transformer is solidly

grounded to facilitate in immediate protection of the system during fault
time. The main transformers for Unit #1 and Unit #2 are designated as X01
and X02 respectively.

Main Transformer Unit # 2 - X02

The main transformer for Unit #2 is an outdoor two winding, three

phase, 50 c/s, 260 MVA (with 200 MVA cooler), 12KV/230KV (Primary
winding is connected in delta and secondary winding is connected in star) oil
forced air forced (OFAF) transformer. Transformer is provided with an off-
circuit tap (+10% in steps 2.5%) changing switch at the neutral end of HV
winding for getting voltage variation on HV circuit. The transformer must be
de-energised before changing taps. Oil Forced Air Forced (OFAF) type
cooling is adopted for this transformer consist of finned tube radiators, fans
and pumps.
 For forced cooling of transformer oil, four no. of pumps and eight no.
of fans are provided. The pumps and fans are divided into various groups.
For full load operation of the transformer two pumps and four fans are
required. The standby fans start automatically by oil temperature switches.
Running pumps or fan failure is annunciated in control room. Power supply
to the pumps and fans are provided from two different 415 V MCCs .Pumps
and fans are arranged to switch over from one source to the other upon
failure of the one of the source.

Lightning arresters rated for 192 KV 10,000 A and equipped with

discharge counters are connected to HV terminals and are mounted directly
on the transformer. A set of three current transformers on the transformer
side of the HV circuit breaker located in the 220 KV switchyard is used for
the overall differential relays and the generator startup over current relays.

There are 2-core current transformers on each of the two bushings.

These are used for over current relay and restricted earth fault relay. There is
a 3-core current transformer on the bushing. These are used for over-current
relay, restricted earth-fault relay and winding temperature relay.

A Buchholz relay operating from internal cooling oil conditions

provides back-up protection. The transformer is provided with a local
annunciator to facilitate the indication of transformer trouble and initiate the
transformer trouble alarm in main control room.

Neutral point of the secondary winding of the transformer is solidly

grounded to facilitate the immediate protection of the system during fault
time.

Unit Auxiliary Transformers – X04/X05

 The unit auxiliary transformer for each unit is an outdoor, two
winding, three phase 20,000 KVA, 12KV/3.3KV (Primary winding is
connected in delta and secondary winding is connected in star) forced oil-to-
water cooled transformer. The H.V. winding has two 2½% full capacity taps
each above and below rated voltage are provided. The transformer must be
de-energized before changing these taps.

The low voltage winding is rated for 3.3KV line to line and its neutral
is grounding with resistance to limit the fault current during fault time. The
low voltage line terminals are connected to the 3 phase non-segregated phase
bus duct. The low voltage winding has sixteen 0.625% taps each above and
below rated voltage. The low voltage automatic tap changer can be
controlled both locally and from the main control room while delivering its
full KVA rating. Local and remote (main control room) tap position
indicators are provided.

The Forced Oil-to-Water (FOW) cooling system consists of 3 sets of

pumps and heat exchangers and is provided with manual and automatic
control. Sufficient cooling capacity is provided so that full rated transformer
capability is available with one set out of service. Two 415 volt feeders from
separate motor control centers are supplied to the pumps and are arranged to
switch over from one source to the other upon failure of the one of the
source.

There are two current transformers on each high voltage bushing of

the unit auxiliary transformers. One set is used for unit auxiliary transformer
differential relaying. The other set is used for the overall unit differential
relays.

One low voltage neutral bushing current transformer is

provided on each of the unit auxiliary transformer for the ground over
current relays.
 Back-up protection is provided by a sudden pressure relay.

A local annunciator is provided to monitor important transformer

conditions and is equipped with a common remote alarm to annunciate
transformer trouble in main control room.

Station unit auxiliary transformer for Unit #1 and Unit #2 are

designated as XO4 and XO5 respectively.

Station Start-up Auxiliary Transformers- X03A/B

There are two Nos. of start-up transformer in TAPS. The station start-
up auxiliary transformers for Unit #1 and Unit #2 are designated as XO3A
and XO3B respectively. However, any of the above two transformers can be
used for both units or each transformer (XO3A and XO3B) can be used for
individual units.

XO3A: The station start-up auxiliary transformer (X03A) is an out

door three winding, three phase, 20,000 KVA, 230KV/3.3KV forced oil-to-
water cooled transformer. The high voltage winding is “Wye” connected
with the neutral solidly grounded and rated 230KV line-to-line and has two
2 ½% full capacity taps above and below rated voltage. The transformer
must be de-energised before changing these taps.

The low voltage winding is wye-connected with a low resistance

grounded neutral and a line-to-line voltage rating of 3.3KV. The low voltage
line terminals are connected to the non-segregated phase bus duct. The low
voltage tap changing equipment provides +10% voltage regulation in
0.625% steps at full transformer output capability. The automatic tap
changers can be controlled both locally and from the main control room and
have tap position indicators both locally and in the main control room.
 A delta connected tertiary winding is provided to serve as neutral
stabilization. This winding is rated for 35% of the rated output. The voltage
rating of this winding is capable of withstanding without injury, the stresses
due to any system faults on the 230KV system.

The forced oil-to-water cooling system is similar to that of unit

auxiliary transformers.

Lighting arresters rated 192KV with discharge counters are provided

for connection to the high voltage terminals. There are two current
transformers mounted on each of the high voltage bushings.

One set is used for transformer over-current relaying. The other set is
not presently used.

A set of three current transformers on transformer side of the high

voltage circuit breaker located in 230KV switchyard together with the
current transformers provided on the 3.3KV bus connections to the 3.3KV
switch gear is used for differential protection of the transformers.

One low voltage neutral bushing current transformer is provided for

the transformer ground over-current relay.

An annunciator similar to the unit auxiliary transformers is also

provided.

XO3B: Start-up transformer X03B is all most similar to XO3A except

some points those are given below:
 1) XO3A has atmo-seal but XO3B has conservator tank.
2) Cooling of XO3A is FOW type (due to provision of oil
circulating pumps and heat exchangers-3 Nos.)Cooling of
X03B is ONAF type (due to provision of Radiator and cooling
fans – 4 Nos.).
3) XO3A has sudden pressure relay but XO3B has Bucholz relay.

Normally XO3A will be feeding AO2 and XO3B will be feeding AO3
with bus coupler breaker open. AO1 and AO4 are supplied by respective
unit’s auxiliary transformer. But following conditions can also be achieved:

a) XO3A feeding AO2 and AO3 with bus coupler close AO1 and
AO4 on respective unit auxiliary transformers.
b) XO3B feeding AO3 and AO2 with bus coupler close AO1 and
AO4 on respective unit auxiliary transformers.
c) XO3A feeding both AO1/AO2 and XO3B feeding AO3/AO4
with bus coupler breaker open.

Transformer Protections

a) XO1 (GE Make) :

i) Sudden pressure Relay - Lockout
ii) Differential Relay (Generator combined) - Lockout
iii) Phase over current Relay - Main breaker trip
iv) Pressure Relief Device - Alarm

b) XO2 (TELK Make):

i) Bucholz Relay - Lockout

ii) Differential Relay (Generator combined) - Lockout

iii) High winding temperature - Lockout

iv) High Oil temperature - Lockout

v) Phase over current - Main breaker trip

 vi) Pressure relief device - Lockout

vii) Backup Earth fault Relay - Lockout

c) XO4/XO5 (GE Make):

i) Ground over current Relay - Lockout

ii) Differential Relay - Generator Lockout
iii) Sudden Pressure Relay - Generator Lockout
iv) Phase over current Relay - 3.3kv bkr. trip

d) XO3A (GE Make) :

i) Ground over current Relay - Lockout
ii) Differential Relay - Transformer Lockout
iii) Sudden Pressure Relay - Transformer Lockout
iv) Phase over current Relay - 220kv bkr. trip

e) XO3B (BHEL Make) :

i) Ground over current Relay - Lockout
ii) Differential Relay - Transformer Lockout
iii) Bucholz Relay - Transformer Lockout
iv) Phase over current Relay - 220kv bkr. trip
v) High winding temperature - Transformer Lockout
vi) High oil temperature - Transformer Lockout

Station Auxiliary Switch Gears

All switch gear required for unit and station auxiliary

equipment are complete in all details and accessories, necessary for station
safety and operation. The equipment consist of four basic grouping or
classifications.

1) Medium voltage switch gears (3.3KV)

2) Low voltage switch gears (415 volts)

 3) Motor control centers (415 volts)

4) Power and lighting panels (415Volts, 3phase)

(240Volts. 1phase.)

Medium Voltage Switchgears (3.3KV)

These switch gears consists of metering, relaying and circuit

interrupting equipments designed to operate at station auxiliary voltage level
of 3.3KV line to line. Four switch gear buses (AO1, AO2, AO3, AO4) are
provided for this purpose. Bus sections AO1 and AO2 are used for unit #1
equipments and AO3 and AO4 are for unit #2 equipments. These buses are
indoor type totally enclosed in metallic enclosure. The switch gear sections
consist of a series of individual cubicles having a common bus duct. The bus
duct and connections are fully insulated for the system operating voltage and
pressure type terminals are provided for cable connections. Metal barriers
are separating the cubicles from each other.

The air circuit breakers are of the vertical lift draw out type and of the
“stored energy” trip free design. The circuit breakers have an interrupting
rating of 37,500 Amps. asymmetrical at 3.3 KV. The switch gear buses are
capable of withstanding a momentary fault current of 60,000 Amps. Control
supply voltage for the circuit breakers is 250V DC. All breakers units are
having like rating and are physically and electrically interchangeable. Each
breaker is provided with mechanical emergency manual trip device,
mechanical “closed” and “open” indication and mechanical breaker
operation counter.

Control switches, indicating lights, flush mounted indicating

instruments and protective relays are located on the front of the associated
breaker compartments. Local breaker control switches are connected for
operation in the test position only and control of the breakers in the
operating position only is by means of remote control switches located in the
main control room.

Secondary sides of the unit auxiliary transformers and the start-up

transformers are connected to the 3.3KV buses. In normal station operation
AO1 bus is connected to Unit #1 auxiliary transformer X04 and AO2 bus is
connected to one of the two start-up transformers. AO4 bus is connected to
the Unit #2 auxiliary transformer X05 and AO3 bus is connected to one of
the start-up transformer i.e. half of auxiliary load of each unit is shared by its
auxiliary transformer and half of the auxiliary load of both units is taken up
by the start-up transformers. However, complete auxiliary load of each unit
can be connected to its auxiliary transformer or its start-up transformer.
Low Voltage Switch Gears

The low voltage switch gear consist of seven double ended and three
single ended 415 volts load center buses for use in the auxiliary power
system of the two generating units. The buses are designated as BO1 to B10.
Each of the ten load center buses are supplied with an integrated 750 KVA,
3.3KV/415V, 3ph, 50 cycle open dry type transformers. Delta connected
high voltage windings are connected to the low resistance grounded 3.3KV
system. The “wye” connected low voltage winding are solidly grounded.
The high voltage winding of each transformer has two 2 ½% full capacity
no-load taps each above and below rated voltage. The transformers are
capable of continuous operation at rated capacity over a frequency range at
47.5 c/s to 51.00 c/s and current rating of 1040 amps.

The air circuit breaker elements for the incoming lines and bus ties
between double ended load center buses have a continuous current rating of
1,600 Amps. and interrupting capability of 60,000 Amps. asymmetrical at
480 volts. Current transformers for phase and ground over current protective
relaying are provided for the incoming circuit breaker trips. One single
phase ammeter is provided for each load center bus. Motor and feeder
circuits have air circuit breaker rated at 600 amps depending on the load
requirements. Circuit protection is provided by micro versa trip devices.

All circuit breakers are of “Stored Energy”, trip free design. All
breakers are electrically operated from 250V DC Control source and suitable
for operation from either a maintained or a momentary contact type initiating
device.

Local breaker control switches at respective BO buses are provided

for following loads:

1) Motor Control Centers (MCC).

 2) AC Chillers 1K4, K4, 2K4.
3) Tie circuit breaker between BO2 to BO3 (52-211), BO3 to BO4
(52- 309), BO5 to BO6 (52-603) and BO7 to BO6 (52-703).

1MVA Utility Sub Station:

This sub-station facility is provided to cater to the additional

loads of TAPS particularly in outside areas of main plant. These loads being:

a) Power supply to chiller cooling tower pump house (CTPH)

equipment.
b) Power supply to MCC B-73 (Workshop MCC).
c) Power supply to MCC B-22 (Adm. Bldg. MCC).
d) Power supply to Radwaste Air compressor K-1D and
Decontamination center.
e) Power supply to TRAP for processing T-49C and T-49D water
received from TAPS.
f) Power panel 18P supplying main library loads.
g) Power panel 20 P supplying other power panels.

Following power panels are also supplied by 1MVA utility sub-station

1) 17P Caskyard Area in turn (supplied by 20P-2)

2) Receipt Section (supplied by 18P-8).
3) 21P Near main gate (supplied by 20P-3).
4) 22P in K1-D Room.

The incoming power supply to 1MVA Substation is provided

by two different sources X-27A and X-27B. X-27A is supplied by AO1 bus
and X-27B is supplied by AO4. X-27A /B are 3.3 KV/415V, 3 Phase. 50
cycles oil cooled transformers of capacity 750 KVA and 1MVA
respectively.

Motor Control Centers (MCC)

 A total twenty (22) 415V AC motor control centers are provided as a
means for centralizing motor control and related control equipment. Motor
control centers consists of:

1) Grouped, low voltage, circuit breaker type, combination starters

2) Fusible switches for feeder circuits
3) Feeder circuit breakers.

These are assembled in standardized vertical sections which are

bolted together to form a single panel assembly panel assembly and are
connected by means of a continuous main bus with a capacity of 600 Amps.
MCC breakers are having thermal over load, ground over current and
instantaneous over current protections.
Power and Lighting Panels:

They are wall-mounted cabinet type having 415V,3ph circuit breakers

and 240V AC single phase circuit breakers. There are 32 lighting panels and
28 power panels. The lighting panels provide supply to the station lighting
circuits and power panels provides for space heaters, small capacity motors,
power outlet receptacles etc.
DRG 168A
DRG 168B
DRG 168C
 48V DC Neutron Monitoring
Power Supply System

Purpose:

The purpose of the 48V DC system is to provide adequate and

uninterrupted power supply for the Neutron Monitoring system.

Description:

Two identical and independent 48V DC systems are provided for

supplying the neutron monitoring system of two reactor units of the plant.
Each system consists of the battery, charging equipment, distribution panels,
necessary controls and instrumentation required for efficient operation. Two
independent DC distribution panels D16 and D17 (D26 and D27) are
provided for each unit. Each panel is equipped with the necessary feeder
circuits to supply power to approximately one-half of the neutron monitoring
channels of one reactor.

The battery consists of 24 cells with insulated center tap connection

and is normally rated for 48V DC. The cells are of the lead acid type with
plante positive plates.

The battery has a normal capacity of 80 amps-hrs. at 10 hrs. discharge

rate. One static battery charger and one battery bank is provided for each of
the two systems. The battery charger has a rated output at +28 and –28 volts
measured from the center tap of the battery. The battery charger provides
two basic charging rates “floating” (+25.8 and –25.8V) and “equalizing”
charge of (+28 and –28V). One standby battery charger is provided for each
unit which can supply to any of the buses D16 or D17 (D26 or
D27).Provision of alternate supply has been made from one panel to the
other panel during the battery charger failure or during battery bank outage,
however the breakers will be switched over manually.

Design Basis:

The 48V DC batteries are sized to furnish for a period of four hours
the normal load requirements of the neutron monitoring instruments in the
event of loss of power to the chargers.

The battery chargers are capable of continuously supplying the normal

load requirements of the neutron monitoring equipment with the batteries
disconnected.

Mode of Operation:

During normal operation of the two 48V DC systems, the battery

charger of each is operated in parallel with its associated 48V battery. Each
battery charger is designed as a two circuit unit. Closing the AC switch on
the charger cabinet energizes both circuits. Closing the DC switch connects
both circuits to the battery. Duel potentiometers are provided for each of the
two circuits so that both the float and the equalizing potentials may be
independently adjusted. A 24 hours equalizing timing is provided to get the
desired equalizing time. The timer switch transfers the charger from the float
to the equalizing charge rate. When the timer times-out it will automatically
return the charger to the float charge position.
 AC power failure contacts are provided which will cause on alarm in
the main control room indicating battery charger failure. Also, provided are
under and over voltage relays for each of the two (+24V and –24V) circuits.
Over or under voltage of either circuit will trip the main breaker of the
distribution panel and will result in the loss of one half of the neutron
monitoring channels of associated reactor. This condition will be
communicated in the main control room.

Battery banks are taken out of service on monthly basis for boost
charging with external chargers. When one of the battery bank is taken out
for maintenance the affected panel D16 or D17 is tied with the other in-
service battery bank .This prevents power failure to NMS as one battery
bank is capable of supplying both the panels in case of charger failure.
DRG 170A
 250V DC System

Purpose:

Purpose of the 250V DC power supply system is to provide an

adequate and uninterrupted power supply for control and power
requirements of all 250V DC loads. The loads supplied by 250V DC system
include emergency seal oil pumps, emergency bearing oil pumps, controls,
annunciators, instruments, protective apparatus, emergency lighting and
other essential auxiliaries necessary to keep plant in safe conditions in case
of loss of all other station power.

General Description:

The 250V DC system consists of the station battery, Battery charging

equipment, switch gear, distribution panels and necessary controls and
instrumentation.

The station battery consists of two independent full capacity banks of

120 cells each. Each bank is nominally rated for 250V DC and has a nominal
capacity of 1200 ampere-hrs. at 10 hrs. discharge rate. The battery banks are
located in service building at 133’ elevation in Division #1 and Division# 2.
The two battery banks are physically located in different locations to avoid
their simultaneous non-availability by a common cause such as fire.

The static type battery chargers are provided for each of the two
systems to maintain a float or equalizing charge of the station battery bank.
Unit #1 battery chargers are located at 118’ Cable spreading room Division
#1 and Unit# 2 battery chargers are located at 133 elev. in service building.
 The main DC Distribution Panel for Unit#1 is located in cable
spreading room Division #1.Panel is divided into three sections
(D10A/B/C). Section D-10C is supplied from the battery bank No-1 and
sections D-10A/B are supplied from D-10C. The battery chargers G-4A/B
are connected to panels D-10A/B respectively. The main DC Distribution
Panel for Unit#2 is located in cable spreading room Division #2.

Panel is divided into three sections (D-20A/B/C). Section D-20C is

supplied from the battery bank No-2 and sections D-20A/B are supplied
from D-20C. The battery chargers G-4C/D are connected to panels D-20A/B
respectively.

Under normal operation the tie breakers between all the three sections
are kept closed thus all the three sections effectively operate as a single bus.
Normally one of the two chargers is kept in service and the other one is kept
as standby. In the event of driving power failure to the running chargers, it is
automatically disconnected from the DC bus.

Normally D-10 A/B/C supply to the following DC distribution panels

of Unit #1.

1) MCC Bus DO3

2) MCC Bus DO5
3) MCC Bus D13
4) MCC Bus D15A

Normally D-20 A/B/C supply to the following DC distribution panels

of Unit #2.

1) MCC Bus DO4

2) MCC Bus DO6
3) MCC Bus D14
4) MCC Bus D15B

Alternate supply to distribution panel DO3, DO5, D13 and

D15A can be given from D-20 A/B/C panel and alternate supply to
distribution panel DO4, DO6, D14 and D15B can be given from D-10
A/B/C panels. Alternate supply is given through auto change over switches.
Alternate supply breakers are normally kept off.
Location of Distribution Panels:

a) DC distribution panels D13 and D15A are located in service

building at 118’ elev. cable spreading room Division #1
b) DC distribution panels D14 is located in Cable spreading room
Division #2 and D15B is located in a room adjoining cable
spreading room.
c) MCC DO3 and DO4 are located in reactor building at 143’
elev.
d) MCC DO5 and DO6 are located in turbine building at 103’
elev. lube oil area.

The control switches and voltage adjustment push buttons for Unit #1
Static battery chargers, metering instruments for the Station battery bank
No.1 and ground fault detector unit are located on Battery Charger and DC
distribution panels at Cable spreading room Division #1.

The Battery chargers and control switches of chargers for Unit #2 are
located at 133’ Service building, While D-20A/B/C panels are located at
Cable spreading room Division #2. There is a permanent link arrangement to
tie both the battery banks while taking out one of the battery bank for
maintenance. Battery banks are taken out for monthly boost charging by
external chargers. During this period other units battery bank is tied with
250V DC Bus.

Normal mode of operation :

Under normal operation G-4A or B static battery charger is kept

running for charging battery bank #1 and static battery charger G4C or D is
kept in service for charging battery bank #2. The battery chargers are
supplying normal load as well as charging the battery bank. If the running
battery charger trips, this condition is annunciated in main control room.
Operation During TLOP:

When loss of power to the station (TLOP) occurs both the supplying
battery chargers trip and the respective units battery bank supplies the
essential loads. When EDG comes in service and class-III power becomes
available one of the battery chargers is taken in service and battery bank
voltage is brought up to the rated voltage. Other battery charger is kept on
standby.

DRG 173A
220 KV and 33 KV Switchyard

1) General :

The power generated at 12 KV by two turbo-generators at

TAPS is stepped up to 220KV by two main transformers X01 and
X02 of 12KV/220KV, 227 MVA and 260 MVA capacities
respectively. The power is fed to 220KV switchyard through overhead
lines. Two 220KV Maharashtra feeders supplies to BOISAR and
BORIVALI. Two 220KV Gujarat feeders supplies to BHILAD and
VAPI. Thus 220KV switchyard feed power to the electrical grids of
both the states. Two station start up auxiliary transformers X03A and
X03B of 220KV/3.3KV, 20 MVA capacity take power from 220KV
switchyard and feed about 50% of station auxiliary load. The 220KV
switchyard also feeds power to Zone-III. 220 KV Switchyard outages
are controlled by Western Regional Load Dispatch Centre.

The switchyard is divided into three zones with bus

sectionalizer breaker between adjacent zones.

The zone-II (towards north) of switchyard has equipment and

breakers for feeder Borivali feeder, Vapi feeder, Startup auxiliary
transformer X03A, Generator No.1, Bus Sectionalizer No.1 and Bus
coupler No.2. Potential transformer 2 is used for sensing voltage for
Zone-II for the purpose of monitoring, metering and protection. The
Zone-I (Middle) of Switchyard has equipment and breakers for Bhilad
feeder, Boisar feeder, Start up auxiliary transformer X03B, Generator
No.2, Bus Sectionalizer No.2 and Bus coupler No.1.
 Potential transformer 1 is used for sensing voltage for Zone-I
for the purpose of monitoring, metering and protection. The control
panels for Zone-I, Zone-II and Bus Sectionalizer-2 are located in
TAPS Main Control Room. These control panels have controls for
feeder breakers, synchronizing facility for feeders, feeder protection
relays, bus bar protection relays, bus transfer throw-over relays,
annunciators and meters. Control panel for zone III located in zone III
switchyard control room. Control for Generator No.1, Generator No.2
and start up transformers are located on panels C04, C14 and C01
respectively of Main Control room.
Zone - III Switchyard

220 KV Zone-III Main bus is supplied via Bus Sectionalizer

No.2. Zone-III main bus is supplying to DAE installations as well as it
is connected to Grid.220 KV main bus is supplying to 33 KV main
bus via one of the two transformers of 220KV/33KV, 25MVA
capacity. One transformer is normally in service while other remains
charged. Main bus is also supplying auxiliary power to TAPS 3&4
through 220 KV TAPS 1&2 - TAPS 3&4 tie line. 220KV TAPS 3&4
switchyard is connected with 220KV PGCIL switchyard at Boisar.
SF6 breakers are used for 220KV equipments.

33KV bus supplies to the following loads.

1) Feeder No.1 - TAPS 3&4 Plant outside loads.

2) Feeder No.2 – R&D, NPCIL.

3) Feeder No.3 – TMS Colony power supply.

4) Feeder No.4 – BARC feeder No.1 (A3F and PREFRE)

5) Feeder No.5 – AFR.

6) Feeder No.6 - BARC feeder No.2 ( A3F and PREFRE)

7) Feeder No.7 - R&D , NPCIL

33 KV main bus is having sectionalizer isolator. Feeder No.1 to

4 are in Bus section No.1 .While Feeder No.5 to 7 are in Bus section
No.2 BARC both feeders are having separate GOD’s (Gang Operated
devices) for A3F and PREFRE. The GOD can be operated on no load
only to isolate a particular section. Both A3F and PREFRE are
supplied through underground cable. AFR facility is supplied through
a 2 MVA, 33 KV/3.3 KV transformer. 33 KV breakers used are
Vacuum circuit breakers and having the facility to operate locally as
well as remotely.

220 KV TAPS 1&2 to TAPS 3&4 tie line is an important Start

up auxiliary supply for TAPS 3&4 and line shall be normally in
service except during Zone-III main bus outage for maintenance
works. Since commissioning of TAPS 3&4, Zone-III has became a
part of Grid hence procedure related to Grid must be followed while
taking outage on 220 KV tie line or on 220 KV Zone-III main bus.
 Protections for 220/33 KV transformer

1. Transformer differential protection.

2. H.V. Directional Over current and Earth fault protection.

3. L.V. Directional Over current and Earth fault protection.

4. OLTC and Main Tank Bucholz relay protection.

5. High Winding temp. alarm and trip.

6. High Oil temp. alarm and trip.

Protections for 33 KV feeders

1. Over current and Earth fault protection.

Protections for 2MVA transformer for AFR feeder

1. Transformer differential protection.

2. H.V. Directional Over current and Earth fault protection.

3. L.V. Directional Over current and Earth fault protection.

4. Main Tank Bucholz relay protection.

5. High Winding temp. alarm and trip.

6. High Oil temp. alarm

2. Details of Equipments used in Switchyard

2.1) 220 KV SF6 Circuit breaker

All the equipments and feeders in Zone 1 and Zone 2 of TAPS
switchyard are having SF6 breakers which are Crompton Greaves
make identical and of similar rating. The rated current for SF-6
breaker is 3150 Amps and the breaking current capacity is 40KA. SF6
gas circuit breaker makes use of SF6 (Sulphur Hexafluoride) gas,
which has excellent arc quenching capability and exceptionally high
electrical insulating characteristics.

Properties of SF6 gas:

1. Inert, non-toxic, non-flammable and odourless gas.

2. Density of SF6 gas is five time than that of air.

3. Excellent arc quenching properties.

4. High insulating properties.

5. Thermal stability.

6. De-composition of gas after arcing is less.

Basic Features of SF6 Breaker:

In SF6 the arc voltage remains low until immediately before

current comes to zero, so that the arc energy does not attain high
value. More over the arc time constant for SF6 is very low. Further
more, SF6 and its decomposition products are electronegative
permitting electron capture at relatively high temperature. Thus the
die-electric strength rises rapidly and enable the breaker to withstand
the recovery voltage even under extreme switching condition. In air-
blast circuit breakers air is allowed to escape following the quenching
operation. This obviously would be uneconomical. Hermetically
sealed circuit breaker chamber are therefore developed in which even
the gas pressure remains practically constant over long periods.
 Owing to the low contact erosion in SF6 and almost negligible
decomposition of the gas in arc, the breaker can be operated for
several years without having to be opened for the purpose of
overhauling.

A complete three phase auto re-closing type circuit breaker

consists of three mechanically independent phases. air reservoir
interconnected electrically and pneumatically and a central control
cabinet. Typical single pole of breaker consists of pole unit and
mechanism box. The housing comprises of pneumatically operating
mechanism, compressor unit for middle phase, air reservoir. The
mechanism is connected to the pole through linkage. To monitor air
pressure and gas pressure a set of air & gas pressure switches and
pressure gauge s are given. The electrical control units are mounted on
control panel. :

a) Local electrically.
b) Remote electrically.

Normally breakers are operated remote electrically. The

breakers are normally closed from control room and they trip when
trip signal is received from Operator or protective devices. The
approximate closing and tripping timings for breakers s are 100 msec.
and 30 msec. respectively. Breakers of feeders have single phase and
three phase auto re-closing facility. This facility is not used presently.

2.2) 33 KV Vacuum Circuit Breakers

 Porcelain clad Vacuum Circuit breakers are used for 33 KV
Feeders .The breakers are free from maintenance, highly reliable and
completely free from the menace of vermin. The outdoor application
calls for adequate clearances, sufficient creepage to suit polluted
atmosphere and must ensure that there is no communication between
the inside of pole unit and atmosphere. Porcelain clad Vacuum Circuit
breakers are specially designed to meet these requirements.

Vacuum has superior dielectric properties and thereby serves as

an excellent arc quenching medium. During switching operations, the

rate of recovery of dielectric strength is extremely quick and hence arc

quenching is accomplished within 22 mm of contact gap. There is no

deterioration of quenching medium. The Vacuum integrity is ensured
by the design and manufacturing technology of the interrupter. More
over, the contact erosion is minimal due to short arc duration. This
makes the Vacuum interrupter a highly reliable switching device with
very long contact life. Therefore, the circuit breaker requires little
maintenance except periodic lubrication of mechanical parts.

The interior of each pole contains dry inert gas at positive

pressure. This ensures that there is no trace of moisture in the pole by
breathing. The individual pole is independently filled with gas and
there are no interconnecting pipelines. Dry gas is filled in each pole at
a pressure of 0.5 to 1 Kg/cm 2.

Construction and Operation

The VCB consists of three gang operated individual poles

mounted on a rigid support frame. This support frame is bolted to the
mechanism housing .The entire assembly is fastened on to a structure
to acquire desired height of the live terminal above the ground level.
 The ON/OFF indicator and the operation counter are visible
from exterior through the window glass fitted to the front door of the
operating panel. The mechanical ON/OFF indicator shows the state of
the interrupting unit. The moving contacts of the circuit breakers are
operated through linkages by a motor charged spring-closing and
spring-tripping mechanism. The springs can be charged manually also

by manual charging handle. Closing and tripping coils of 240 V DC

supply are used for local/remote electrical tripping .Control supply for
operation of VCB is from 240 V DC batteries.

SPECIFICATIONS

1 Rated System Voltage 33 KV

2 Highest System Voltage 36 KV

3 No. of Poles 3

4 No. of breaks per Pole 1

5 Rated Normal Current 800 Amps

6 Rated Symmetrical Breaking 26.3 kA

7 Motor Voltage 220 V AC

8 Coil Voltage 220 V DC

9 Power required by Trip Circuit 600W Max.

10 Mechanism Motor Charged Spring Mechanism

2.3) Isolators :

These are devices to isolate the circuit after the opening of the
circuit breakers to carry out maintenance of Circuit breakers and
line/line equipments maintenance as well as to give complete isolation
on any equipment/feeder. Normal current carrying capacity is 1250
Amps except for Bus Sectionalizer#1 isolators which are having 2000
Amps capacity. The isolators are operated manually.

2.4) Current Transformers (CTs):

The Current Transformers (CTs) are provided on all phases of

incoming and outgoing lines of 220KV switchyard. The CTs are also
provided on either side of bus sectionalizer breakers. The CTs are
rated such that full load current on secondary of CT is 1 Amps.
Measuring instruments and protective relays are connected on
secondaries of CTs. Three core CTs are provided for equipments (i.e.
Generator No.1, Generator No.2, X03A and X03B). One core is used
for metering, second for equipment differential protection and third
for 220 KV bus differential protection. Similarly, three core CTs are
provided on feeders also.

One core is used for metering, second for feeder protection (i.e.
distance protection and back up earth fault protection) and third for
220KV bus differential protection. Three core CTs are also provided
on either side of bus-sectionalizer breaker. One core is used for
220KV bus differential protection and others are spare.

One set of CT with 5 cores is provided for TAPS 1&2 –TAPS

3&4 tie line. First core is used for metering, second core is used for
pilot wire protection and third core is used for 220 KV bus differential
protection, fourth core is used for directional back up over current and
earth fault protection, fifth core is spare.
2.5) Potential Transformers (PTs):

One set of electromagnetic potential transformers is provided in

Zone-I and Zone- II of switchyard. One set consists of 3 PTs i.e. one
on each phase. The secondary voltage of PTs is 110V. The PT
secondary supplies to meters, feeder protection relays, bus differential
protection and synchroscope.

2.6) Capacitance Voltage Transformer :

There are capacitance divider type voltage transformers. These

are provided on one of the phases of each of the outgoing four feeders.
One tap on the capacitance divider gives indication of the voltage on
the line voltmeter. It also feeds the synchronizing panel for
synchronizing the respective lines with Tarapur Bus. C.V.T. is also
being used as a coupling capacitor for the high frequency currents of
Power Line Carrier Communication (PLCC).

One set of CVT is provided for TAPS 1&2 –TAPS 3&4 tie line
for voltage indication purpose.

2.7) Coupling Capacitor:

One additional coupling capacitor is provided on one of the

phases of each of the outgoing four feeders for PLCC (Audio
frequency coupling capacitor are provided for carrier communication
between TAPS and local receiving station).
2.8) Wave Trap:

This is a parallel tuned circuit which blocks the flow of the high
frequency currents into the bus and equipment, thus

i) Avoiding loss of signal in equipment such as transformer etc.

connected to the bus.
ii) Preventing cross talk in communication between different
stations. The wave trap has to carry the full load current (power
frequency) as well as fault current in case of fault on lines.
These are provided only one unit on the same phase as the CVT
or coupling capacitor for the four lines.

2.9) Lightning Arrestors:

These are provided on all phases of the four feeders at the take
off from the TAPS switchyard. They safeguard the equipment in
switchyard by absorbing dangerous voltage surges due to lightning
stroke, on the way of the transmission line. Surge counters are
provided one for each arrestor to record the number of times the
arrestor has operated to absorb the traveling wayes.

2.10) Main and Aux. Bus :

The main Bus is of twin 0.5 Sq. in copper conductors equipped

with FOG type suspension and tension insulators and associated
clamps. The Aux. Bus is similar to main bus except that it is of single
conductor. Recently silicon composite insulators are also used for
main bus.
2.11) Demineralized Water Supply:

The demineralized water is required for hotline washing of

insulators. The required demineralized water is supplied from demin.
water system of Plant.

3. Saline Pollution:

3.1) The proximity of the Tarapur 220KV switchyard to sea presents the
acute problem of insulator contamination due to saline deposits.
When the insulator is dry and the pollutant is also dry there is no
problem. Let us see what happens when the surface becomes wet.
The surface conductivity of the porcelain insulator increases. The
leakage current increases, thus heating the pollutant and drying it up.
Since the surface deposit is never uniform, the wetting and consequent
drying of the portion of the insulator surface is not uniform.

At places where the drying is more which are termed as dry

bands, greater wattage develops further increasing the resistance. A
stage will reach when the voltage across the dry band may attain
sufficient strength to ignite an arc that short circuits the band. This
happens at several dry band and consequently a complete flash over
may occur.

3.2) Remedial measures

3.2.1) Increasing the creepage distance of the insulators was done to

overcome this problem. This also cannot be increased indefinitely as
it would disturb the insulation co-ordination of the system. All the
low creepage 220 KV ABCB’s were replaced with high creepage
SF6 breakers. Recently some of the gantry and main bus insulators
were replaced with silicon composite insulators which are light
weight and does not allow water droplets deposition on the surface
thus eliminating hot line washing of these insulators.
3.2.2) Periodic washing of the polluted insulator surface with jet of demin.
water (in which CO2 is dissolved) at a pressure of 200 psi. (when the
equipment is live) is now in practice at TAPS Switchyard. Another
system of high pressure jet at 400 psi by using a high pressure pump
is also used for insulator washing. This is known as hot line washing
and does not require outage on any equipment.

2) Auxiliary Bus and Bus Coupler Breaker:

The auxiliary bus and bus coupler breaker is provided to

facilitate maintenance of any equipment or feeder breaker, without
taking the equipment or feeder out of service. During maintenance of
particular SF6 breaker, the bus coupler breaker and the auxiliary bus
keep the equipment or feeder in service.

One bus coupler breaker (SF6) is provided in each zone of

switchyard. Bus coupler No.1 can be used as a breaker for any
equipment or feeder breaker in Zone-I. Similarly bus coupler No.2 can
be used as breaker for any equipment or feeder in Zone-II.

When the bus coupler is in service for a particular equipment or

feeder, the controls and protections are transferred to the bus coupler
breaker by throw-over relays. During transition period of transfer
from equipment or feeder breaker to bus coupler breaker or vice-versa
the controls and protections remain on both the breakers.

3) Auto Reclosure :

Majority of faults on overhead transmission line are of transient

nature. Such faults can be cleared by momentary de-energisation of
feeder. Auto re-closure facility has been provided for feeders so as to
maintain service continuity and system stability. When a fault occurs
on a feeder the feeder breaker trips and re-closes after a time delay.
 The relay equipment for auto closure consists of various time lag
relays and selector switch. The auto closure can be selected for single
phase or three phases. This facility is not being used now.

4) Feeder and Bus Bar Protection:

4.1) Feeder Protection:

At TAPS switchyard all the four feeders are protected by

numerical distance protection relays. It works on the principle of
measuring the impedance of the line between the relaying point and
the point of fault (Quadrilateral characteristic).

This impedance measurement is directly proportional to the

length of the conductors forming the loop, which terminate in the
short circuit. The actual value of impedance of the primary conductors
depends upon the length and size of conductor, distance from ground
spacing between conductors and the earth wire etc.

220KV Feeder Distance Protection Relay

M/s. ALSTOM MICOM RELAY P442 distance protection relays

provide flexible and reliable integration of protection, control,
Monitoring and measurement functions.

MiCOM relays offer fast, secure clearing for any type of faults.

Unique distance and directionalizing implementations provide an
optimum mix of speed, selectivity and security of difficult fault type
and application situations.

Simplified spares holding with dual rated CT inputs.

No need for additional equipment (voltage protection, current
protection, auto-recloser, synchronism check, disturbance recorder,
measurement devices).

Fast fault diagnosis with fault information, disturbance and event
records.

Maximize protection availability through extensive self- monitoring
and self-test, System supervisor (CT, VT, trip circuit monitoring).

Enhanced reliability for all faults through two different measurement
techniques.

Operation of Micro relays based on combined use of two types of
fault detection with duel algorithm principle.
Algorithms used in the MiCOM relays are Delta Algorithm and
Conventional Algorithm.
Features of Distance protection :

Dual distance protection algorithm

Typical operating time 1.25 cycles

Operating time for distance protection is 18 ms and time for over
current protection is 10ms.

Five independent zones of protection.

Loss of load protection

Current reversal guard protection and parallel line protection.

Switch on to fault and zone selectable trip –on-reclose protection.

Directional / non directional phase over current.

Directional / non directional negative phase sequence over current.

Under/ Over voltage
• Broken conductor
• Directional / non directional earth fault
• Circuit breaker failure
• Voltage transformer supervision

Current transformer supervision.
Post fault analysis
• Fault location: Fault location algorithm provides distance to fault in
miles, Kilometers, Ohms or percentage of line.
• Event and Fault records: Up to 250 time tagged event records are
stored in non-volatile memory and can be viewed on front panel
display. Records of last 5 Faults are stored in non-volatile memory.

Information provide in the fault records include :

• Indication of faulted phase
• Protection operation
• Active setting group
• Fault location
• Relays and CB operating time

Current, voltage and frequency
Monitoring
 • Trip circuit monitoring
• Breaker state monitoring

Breaker condition monitoring.

4.2) Back up Earth fault relay:

For earth faults, the back-up protection is given by a separate relay i.e. 3 step
directional earth fault protection.

4.3) Carrier inter trip:

To clear end zone faults of the line without time delay a carrier signal is
sent from the end (where the first zone element of the distance protection acts to
clear faults) to the other end to trip the breaker at the other end.

5. TAPS 1&2- TAPS 3&4 TIE LINE:

a) Pilot wire protection:

As line length is only 800 meters the distance protection relay can not be
used hence pilot wire differential protection is used for tie line. This relay
is used at both ends and interconnected with CT and inter trip circuit pilot
wires between TAPS 1&2 to TAPS 3&4. This relay will operate only for
the faults in between the line. After sensing the fault the tripping
command will be sent to the remote end breaker through pilot wire. For
through faults this relay will not operate.

b) Directional back up over current and earth fault protection:

To take care of tie line through faults three phase directional back up over
current and earth fault protection are provided at both the ends.

5) Bus bar protection:

A bus bar protection is a device which protects bus bars short-circuits and
earth-faults. A 220KV bus fault can be highly disastrous as it involves heavy fault
MVAs. Such fault can be highly dangerous to the personnel and it can damage
equipment and lead to network instability, pole slip of nearby generators and even
total system collapse.
 For bus bar protection applications, it is extremely important to have good
security since an unwanted operation of bus differential relay will have the similar
effect from operational point of view as simultaneous faults on all power system
elements connected to the bus. On the other hand, relay has to be dependable as
well. Failure to operate or even slow operation of the differential relay, in case of
actual internal fault, can have serious consequences. Human injuries, power
system blackout, transient instability or considerable damage to the surrounding
substation equipment and close-by generators are some of the possible outcomes.

Very fast clearance of the bus fault and complete stability for through
faults is achieved by low impedance numerical bus bar differential protection
relay REB 670.The relay operates in 20 msecs. and isolates the faulty zone.

When a bus fault occurs, the balance between incoming and outgoing
currents of that zone gets disturbed and differential current flows through the low
impedance relay and actuates it to trip all the breakers in the zone to isolate the
fault.

Bus differential relay provides open circuit protection at primary current 40

Amps (20 sec time delay) and gives alarm. It gives spill current alarm at 160
Amps (5 sec time delay) and blocks Zone differential relay for that phase which is
having spill current/OCT. However protection will be available for healthy
phases.
Zone differential relay actuates instantaneously at differential primary
current of 800 Amps. Whenever spill current/OCT alarm comes RESET push
button provided at relay panel shall be pressed to clear the alarm and make relay
effective for that particular phase. Relay is also actuated in case of Pole
discrepancy or breaker lockout of Generators or Start up transformers. Some of
the features of the numerical relay are as follows.

High speed tripping for internal faults. Typical operating time 20 milli seconds.

Complete stability for through faults, with heavy CT saturation.

Low CT requirement, only 2 ms to sense CT saturation.

Intelligent detection for open or shorted CT secondary circuits and configurable
blocking of differential protection zone.

Built in data communication modules.

On screen display of all measured bay currents and all calculated differential
currents.

Versatile local human machine interface.

Extreme self supervision with internal event recorder.

Status monitoring of individual switch gear devices.
7) Pole discrepancy:

A protection is provided for the equipment (i.e. Generators and Start up

transformers) in case all the three phases of breaker fail to open or close together.
 In such situation the bus differential protection is actuated and complete zone is
de-energised for protection of equipment.
8) Low Gas/Air pressure Lockout:

Breaker Lockout protection is provided in order to protect the equipment (i.e.

Generator and Start up transformers) in case the SF6 breaker fails to open due to
low gas/air pressure. In such situation the bus differential protection master trip
relay is actuated and complete zone is de-energized for protection of equipment.

DRG 187A
DRG 187B

DRG 187C
DRG 187D
DRG 187E

DRG 187F
 Emergency Diesel Generators

The emergency diesel generators are provided to supply the electric

power to essential equipment following a complete loss of station A.C.
power. Total loss of station power is defined as the loss of voltage on
emergency buses BO4 and BO5 or BO4, BO5 and BO9 or during test run of
one of the three DGs under voltage on the other two emergency buses. The
essential equipment supplied include normal and emergency cooling systems
for removal of core decay heat, emergency feed water supply isolation
valves, instrumentation etc.

The system consists of three identical diesel generator sets G2A, G2B
and G2C connected independently with three 415V emergency buses BO4,
BO5 and BO9 respectively. The system also includes control circuits for
auto starting, load shedding, auto synchronizing, automatic loading etc. The
diesel generator sets are capable of quick starting and loading. The system is
made fully automatic to minimize the off time of essential services. One
diesel generator is sufficient to cater all the essential loads including CSPI
during TLOP incident if other two EDGs becomes unavailable.

Three emergency diesel generators of 415V, 3φ, 50Hz, 800 KWe

capacity each are provided for supplying power supply to essential loads in
case of total loss of power to the station. Each emergency diesel generator is
capable to cater power supply to all the station emergency loads
(647.94 KWe). The three diesel generators G2A/B/C are connected to load
center buses BO4, BO5 and BO9 respectively.

All the three emergency diesel generators shall start automatically

through EMTR. The diesel generator after attaining its rated voltage and
frequency shall close its breaker on their respective dead bus. After closing
the generator breaker on emergency bus, the essential loads shall be started
by EMTR’s through PLC based load sequencers. All the three DGs are
installed outside the main plant building in dedicated rooms with physical
separation to avoid common cause failure.

The emergency diesel generators G2A, G2B and G2C start

automatically on any one of the following anticipatory start signals.
a) Respective DG on emergency bus (BO4/BO5/BO9) under voltage.
 b) Total loss of station power.
c) Reactor water low-level scram for Unit-1 or Unit-2

d) Start up transformers XO3A or XO3B lock out

e) Generator Unit #1 or Generator Unit #2 lockout.

f) 3.3 KV Zone A or Zone B differential protection.

g) Safety system inverter DY01A/B/C or DY02A/B/C auto

changeover switch on alternate supply position.

All generators are identical, direct driven, horizontal synchronous type

with air-cooling and drip proof enclosures. Each diesel generator is rated for
800 KWe at 0.8 power factor, 415 volt, 3 phase, 50-cycle AC supply. The
drivers are identical, four stroke, vertical, single acting with mechanical fuel
injection type, super-charged, V-12 diesel engines, with speed governors
(0 to 4% droop), automatic synchronizing relay for test synchronization and
electric starters. Engines are rated for 1470 BHP at 1500 rpm. The fuel
consumption at rated load is about 215.7 liters/hr. Auto starting and
acceleration of engine to rated speed is accomplished in approximately 10
seconds. The DG sets are mounted on seismically qualified rigid foundation.

Control Panel and 415V switchgear:

Free standing control panel for engine, auxiliaries, breakers

control, indications and annunciation is provided in separate
room. Also a 415 V switchgear panel housing 2000 amps air
circuit breaker along with protective relays, CTs and PTs is
provided. The switchgear panel is floor-mounted type and
installed adjacent to control panel. The panels are adequately
anchored to base channel grouted to the floor.

24 V battery of 490 ampere-hour rating has been provided for

six consecutive starts (assuming two successive start signals of
three cranking cycle operation) as well as control and
instrumentation supply of DG system. The batteries are kept on
metallic stands grouted to the floor.
 The diesel engine primary cooling water loop consists of
demin. water stored in engine mounted cooling water expansion
tank having facility for manual top up. The secondary cooling
water loop consists of a heat exchanger, cooling tower and two
cooling water pumps. The cooling tower sump water loss is
made up by gravity filling from the domestic water tank having
water inventory more than 33000 gallons.

The diesel oil bulk storage tank T12A is having a capacity of 76,000
liters. The low level alarm appears in the main control room when the
quantity of diesel oil in the tank falls below 40,000 liters which is well above

the requirement of one diesel to run at rated load continuously for seven
days.

The second diesel oil bulk storage tank T12B is having a capacity of
55,000 liters. The low level alarm appears in the main control room when
the quantity of diesel oil in the tank falls below 40,000 liters.

Each diesel generator is provided with a 3000 liters capacity high-

speed diesel storage day tank installed above the ground. The day tanks
diesel supply lines are dedicated from the diesel oil transfer pumps. Each
day tank over flow line goes to a separate open pit for collection of the
spilled diesel.

Each tank is provided with a level indicator and a level switch with
alarms at high and low level. Manual starting of one of the two-diesel oil
transfer pumps P-20A or P-20B does filling of the day tanks. Starting of
diesel oil transfer pumps from the respective DG day tank instrument panel
can fill the day tanks. In case of high level in any one of the three day tanks,
the diesel oil transfer pump shall stop automatically.

Modes of Operation

The Emergency Diesel Generators have two modes of operation:

i) Manual
ii) Automatic
Normally, the emergency diesel generators are left in the automatic mode of
operation. The manual mode of operation is used for testing or running the
diesel generators other than loss of power situation. As such if a diesel
generator fails to start automatically during total loss of station power, it can
be started manually

Fire detection and CO2 Fire suppression system:

Fire detection system has been provided in each of the diesel

generator rooms. Total flooding type CO2 fire suppression system operates
upon detection of fire in any DG room on automatic mode. Provision is also
made for manual operation of fire suppression system from local control
panel. Local actuation station is provided in each DG room. Further,

provision is available for manual operation in the event of non-availability of

control supply.

The system consists of two banks of 29 CO2 cylinders each (of 45 Kg

capacity). One bank is called as main bank and other is called as reserve
bank. One bank to other bank changeover is manual and normally one bank
is kept selected. The actuation system of each bank consists of a Master
cylinders and a 5 lbs capacity N2 control cylinder. In case of fire in diesel
generator, the system shall automatically get actuated.

The system is having provision for manual actuation in case of power

failure. Auxiliary N2 cylinder is provided for each bank for manual actuation.
Affected EDG directional valve needs to be opened manually.

Emergency Diesel Generator controls on local panel

i) Engine start/stop
ii) Raise/neutral/lower speed control switch.
iii) Raise/neutral/lower voltage control switch.
iv) Engine emergency stop switch.
v) Auto/manual HS with voltage IN/DEC push buttons for battery
charger.
 vi) ON/OFF push buttons for Fuel transfer pumps.
vii) Local /Remote selector switch for remote and local voltage
adjustment
viii) Auto/manual selector switch for DG set.
ix) DG test /reset push button.
x) Synch. switch and synch. check relay.

Automatic operation of system on total loss of power:

Each DG set is independent for starting, accelerating and developing

voltage. DG local panel is provided supply from the respective DG local and
remote MCC. Automatic change over of power supply to local MCC takes
place whenever respective DG is started or stopped.

Automatic bus isolation, load shedding, engine starting, DG or tie

breakers closing and sequential restarting of emergency loads is achieved
through PLC based redundant EMTRs catering to both the units.

The 415 V AC power supply is necessary to sustain normal plant

operation. There are ten separate load centers buses located in various
buildings. The load center buses are designated as BO1 through B10.

Out of these buses BO4, BO5 and BO9 are designated as the
emergency buses. Following a complete loss of station power, the EMTR
will initiate (sensing the respective emergency bus under voltage) bus
isolation, load shedding and starting of respective DG sets. Normal source
breakers or tie breaker connecting emergency buses shall also be tripped
automatically by EMTR for achieving bus isolation. However, the
emergency lights, the poison injection pumps (MCC B41 & 52) and Core
spray/Post-incident system MOVs (MCC B-43, B-53 & B91) remain
connected.

Once the diesel generator attains rated voltage and frequency, it shall
automatically close it’s output breaker to the respective emergency bus
provided that the bus is healthy and isolated from the other supply sources.
All the three buses shall operate independently with it’s own DG connected
to it and pick up the loads on the respective emergency bus. If a DG system
is either on maintenance or fails to start, an automatic bus tie breaker closure
command shall be initiated by the PLC based EMTR to restore supply to the
bus from the adjacent energized emergency bus.

Load restoration on the emergency buses shall be completed

automatically after the supply to the emergency buses B04 and B05 has been
restored. There are total 18 load restoration sequences to complete this task
under various situations such as failure of the DG to connect and supply
power to the designated bus, bus lockout, DG outage for maintenance and
LOCA condition in one of the units. The emergency loads on these buses
shall be restored one by one at a time interval not exceeding four seconds. In
case of incident in one of the units, the priority shall be given to the core
spray and post incident loads and the normal sequence shall start on
completion of the post incident header pressurization.

Each DG has been located in dedicated room and the cables for the
DG are segregated from the other DG. Any one of the three diesel generators
is capable to meet the load demand during total loss of power to the station
together with the demand of core spray and post incident system. Two of the
three DG sets serve as 2 x100 percent capacity DG sets, thus providing
100% redundancy. Third DG set is treated as maintenance stand by. The
maximum load during total loss of power with CS / PI system in operation is

listed in the table given below. This also meet the requirement of one DG
under maintenance and one of the remaining two DG sets fails to start. The
same relays which initiated the isolation, interconnection and load shedding
of buses BO4, BO5 and BO9 also automatically start all the emergency
diesel generators.

The first diesel generator which reaches normal voltage and frequency
closes its output breaker automatically and energizes the emergency bus and
picks up the loads as per the EMTR loading sequence.

Expected time for automatic sequencing of events / load pick up:

c) Without CS/PI actuation

 Time in Event description
seconds

Buses BO4, BO5 and BO9 load shedding, bus isolation, starting of DG, acceleration,
0-15
remote breaker closure and energisation of the essential loads connected to the bus.

16-20 Starts RBCW pump P13A

20-24 Starts emergency clean up fan V-25A

24-28 Starts salt service water pump P11A

32-36 Starts RBCW pump P13B if P13A fails to starts

36-40 Starts emergency clean up fan V-25B if V–25A fails to starts

40-44 Starts salt service water pump P11B if P11A fails to starts

44-46 Energizes MCC B42

46-48 Closes dry well RBCW MOV 1342

48-50 Closes dry well RBCW MOV 1343

50-52 Energizes MCC B51

52-54 Closes dry well RBCW MOV 2342

54-56 Closes dry well RBCW MOV 2343

d) With CS/PI system actuation:

(Sequence given for Unit-1)

Time in
Event description
seconds
Buses BO4, BO5 and BO9 shed load, isolate, DG starts, accelerates, remote breaker
0-15
closure and assumes the essential load connected to the bus.
15-20 Suppression pool outlet motor operated valves open (MO1288, MO1289)
Starts core spray pump P25A (or P25C or P25B or P25D if P25A or P25C orP25B
20-24
fails)
Opens core spray sparger MOVs if reactor pressure is less than 200 psig (14 kg/cm2)
24-28
(MO 1312 and MO 1313 or MO 1605)
28-32 Starts core spray pump P-25B (or P25C if P25B fails)
32-42 Starts post incident pump P80-A (or P80C if P80A fails)
42-52 Starts post incident pump P80-B (or P80D if P80C started)
52-54 Opens drywell sparger MOVs (MOV 1295 or MOV 1296)
52-54 Opens post incident heat exchanger cooling water MOV-1311
52-54 Opens common chamber spray water inlet MOVs-1750 & 2750
 54-64 Starts RBCW pump P13A
64-68 Starts emergency clean up fan V-25A
68-72 Starts salt service water pump P11A
72-76 Starts RBCW pump P13B if P13A fails to starts
76-80 Starts emergency clean up fan V-25B if V–25A fails to starts
80-84 Starts salt service water pump P11B if P11A fails to starts
84-86 Energizes MCC B42
86-88 Closes dry well RBCW MOV 1342
88-90 Closes dry well RBCW MOV 1343
90-92 Energizes MCC B51
92-94 Closes dry well RBCW MOV 2342
94-96 Closes dry well RBCW MOV 2343

The above emergency equipment shall continue to run even after

restoration of normal supply to the emergency buses. However the
equipment can be switched off manually.

EMTR:
PLC based Emergency Transfer (EMTR) Scheme is provided to
restore class-III power to emergency buses B04, B05 and B09 automatically
when class-IV power to these buses is lost. EMTR performs automatic
functions such as the starting of EDGs, load shedding, emergency bus
isolation, connecting the running DG to emergency buses and sequential
starting of emergency loads. There are two identical EMTR’s provided
which are located in Cable spreading room .EMTR #1 is located in Division
1 of Cable spreading room while EMTR #2 is located in Division 2 of Cable
spreading room.

The station Emergency AC power and control power supply system

comprises of:

(i) 3 nos. of 800 KWe, 415 V emergency diesel generators.

(ii) 415 V Class-III buses BO4, BO5 and BO9.
(iii) 3.3 KV/415 V, 750 KVA dry type load center transformers.
(iv) 2 nos. of EMTR’s.
(v) 250 V DC battery banks.
(vi) 120 V AC Class II inverters.
Associated interconnections

1. Two identical EMTR units consisting of CPU module, power supplies

module, communication module, local input /output driver, local
input/ output receiver, input/output buffer modules, input/ output
modules, mounting base and programming units are located each in
cable spreading room division-1 and division-2. These redundant
divisions are physically and electrically isolated. Separate 120 V
single phase class II AC supply feeder for each EMTR panel shall be
provided and each PLC shall have independent control power supply.
One feeder of 250V DC (2 wire unearth system) supply variation of –
20% and + 10 % shall be provided for input output contactor coil
energization for EMTR of each division. The above control power
supplies shall be monitored within the EMTR for each division.

2. Power supplies, inputs and outputs are provided such that availability
of any one of the systems shall ensure desired functioning of EMTR
scheme.

3. For brief functional description of the PLC modules manufacture’s

instruction manual shall be referred however the general requirements
are given below.

CPU Module

The CPU module includes logic solver and memory. The ladder
circuits are stored in the memory and solved according to the input
data sent from a local Input/Output driver. The results are output to
the local Input/Output driver. The U84 is capable of dealing with
discrete inputs/outputs up to 2048 points and up to 256 register
inputs/outputs.

Power Supply Module

The main power supply module provides DC power to the CPU

module and peripheral modules including communication module and
local Input/Output driver. The auxiliary power supply module
supplies DC power to the local Input/Output receiver, Input/Output
buffer and Input/Output modules.

Communication Module

The communication module includes two RS-232C ports for

communication with the programming panel and a computer. By
operating the front Register Access Panel (RAP), it is possible to
display the status of the coils and input relays to perform simulation
(forced ON/OFF), to display and alter the contents of the registers and
to set and display communication parameters.

Local Input/Output Driver

Receiving the reference from the CPU module, the local Input/Output
driver transfers input data from the input module to the CPU module
and output data from the CPU module to the output module for local
Input/Output.

Local Input/Output Receiver:

The local Input/Output receiver is used for local Input/Output

channels and it exchanges signals between the local Input/Output
driver and the Input/Output modules.
Input/Output Buffer Modules:

The Input/Output buffer module is used to install 22 or more Input/

Output modules in one Input/Output channel.

Input/Output Modules:

One module is provided with inputs or outputs of 16 or 32 circuits. It

is usable for numeric signals (by Input/Output allocation).
 Mounting Base:

The CPU module, power supply module, peripheral module, and

Input/Output modules are mounted on a mounting base. The type of
the mounting base varies with the type of module. The modules
mounted on the base are connected to each other via built-in
motherboard. Connection between mounting bases are made with
cables.

Programming Unit:

The programming panel permits storing a programme, altering or

deleting the stored programme, monitoring status, and printing out a
ladder diagram through a connected printer. Programming unit
includes personal computer, CRT and a tape transport. A software
lock is provided to prevent unauthorized access to programming unit.

Functions of emergency transfer scheme:

The EMTR scheme performs following functions automatically as described

in annexure 1:

(i) To start respective EDG during individual bus under voltage or total
loss of power.

(ii) To provide anticipatory start to all the three diesel generators in case
of
a) Unit-1 or Unit-2 Reactor water low-level scram
b) Start up transformers X-O3A or X-O3B lock out

c) Unit-1 or Unit-2 Generator lockout.

d) 3.3 KV (AO Bus) Zone A or B differential protection activation.

e) Automatic change over of 120V bus Y04A/B or Y05A/B power

supply from inverter to the transformer X-23 / X-24.
(iii) To restore Class-III power supply to 415 V buses BO4, BO5 and BO9
through emergency DG sets whenever the normal class-IV power
supply is lost.
(iv) To sequentially restore identified loads connected to 415 volt Class-III
buses and MCCs after restoring power supply through the respective
bus DG.
(v) To restore supply to the emergency bus (BO4 or BO5) when
G2A/G2B or their respective breakers are under maintenance from the
adjacent emergency bus (BO9) having class-IV power supply.
(vi) To monitor the diesel generators and class-IV supplies that are
connectable to class-III buses and their interconnections for
performing auto functions such as disconnection, reconnection, alarm
and timings to suit the various logics of the respective schemes.

Input to event sequence recorder (ESR)/Alarms and indications on EMTR

and Control room panels have been provided considering their importance
and required response from the operator.
DRG 198A
Station Blackout Diesel Generator (SBO DG)

Station blackout means total loss of station power (class-IV failure)

along with failure of all the three emergency diesel generators to supply
power Class-III power supply. The SBO DG is designed to supply Class-III
power to emergency buses during Station blackout condition. The SBO DG
is sized and selected to provide quick starting and loading on demand. This
800 KWe capacity SBO DG is sufficient to meet the maximum requirement
of 647.94 KWe.

The existing emergency DGs G2A, G2B and G2C provide power
supply to the emergency buses BO4, BO5 and BO9 respectively during total
loss of power. These DGs come on line automatically and pick up loads as
per the loading sequence. In the event of all the three EDGs becoming
unavailable, i.e. Simultaneous failure of "Class-IV" and "Class-III" power
supply leads to the Station Blackout Condition (S.B.O. condition).

Hence in view of above anticipated failure of the EDGs’ supply, a full

capacity (100%) 800 KWe SBO DG has been installed. SBO DG is located
in a separate room near 1 MVA sub station along with its local panel and
auxiliaries. SBO DG has been connected to BO9 with breaker 52-916. To
facilitate the load testing of SBO DG arrangement has been made to
synchronize SBO DG with 1 MVA Sub-station bus through breaker 52-10.
SBO DG can be load tested up to 400 KWe load after synchronizing with
the 1 MVA Sub-station.

Subsequent to the failure of the Emergency Diesel Generators to

supply power to the emergency bus during the loss of power incident the
SBO DG which will be already running has to be manually connected to the
emergency bus BO9. The power supply can be extended to BO4 and BO5 as
they are tied to BO9 through the tie breakers. After the emergency buses
BO4, BO5 and BO9 getting energised the emergency equipment have to be
manually started as per the requirement. During SBO condition EMTR will
not pick up the loads. In case of CSPI requirement, these equipments will
start automatically as per CSPI sequence.

The SBO DG is provided with two mode switches SW2 and SW3.
The mode switch SW2 has four positions namely MANUAL/ AUTO/TEST/
OFF.
 This switch will always be kept in MANUAL mode. Another mode
switch SW3 has two position LOCAL/REMOTE.

If it is in the LOCAL mode the SBO DG can be started manually from

the local panel only but in normal condition this switch will always be kept
in REMOTE mode. When SW3 is in the REMOTE mode the SBO DG will
start on any of the following conditions.

1. Automatic starting on bus BO9 under voltage (by the action of under
voltage relay 27Y95).
2. Remote manual starting from the control room.

The SBO DG can be manually started or stopped by a control switch

in the local panel (switch SW3 in LOCAL mode) or by a remote control
switch located in the main control room (switch SW3 in REMOTE mode).
The control switch in the control room has three positions with spring return
to normal position, START and STOP.

Placing the switch in START position energizes the fuel admission

solenoid valve and the start relay which closes contacts of the two 24 V DC
motors which are gear coupled to the engine flywheel. The unit goes into the
automatic cranking cycle and the engine starts. When the engine starts and
its speed exceeds the cranking speed, the starter motor gear automatically
gets disengaged from the flywheel. Placing the switch in STOP position will
de-energise the fuel admission solenoid valve and cause the engine to stop.
The SBO DG load testing is done by manually from local control panel.

The SBO DG load centre breaker (52-916) connecting the generator

bus to the emergency bus BO9 is controlled by a three positions (i.e. spring
return to center, TRIP and CLOSE) control switch in main control room.
CLOSE position applies power to the closing circuit of the SBO DG breaker
52-916, causing the breaker to close. Once either tripping or closing coil is
energized, the breaker will remain locked in that condition until the other
coil is energized.

The SBO DG has got a local breaker (ACB-52) in the control panel
(C-102) in the SBO DG room. This breaker is normally kept closed. It can
be closed or tripped from the local control panel only. The breaker trips
automatically on engine and generator protections.
 When the SBO DG control switch is in the center position, the master
start relay can be energized by closing of contacts on the BO9 bus under
voltage relay.

Hence the engine will start anticipatory on under voltage of BO9. If

the engine fails to start after 3 sec. of cranking the starter motor will be de-
energised for 5 secs., after which a second cranking cycle will be initiated
should the engine fail to start in 3 attempts, the cranking stops. The engine
fail to start relay will pick up and starting signal will be cut off. An alarm
“Engine failed to start” will be annunciated on the local panel.

A cooling tower is provided for the cooling water supply for the
engine. The power supply for the cooling tower fan and cooling water pump
is provided from the SBO DG bus.

Once the SBO DG starts on bus BO9 under voltage the closing of its
load center breaker 52-916 requires manual action. This manual action
depends on the availability of the Emergency Diesel Generators G2A, G2B
and G2C to cater to the emergency load requirement. For this, the SBO DG
breaker 52-916 has to be closed from the main control room and
subsequently the emergency loads have to be started one by one manually.

The SBO DG is provided with a 990 liters capacity fuel tank. The tank
is provided with a level indicator and switch, which will annunciate an alarm
on local panel whenever the oil level in the tank reaches low level. The oil
supply to the fuel tank is from the diesel oil storage tank.

4 Nos. of 12 V, 400 AH capacity batteries are provided for starting the

engine. A battery charger rated for 30 Amps is used for keeping the batteries
charged. 2 Nos. of 24V DC motors get started when START signal is given
to the engine.

The main generator circuit breaker (ACB-52) is continuously rated for

2000 Amps. It is an air circuit breaker with over load and short circuit
protection.
 The following type of relays are provided for control and protection of
the generator:

1) Reverse power relay.

2) Voltage control inverse time over current relay.
3) Field failure relay.
4) Differential protection relay.
5) Earth fault relay.
6) Generator voltage sensing relay.
7) Under frequency relay.
8) Over frequency relay.
9) Master trip relay.
10) Engine starting relay.
DRG 202A
 Air Compressor

The function of a compressor is to compress a gas and carry it to the user

through piping.

Vacuum Pumps:

Compressors which operated with an intake pressure below atmospheric and

a discharge pressure which is atmospheric or slightly higher are called
vacuum pump.

Parameters:

The main parameters characterising the performance of a compressor are:

1) volumetric capacity – Quantity of gas moved by machine under

suction condition (Normally standard condition
i.e. at T = 273 K and H = 760 mm of Hg.).

2) Initial or intake and final or discharge pressure.

OR

Compression Ratio: Ratio of discharge pressure to the intake

pressure.

3) Rotative speed.
 4) Compressor shaft power (H.P.)

Classification : The compressors may be classified by the principle of

operation.

1) Positive displacement type

2) Dynamic type
3) Jet type

Positive displacement type compressors are divided into:

1) Reciprocating
2) Rotary
Dynamic Compressors are divided into:

1) Centrifugal
2) Axial

Reciprocating Compressor:

The process phases of expansion, suction, compression and discharge are

accomplished by the reciprocating motion of a piston. The reciprocating
compressor principle of operation based on displacing a gas by the piston
makes it possible to build units of small piston diameter and stroke that
develop high pressures of relative low capacities.
Rotary Compressors:

As rotor rotates gas is trapped in the space between vanes and conducted
from suction to discharge nozzle to be then discharged.

Centrifugal Compressors:

Energy from the shaft is transferred to the gas flow through a impeller. The
gas is rotated about centre at angular velocity. The resulting centrifugal
forces move the gas towards the periphery and throw it into the passages
surrounding the impeller. Thus its kinetic energy is converted into potential
energy through diffusion vanes.

Compression may take through three basic equation:

1) Polytropic process : PVn = constant

2) Adiabatric process : PVk = constant

3) Isothermal process : PV = constant

Reciprocating Compressors:

Indicator diagram:

Compression ratio = P2/P1

Volumentric ratio = Vs/Vdis Vs = Suction volume

Vdis = Displaced volume

By increasing compression ratio capacity is reduced, power is increased.

Capacity Controls:

a) Speed Regulation
b) Suction throttling
c) Holding the inlet valve open
d) Clearance variation

Construction:

Cylinders - Normally cast iron may be fabricated from steel

casting or forging for higher pressure.

Piston - Cast Iron or Steel.

Stuffing box - Cast iron.

Packings - Graphite – impregnated cotton or asbestos,

Graphite impregnated wire inserted braided

Asbestos

Tappered split cast iron rings.

Checks Before Starting a New or Repaired Compressor:

1) Lubrication system.
2) Crank compressor by hand until all parts get lubricated.
3) Tighten all nuts and bolts.
4) Check for all cooling water leaks and circulation.
5) Check for any discharge line blockage or closed valve or check valve
and safety valve.
6) Pump the motor and let it come to rest.
7) If no abnormality is found run the compressor atleast two hours at no
load and then gradually apply load and minimum period repaired for
full load should be taken as 4 hrs.

Oil Quality:

Oil should be low carbon and sulpher content and contain an oxidation
inhibitor.

Jacket Cooling Water Temp. :

A good rule is to hold the outlet temp. of water between 120 and 130oF.
This range will allow for good cooling and lubrication and also keep
condensate in the cylinder to a minimum.

How to locate valve trouble:

1) Low net air delivery

2) Heating around the valve compartment
3) If the suction valves are leaking blow back sound can be heard in the
air cleaner when the compressor is operating at full load.
4) In two stage – Inter cooler pressure can be utilised to guide to locate
defective valve.

Low pressure - LP side valve defective.

High pressure - HP side valve defective.

Note: When valve disc or plate wears to less than ½ its original thickness
it should be replaced.
Problems And Checks:

1) Low Oil Pressure :

a) Low oil level

b) Plugged oil pump strainer
c) Leaks in suction or pressure line
d) Worn out bearings
e) Defective oil pump
f) Dirty oil filters.
g) Oil pressure bypass leak.

2) High Oil Pressure:

a) Oil pressure line checked

b) Defective oil filter mechanism
c) Excessive spring tension on filter check valves
d) Excessive spring tension on oil pressure adjusting mechanism

3) Over heated low pressure cylinder:

a) Insufficient cooling water

b) Scored piston or cylinder
c) Broken valves or valve springs
d) Excessive carbon deposits
e) Packing too tight
f) In sufficient lubrication
g) Corroded or clogged cylinder water passage

4) Over heated H.P. cylinder:

a) In sufficient cooling water

 b) Scored piston or cylinder
c) Broken valves or valve springs
d) Excessive carbon deposits
e) In sufficient lubrication
f) Packing too tight
g) Corroded/clogged cylinder water passage

5) Water in cylinder:

a) Leaking head gasket

b) Cracked cylinder or head
c) Condensate caused by too much cooling water

6) High Inter cooler pressure :

a) Broken or leaking high pressure valves

b) Defective gauge
c) Defective or leaking valve seat gasket

7) Low Inter cooler pressure :

a) Broken or leaking low pressure valve

b) Leak in inter cooler
c) Piston rod packing leaking

8) Knocking Sound :

a) Excessive carbon deposits

b) Scored piston or cylinder
c) Defective lubricator
d) Foreign material in cylinder
e) Piston hitting cylinder head
f) Loose piston or piston pin, lock nut
g) Burned out/damaged crank rod bearings
h) Loose main bearings
i) Scored cross head or cross head guides
9) Scored cylinder, Liner or Piston :

a) Foreign material
b) Dirty or in-sufficient air cleaning
c) Lack of lubrication
d) Too much end too cold cooling water causing excessive
condensate due to which excessive corrosion or washing out of
lubricant
e) Excessive heat
f) Plugged water jacket cooling line

10) Broken Valves and Springs:

a) Too much condensate causing rust

b) Carbon deposits
c) Foreign material not removed by air cleaner
d) Incorrect assembly
e) Acid condition prevailing at location of suction air inlet.

11) Control Trouble:

a) Suction valve un-loader stuck open or closed

b) Pressure switch defective
c) Solenoid burnt oil
d) Foreign material inside valve
e) Vibration of control
f) Voltage drop or loss of power
g) Plugged/damaged air line/strainer
h) Incorrect voltage or cycle
12) Incorrect operation of suction valve un-loader:

a) Leak in un-loader line

b) Foreign material in guides or seat
c) Worn plunger
d) Leaking or ruptured diaphragms
e) Broken springs
f) Manual shut off partly/fully closed
g) Wrong pressure switch setting
Basic Electricity

Electron Theory:

1) This basis of our understanding of electricity is the electron theory.

This theory states that all matter, that is, every thing that occupies
space and has weight, is composed of tiny invisible units called atoms.
Atoms in turn are subdivided into still smaller particles called protons,
neutrons and electrons. The protons and neutrons make up the central
core, or nucleus, of the atom, while the electrons spin around this
central core in orbits.

2) The protons and electrons are charged with small amounts of

electricity. The proton always has a positive charge of electricity on it,
while the electron has a small negative charge of electricity on it. The
magnitude of the total positive charge is equal in amount to the sum of
all the negative charges on all the electrons. The neutron has no
charge on it; either positive or negative, and is therefore neutral and
hence called neutron.

3) Atoms differ from one another in the number of electrons encircling

the nucleus. Some atoms have as many as 100 electrons spinning
around the nucleus in different orbits. The atom of hydrogen gas has
only 1 electron.

4) Positive and negative charges of electricity attract each other i.e.

protons attract electrons. But, the atom does not collapse owing to this
attraction. The spinning of the electron around the nucleus causes a
centrifugal force that just balances the force of attraction and thus
keep them apart. The electron when dissociated from the atom (as it
can be) is a purely electrical, nearly mass-less minute particle. From
whatever atom they are derived all electrons are similar. The mass of
an electron is m = 9 x 10-23 gm. The mass of proton is 1.63 x 10-24 gm.
And the neutron has the same mass as that of proton.
5) The “atomic weight”, A is the total number of protons and neutrons in
the nucleus. If there are Z protons, there will be A-Z neutrons; Z is the
atomic number. The forces that keep the protons together against their
mutual repulsion are conjectural.

Electric Current:

6) The electrons in the outermost orbit of an atom are usually not surely bound to the nucleus and
therefore may fly off that atom and move into an outer orbit of another atom. These relatively free
electrons normally move at random in all directions.

However, when an electrical pressure (voltage) is applied across a

length of wire, the free electrons in the wire give up their random
motion and move or flow in one general direction. This flow of free
electrons in one general direction is called an electric current or
simply current.

Basic Concept of Electric Circuit:

7) A simple way of understanding how an electric circuit works is by the

hydraulic analogy. Imagine a reservoir full of water from which a pipe
connection is taken and terminated on a water tap. When the tap is
closed no water flows, but, the pipe is subjected to the full pressure.
This water pressure corresponds to the potential difference of the
electrical circuit and amount of water flowing in the tap corresponds
to the electric current. The obstruction caused to the flow of water by
opening in the tap represents the resistance. The smaller the opening
(the smaller the diameter of the wire) the greater will be the
resistance. If the tap is closed, it corresponds to the open circuit
condition i.e. a break in the circuit when no electrical current flows.
Now, the pump which pumps water from the lower level to the higher
reservoir corresponds to the battery or generator which produces and
maintains the potential difference of voltage. All these fundamental
units are related to each other.

8) E.M.F.:- In the electric circuit the generator does not create electricity;
the generator merely produces an electrical pressure that causes
 electricity to flow. If there is no electrical pressure no current will
flow. This pressure is called Electro Motive Force (EMF).

9) The Volt:- To measure the strength of the electric pressure, it is

necessary to know a unit that unit is the volt.

10) The Ampere: - The ampere is the unit of electric current. We can
express how much electricity is flowing in a wire by saying it in
Amps say 25 amps.

11) Resistance: - The electricity can travel with less difficulty through
some metals than through others. It travels easily through copper,
therefore copper wire is widely used. Copper is therefore called a
good conductor. Any substance that offers little resistance to the flow
of electricity is called a “good conductor”. Hence resistance is the
opposition offered by any substance to the flow of electricity. A “Poor
conductor” is the one which offers high resistance to the flow of
current; whereas an insulator is a “bad conductor”, which practically
does not allow any current to flow through it. Hence, this is used as a
covering for electrical conductors, so that, the current will not flow
away from its path. In an electric conductor, the resistance a
conductor offers to the flow of current will depend on its length and
its thickness or diameter. If the wire is very long, more friction must
be overcome than if it is short; if it is also of small cross section, it
will take still more effort to crowd the current through the wire.

12) The Ohm :- The unit of resistance of wire is Ohm.

Ohm’s Law

13) From the foregoing, it is clear that resistance will reduce the amount
of current that will flow. The number of amperes that will flow in a
circuit will therefore not be determined wholly by the voltage or
pressure which causes the current to flow but, also by the amount of
friction or resistance in the wires. Thus, with a given voltage the
greater the resistance of a circuit, the smaller the current will be that
flows, and the smaller the resistance, the greater the current will be.
This general relation between voltage, current and resistance is
 commonly called “Ohm’s Law”. It is a law because it has been found
to hold in every case. It is written thus :

Current = Voltage or Amperes = Volt

Resistance Ohms

Or Ohms = Volts

Amp.

The law as stated above applies only to direct current circuits, that is,
a circuit in which the current continuously flows in one direction in the wire.
Electric Power:

14) Power is the rate of doing work. The amount of power delivered by an
electric circuit to an electric load (say motor) depend upon the number
of amperes flowing and the number of volts of pressure. The greater
the current the greater will be the amount of power developed by it,
and the greater the pressure the more effect will be current have, the
actual value of power in a direct current circuit (not true for an
alternating current circuit) is equal to the product of volts times
amperes, thus

Power = Volts x Amperes

15) The Watts:

The unit of power in an electric circuit is the watt. An ordinary

electric lamp when connected to an electric circuit will draw about say
150 watts from the circuit. When the applied voltage is 150 volt the
current flowing in the lamp circuit will be 1 amp.

16) To measure the current in a circuit, the ammeter is used, the ammeter

connected in series with the circuit. To be sure the voltage a voltmeter

is made use and connected across the supply. To measure power, a
wattmeter can be used.

Electric Energy:

17) The electric energy depends upon power and time. In order that
electricity may do useful work, it must act for a period of time. The
power expressed in watts tells how much electricity is working, and
the hours express the time during which it acts.
 The product of these two factors gives the amount of work done.

Thus

Power x Time = Energy

Watts x hours = Watt hours

The total amount of electrical energy consumed over a period of time,

such as a day or month or year, is indicated by a watt hour meter. The
common house meter is an energy motor read in kilo watt hour.

18) Assignment:

a) How many protons are there in a gram of Uranium 238 ?

b) Find current, energy expanded in a circuit containing a lamp of
100 watts remaining on for 6 hrs.

Kind of circuits:

19) Series :-

An electrical circuit can be arranged in several ways, just so the path

for the electric current is closed. The simplest arrangement is the so-
called series circuit. In the series circuit all the elements of the circuit
are connected onto each other. The same current from the battery
flows through all the lamps. If for any reason one of the lamps burns
out, all the lamps will go out because the circuit is no longer closed.

20) Parallel :
 Another arrangement is the so-called parallel or multiple connection.
Instead of all the lamps being connected onto each other and then on
to the battery, each lamp is individually connected across the battery.
The lamps are now said to be in parallel with each other. If any given
lamp burns out in such an arrangement, the remaining lamps will
continue to burn, as the path for the current through each of them is
still closed.

21) Series Parallel :

A third arrangement is a combination of the series and the parallel

circuit. In such a circuit, part of the circuit is in series and part in
parallel. In the series part all the current flows through each element,
and in the parallel part the current divides and only a portion of the
current flows through each of the parallel paths.

22) When two or more resistances are connected in series, the equivalent resistance of the combination
is equal to the sum of the resistances of the individual resistors or

R = r1 + r2 + r3 + .................

The equivalent resistance R of a parallel combination of resistors is determined from the relation

1 + 1 + 1 + 1 + ...........
R r1 r2 r3

When two resistances are connected in parallel it can be written as

R = r1 r2
r1 + r1
23) Series Parallel Circuit :

Some of the resistances are in series, some in parallel, and it is required to find the equivalent
resistance between A and B, the problem is solved step by step, by combining the resistances in
series and adding them with other series resistances. Begin by combining the resistance V2 and
V3 into one. Then find the combined resistance of r4 and the above resistance. Then add upto r1,
which gives the total resistance.
24) Assignment :

a) Show the arrangement of the following lamps in a 240V supply system.

120V 240W Qty 4

240V 480W Qty 2

b) Find the equivalent resistance across A & B and find the total current taken by the system.

Faraday’s Laws of Electromagnetic Induction:

25) (a) An electromotive force is generated in a circuit when there is a change of magnetic flow threading
or linked with the circuit.

(b) The magnitude of the induced emf is equal to the rate of change of flux N.

i.e. emf = - dN
dt

26) Lenz’s Law :

The direction of induced current in a circuit is such as to oppose the cause producing it.

Kirchoff’s Law:

27) (a) The algebraic sum of the current toward any junction point is zero.

i.e. The current going towards a junction must be equal to the current going away from the junction.

(b) The algebraic sum of the voltages around any closed path in the net work zero.

i.e. The sum of the product of current and resistance must be equal to the applied voltage in a closed
circuit.

Joule’s Law:

28) The heat produced in a conductor is proportional to the square of the current passing through the conductor,
the resistance of the conductor and the time for which the current is passing.
 i.e. H α I2 Rt.

If r is the resistance between two points of a conductor carrying current i.e. the p.d. between them
and t seconds the time for which the current flows, the work done is given by

W = eit = Eit x 107 ergs.

Where E is expressed in volts and I in amperes.

If this work appears as heat H we have

W = JH = Eit x 107
 Where J is the mechanical equivalent of heat. Substituting
J = 4.2 x 107 ergs/caloris, we have

H = EIT = I2 Rt/4.2

This equation is known as the Joule’s Law.

29) The practical unit of electrical energy is one Joule. Thus 1 joule = 1 volt x coulamb. One coulamb is the
quantity of electricity passed through a conductor when 1 amp. Flows for a second.

Hence 1 joule = 1 volt x 1 amp x 1 sec. = 107 ergs.

But, 1 volt x 1 amp = 1 watt.
So, 1 joule = 1 watt x 1 sec.
= 1 watt x sec.
Or 1 watt = 1 joule per sec.
Hence, H = I2 Rt/4.2 calorie.
Or H = I2 Rt/joules in terms of electrical unit.

Faraday’s Law of electrolysis :

30) (a) The mass of any substance liberated is proportional to the product of current and the time for which
it passes, that is, to the total quantity of electricity which has passed.

(b) The masses of different substances liberated by the passage of the same quantity of electricity are
proportional to their chemical equivalents (atomic weight divided by valency)

M α I t (first law)

M α n (second law)

M = kn I t = Z I t.

Where m is the mass liberated, I current, t the time n the chemical equivalent, k a constant and Z the electro
chemical equivalent.
 Portable Fire Extinguishers

1) Soda Acid Extinguishers :

This extinguisher consists of a cylindrical or conical container made

of steel or copper (14 gauge steel or 10 gauge copper for 2 gall. Type) lined
with lead. This type of fire extinguisher is most suitable first-aid protection
for free burning or carbonaceous substances. It is most effective in cooling
down to below the point of ignition, fires involving wood, paper, fabrics,
coal and similar other materials. The various designs may be broadly divided
into “upright” and “turn over” types. The method of operation may either be
(a) driving in a plunger or a concussion device, (b) or driving in a plunger
and then turning upside down. These extinguishers are available in various
designs and sizes, but the most widely accepted ones are the two gallons
type. The charge of the extinguisher is consisted of sulfuric acid and solution
of sodium bicarbonate, the standard proportions of which are 1 ½ to 2 ½
ounces of sulfuric acid and ½ to ¾ lbs. Of sodium bicarbonate, for each
gallon. The sulfuric acid may be in tubes or bottles either hermetically sealed
of fitted with a loose lead stopper. To get the best result only concentrated
acid should be used.

If the extinguisher is provided with a discharge tube, it is an upright

type; or an inverted or turn over type if otherwise, fitted with brackets at top
& bottom. A two gallon type extinguisher, is charged as follows. A little less
than two gallons of water, mixed in it approximately 16 to 20 oz. of
sodabicarb, poured inside the main body of the extinguisher. 5 ounce of
sulfuric acid in tube or bottle held inside a cage at the top. To operate, follow
carefully the instructions written on the body of the extinguisher to
determine if it is inverted or upright type one. When the extinguisher is
brought into action mixing up acid with the alkali, carbon dioxide gas is
generated and some sodium sulphate. This carbon dioxide gas provides the
pressure to throw a 30 ft. to 35 ft. jet. It should be noted that for fire fighting
purposes the resultant jet is mainly water. The sulphate of soda takes no
 appreciable part in the extinguishing of fire. The nozzle diameter of this type
of extinguishers varies from ½” to 1/12”. The body of the extinguisher is
tested every two years by the manufactures, under a hydraulic pressure of
350 lbs. per sq. inch for atleast 2 ½ minutes.

Testing of the extinguishers at station level comprises the following points:

1) Take off the acid jar, stir the solution of water and soda bicarb with a
clean stick, put it in a clean bucket and see if the lead lining is alright
and that no rust is there, refill it if satisfied, to be inspected every
month. See that vent holes & discharge nozzles are kept clean and
unobstructed.

2) In the case of extinguishers having sealed phials of acid, it should be

sufficient if 20% of the extinguishers are tested by discharge annually,
with the proviso that should any extinguisher fail in the test all should
there upon be tested by discharge. All other types are to be tested by
discharge annually.

2) Chemical Foam Type Extinguishers :

The chemical foam type extinguisher extinguish blazing oils and

spirits by the application of a smothering blanket of chemical foam. The
tough skin of the minute foam bubbles is charged with carbon dioxide gas
and the foam spreads freely over the surface of the blazing liquid excluding
the oxygen necessary to combustion and completely blanketing flames.
Foam with stands great heat and prevents re-ignition of surfaces already
covered. It is therefore more permanently effective than the application of an
inert gas.

Portable chemical foam extinguishers are the names of 2 gall. type.

These extinguishers are made of best sheet steel, coated internally with lead,
cylinderical in appearance and tested to withstand a pressure of 350 psi. The
appliance is composed of two chambers, and may be termed as inner and
outer containers. A partly channeled spindled passes through centre of the
cap, one end of which carries a sealing disc which closes the inner container,
the other end is enclosed in a bayonet jointed cover which engages with the
cap. The unlocking of this cover allows the spindle to rise causing a free way
between the channel and the nozzle. The charge is prepared of two solutions
one is acid and another an alkaline. The acid solution is poured into the inner
container and the alkaline in the outer.

The solution in the inner container is generally aluminium sulphate

(approx. 13%) dissolved in clean lukewarm water, while the outer container
houses a solution that contains sodium bicarbonate (8%), together with
stabilisers like, saponine, liquoric, Gum Tag, Turkey red oil. Aluminium
sulphate and soda bi arb produce foam, and seponine etc. add more foam and
make the foam sticky and stable. Capacity of the inner container is ¼ gallon
and the outer container 1 ¾ gallon, but, filling is done up to 1 ½ gallon.
Average production of foam is 1:9 that is a 2 gallon container will yield 18
gallons of foam. Throw 30 ft. to 35 ft. jet approximately at 40 to 50 lbs.
P.S.I. pressure. The jet is ejected by the pressure of carbon dioxide gas
generated by the mixing of acid and alkaline solutions.

Inspection at station level has to be done the following way; Stir up the outer
container with a clean stick and put the stick down stir up the inner container
with another stick and put down the stick on the other, watch the reaction of
formation of the foam. Then empty both the containers carefully into two
separate buckets, check the lining inside. If everything is satisfactory
assemble the extinguisher carefully and correctly and put it back to service
again. Extinguisher showing signs of corrosion and damage must be
condemned and replaced but not to be repaired or soldered in any case. Vent
holes in the cap, nozzles etc. should also be checked to keep clear of dust
metal polish etc.

Discharge Test:

Each foam extinguisher should be tested by discharge, once a year, this

period dates from the last occasion when the extinguisher was discharged,
 whether at a fire or for best purposes. When replacing the head cap it should
be tightly screwed to the container to form a gaslight joint.

Use & Limitations:

Use and limitations of foam extinguisher on various types of risks may be

briefly summarised as below:

1) Effective - On all flammable liquids Not miscible

with water e.g. Patrol, K.Oil, Mobile,
Grease, Kerosine, Paints, Benzene etc.

2) Not so effective and - a) Fire involving liquids which are not

desirable MISCIBLE with water e.g.
Alcohol, Glycerin etc. Fine spray of
water is ideal for such fires.
b) Free burning materials (although small
fires involving wood, paper etc. may be
extinguished by foam but it is highly
uneconomical).
3) Hazardous - a) Electrical risks.
b) Metals like sodium, Magnesium,
Aluminium etc.

3) Carbon Dioxide (CO2) :

It is a colourless gas which is one and half time heavier than air and is
charged within the extinguisher in the form of liquid, by application of
pressure and maintaining a temperature of 60oF. The liquid boils off to form
gas again, at a temperature much lower than normal, and this gas mixing
with the atmosphere surrounding the fire in a proportion of 19% to 29% of
air volume, inhibits the fire i.e. it extinguishes the fire by replacing some of
the oxygen in the air as it does not support combustion.
 The high velocity with which the gas is released and the sudden cooling
effect may in some instances play a part in the extinguishment, though
primarily it is considered to extinguish fires by blanketing effect. It is non-
conductor of electricity.

The extinguishers consists of two principal parts, a steel cylinder containing

the liquified gas charged at a pressure of 744 lbs. P.S.I. at 600oF and a
control valve. By turning on and of the control valve, the extinguisher is
operated and closed. In addition the extinguisher is also provided with a
pressure tube and a horn. The horn is designed to stop the entirement of air
with CO2 and to reduce the velocity to prevent it acting like a blow torch. Its
effective range is 5 to 7 ft. only.
Operation:

To be operated by pressing the trigger in case of squeeze grip type and

turning the valve in case of screw valve type with the horn swivelled over
the fire from as close as possible to the fire.

Charge:

Charge consists of CO2 in liquid form and can only be recharged by the
manufacturers and not at station level.

Caution :

CO2 is non-toxic, it is however an asphyxiating gas and heavy concentration

encountered can cause unconsciousness even death. Besides, the chance of
agitating the rate of breathing is there and that may account for inhalation of
other toxic fumes may be present at the fire ground.

Use & Limitations:

1) Effective - a) Being a non-residual type of
extinguishing media, CO2 is most
suitable for all costly & delicate free
burning materials, equipments, where
water damage is feared if soda-acid is
used.

b) It is also specially suitable for fires in

enclosed type motors and other
electrical apparatus-where C.T.C. or
similar other extinguisher may not be
reaching the fire.

c) For `A’ class fires in concealed or in

accessible spaces.

2) Not so effective - On flammable liquid fires excepting small spills.

Flammable liquid fires an be attacked with CO2 in the absence of foam,
provided simultaneous attack is made from two sides.

3) Hazardous - Magnesium & similar metallic fires.

Its main disadvantages are (a) Comparative heavy weight (b) no visible
check of contents (c) short range (d) unsuitable for use in the open.

Standard Test:

CO2 extinguishers should be tested by weighing annually. The weight

shown by the test should be compared with that stamped on the extinguisher
and a loss exceeding 10% of the contents should be sent to the manufacturer
for recharging.
4) Dry Chemical Powder Extinguisher :

Precisely known as dry chemical extinguisher, used a charge of dry chemical

power, milky white in appearances, to extinguish the fire by blanketing it off
the supply of oxygen. The powder is specially tested to avoid abrasion whilst
on movement, corrosion and saturation whilst on storage. Since it
extinguishes the fire by blanketing with dry powder it has no cooling effect.

Dry powder is very effective for fires that mostly react with water and CO2.

The extinguisher is cylindrical in appearance made of solid drawn steel and

is composed of two chambers. The extinguisher and its components are all
painted in anti-corrosive internally and externally, operating head and
plunger are in stainless steel. Usually provided with a small length of high
pressure hose terminating in a squeeze grip type nozzle attached by a swivel
connection. The extinguisher most commonly visible in 7 to 25 lbs. sizes,
wheeled units of 50 lbs. and 150 lbs. capacity are also available.

Charge:

The charge constitutes of dry powder with a sodium bicarbonate base poured
in outer container. A CO2 cartridge is placed inside the inner container
which is screwed on to the inner side of the cap assembly with the sealing
disc. The interior shape of the extinguisher is so designed that CO2 expels
practically 98% of the contents. It is to be kept on the ground, and the
discharge tube held by the hand. When the fire has been extinguished, the
cylinder to be turned upside down, so that only CO2 gas goes out.

Operation:

1) Remove safety clip.

2) Depress the plunger.
3) Withdraw nozzle from rubber cap & press the squeeze grip.
4) Direct the dry powder to the base of the flame with a fast sweeping
movement.

It is important not to stand too close to the fire as the efficiency of this
extinguisher is then reduced.

Recommendations:

Dry chemical may be used as an alternative to vaporising liquids and CO2

for electrical risks-particularly where toxic factors are important.

OR

The extinguishers may be used for class `B’ and `C’ fires and in premises
where these risks are present. It is an exclusive recommendation for the fires
involving metals.

Caution:

Since the extinguisher has no cooling effect, on the contrary the initial effect
will be to raise the temperature, specific care should be taken to use it at
fires where life is involves in confinement. This extinguisher for the same
reason of non-cooling effect is not safe for applying to fires of Class `A’.

Standard Test:

Dry powder will last indefinitely, notwithstanding vibration or moist

atmospheres. But, the CO2 gas cartridge has to be tested by weighing
annually, loss exceeding more than 10% should be sent for recovery.
Liquid Fire Protection System

The system is provided for protection of equipment and personnel in the

areas of hazard.

System consists of Jocky fire pump installed on raw water storage tank (T-5)
which is a vertical single stage pump with 50 gpm (190 LPM) flow and developing
100 psig. (6.8 Kg/cm2) pressure. The system is designed to give minimum flow of
50 gpm (190 LPM) at 12 psig. (0.81 Kg/cm2) at the highest point of supply. If this
demand is more than 50 gpm (190 LPM) then the selected sea water, screen wash
pump will start and supply the required water supply for the fire system.

The jockey fire pump discharges raw water from storage tank (T-5) (6,00000
gallon capacity) into the fire water system through the accumulator which permits
intermittent operation of the jockey fire pump (P-19). The accumulator (T-10) is
filled with water pumped from raw water storage tank by jockey fire pump to ¾ to
full and then compressed air is admitted to the accumulator (T-10) to keep the fire
system pipe line under constant pressure. This avoids the jockey fire pump
running continuously.

The system is designed to give 50 gpm (190 LPM) flow at minimum

pressure of 12 psig (0.81 Kg/cm2) at the highest point of supply. If the demand of
the water is more than 50 gpm, the sea water is drawn from the intake structure
through screen wash pump (1200 gpm, 100 psig) which serves as electric fire
pump. The electric fire pump is further backed up by the diesel fire pump (1000
gpm, 110 psig) which also draws sea water from intake structure.

Fire hydrants and hose compartments, each containing two length of 50 ft.
(15.38 M) of 2 ½” (6.35 cms) dia. fabric reinforced, rubber lined woven jacketed
hose and accessories, are located around the building areas and spaced 150’ to 200
feet apart (50 to 70 M apart). Inside the building, five hose cabinets are provided,
containing 75 ft. (23 M) long, 1 ½” dia (6.35 cms) with isolation valve, water
nozzle etc. at different strategic locations where water is best suited as the medium
for fire extinguishing.
 The transformer area (viz. X01/X04, X02/X05.X03A/X03B) is protected by
means of a “Deluge Valve” sprinkler system which gets actuated by Heat Actuated
Devices (HAD) which are situated around the periphery of the transformers, which
in event of a fire resulting in a rapid rise of heat would send an automatic release
signal to the control mechanism, thereby operating the “Deluge Valve” allowing
water to flow in the sprinkler loop. Two instrument vaults of each units (1A/1B
and 2A/2B) are protected by the wet sprinkler system which utilizes a number of
fusible sprinkles with a temperature rating of 165o F (75 o C). In event of fire in the
instrument vaults, the fusible inserts in the sprinkles will melt away, allowing the
water to be spread on the fire. During refueling outage or transformer outage
Sprinkler test is carried out to check the throughness of spray nozzles for
transformers.

The liquid fire protection system with raw water is also connected to sea
water as a alternate source of water supply through plant screen wash system.
There are two screen wash pump ( P-10B and P-10C) selected as a electric fire
pump by a selector switch on the local control pannel (C-34), with selected screen
wash pump on “Auto” position and second screen wash pump is on standby
position. In event of the jockey fire pump is not able to come up with the demand
of water requirement, the system header pressure will drop down from normal 90
psig. (6.12 Kg/cm2) pressure to 80 psig. (5.78 Kg/cm2) which will trip the pressure
switch PS-257 and there by give signal to start the designated electric fire pump
to start.

In addition to this signal, PS-257 tripping will isolate raw water section by
closing control valve CV-686 to prevent the flow of sea water in to hydro
pneumatic fresh water system. A non return valve is also provided as a positive
isolation. Also PS-257 tripping will give annunciation on the local panel (C-34) as
well as in the main control room. Running of electric fire pump will also be
annunciated in the main control room. Thirdly, tripping of PS-257 will isolate
screen wash system by closing control valve CV-257A and opening control valve
CV-257B for fire protection system. P-10A pump is supplied from 1MVA
Substation and it can be used during station blackout condition also.P-10A pump is
not having auto start facility as a fire pump however it can be started manually.
 In the event the electric fire pump does not start due to loss of AC power
supply and the fire system header pressure drops down further to 75 psig. (5.1
2
Kg/cm ) Diesel fire pump (1000 gpm/3785 lpm) will automatically start due to
tripping of PS-282 and supply sea water to fire protection system.
As the fire protection system is a critical from the stand point of plant and
personnel safety, monthly auto starting test of jocky fire pump is done by suitably
draining hydro pneumatic tank. Jockey fire pump ON and OFF time is also
monitored to asses the leak in the fire system piping. Diesel fire pump is tested
weekly. Quarterly functional checks are done for electric fire pump P-10B/C, PS-
257 actuation and auto actions, CV-257A/B and CV-686 operation.

Portable fire extinguishers of various types are provided throughout the plant
at suitable points. Carbon dioxide gas cylinders, soda acid water, foam type gas
cylinders, dry chemical powder fire extinguishers are provided at various locations
as per the fire load.
DRG 233A
Carbon Dioxide Fire Protection
CARDOX System
Purpose:

Carbon dioxide (CO2) fire protection system provides automatic control of fire for
the following areas/equipments.

a) Reactor recirculation pump motors of Unit# 1 and 2 inside the drywell.

b) Turbine lubes oil area of Unit # 1 and 2 for following equipments.

i) Tanks: Clean lube oil storage tank T-32, Dirty lube oil storage tank T-
33, turbine lube oil reservoir 1T-29 & 2T-29, lube oil conditioner S-
2.

ii) Local application nozzles on the lube oil reservoir top, protecting
pumps, filter and top of reservoir.

iii) Local application nozzles on lube oil filter pump and lube oil transfer
pump.

c) Emergency Diesel Generators:

The above mentioned areas/equipments are protected by a combination of

“Total flooding” and “Local Application” method. CO2 gas is used as it is
fast, efficient and harmless to the equipment and non-conductor of
electricity.
Reactor Recirculation Pump Cardox System:

The system consists of two cylinder banks. One main bank and another
reserve bank. Each bank consists of 7 nos. of bank cylinders and 2 nos. of pilot
cylinders each of 75 lbs capacity. System is having one common control cylinder
with PRV. PRV down stream pressure is maintained at 300 psig. System is
common for both the recirc pumps.

Control cylinder CO2 is pressurized upto solenoid valves. There are two
temperature switches for detection of fire for each pump which actuates at a
temp. of 225o F (107.2oC). The system is located in valve penetration room
adjacent to RK01/RK11. Actuation of a temperature switch causes solenoid valve
to energise and release CO2 gas for opening of shuttle valves and pilot selector
valves. Pilot cylinders are having actuator heads on the cylinders. These cylinders
are fired by the control CO2 and the gas from pilot cylinder is discharged in main
header. This pressure helps to fire cylinders connected to the main header. The gas
discharged by all the nine cylinders is directed through selector pilot valves
towards the affected pump for extinguishing fire. CO2 control header is provided
with one pressure switch which gives alarm in control room as well as sounds
header inside and outside drywell at 125 R.B. There is a selection switch for
selecting main or reserve bank for each pump. System control power supply is
from 250V DC. Two minutes of time delay is provided for the people to vacate the
area. The system is having three modes of actuation.

1. Automatic System actuation: System is normally kept in this mode. Fire is

detected by temperature switches. When temperature switch actuates it
energizes corresponding SV depending on bank selected for the pump.
Control CO2 is released to actuate pilot cylinders & open pilot selector
valves. Pilot cylinders get fire & in turn fire selected bank cylinders.

2. Remote Manual actuation: When fire is detected and confirmed for a

particular pump and if system did not actuate on auto it can be actuated from
manual control station. There is manual actuation station provided for each
pump at R.B.125’.
2. Manual actuation: The system is having provision for actuating even in case
of loss of Control power supply .Confirm first which is the affected pump
and which is the available bank. Open pilot selector valve of the
corresponding pump by its hand wheel and actuate both the pilot cylinders
of the available bank by their handwheels. This actuates both the pilot
cylinders and subsequently bank cylinders.

Lube oil area Cordox System

The system consists of two cylinders bank of 17 cylinders each of 75 lbs.

capacity. One bank is main bank and another is stand by bank. Each bank consists
of 17 nos. of CO2 cylinders, one N2 Auxiliary control cylinder and a common N2
control cylinder with PRV. Under normal conditions control N2 pressure is
Mainted at 300 psig. upto solenoid valve. There are six temp. switches for
detection of fire which actuates at a temp of 200oF (93.32). The system is located
near chiller area.

Actuation of a temperature switch causes solenoid valve to energise and

release N2 gas into control header for opening actuator valve and directional valve.
The cylinder in the banks are having two connections one for control gas and
another for discharge header. The N2 gas in control header actuates cylinders
connected in the main or reserve bank depending and selection of bank. The
cylinders get fired and the CO2 gas from all the 17 cylinders is directed towards
lube oil area to extinguish fire.

When gas enters control header it actuates pressure switch which gives
alarm in control room. The PS trips running makeup area supply and exhaust from
V4 A/B and V5A/B. The PS also trips 1K5, K5 & 2K5 vapour extractors. It will
also sound hooters in lube oil and make up demin. area.

Two minutes of time delay is provided since the activation of system to

discharge of gas to allow the peoples to vacate the area. The system is having three
modes of operation.

1. Automatic System actuation: System is normally kept in this mode. Fire is

detected by the temperature switches. When temperature switch activates it
 energizes solenoid value. The control gas is directed to operate activator
valve & directives valves. The fuel gas fire the bank cylinders & the CO2 is
directed towards lube oil area.

2. Remote manual actuation: When fire is detected & confirmed in the area &
if system did not activate is auto it can be activated from manual activation
station in lube oil area.

3. Manual actuation: The system is having provision for actuating even in case
of loss of Control Power Supply. Confirm first which is the selected bank.
Open the directional valve by its hand wheel and open

manual by-pass valve of pneumatic discharge delay. Open the ball valve in
the discharge of auxiliary N2 cylinder valve and operate auxiliary N2
cylinder valve. This will cause actuation of selected bank cylinders. Both the
Cardox Systems are tested during refueling shutdown. Temperature switches
are actually heated upto required
temp. and system is actuated with one cylinder connected to a bank. This test
is called puff test.
EDG CORDOX System

The CO2 system consists of a bank of 29 cylinders in which one cylinder is a

master cylinder and 28 cylinders are slave .There are two cylinder banks, normally
one bank is selected and other one remains standby. Each CO2 cylinder is having
45 Kg of gas. The CO2 system comprises of a bank of cylinders, each connected to
a release manifold via discharge hoses. In order to enable the removal of a
particular cylinder, a check valve is provided in between discharge hose and
manifold. Check valve is normally closed and can open only in the direction of
flow.

The system is common for EDG G2A, G2B and G2C. The manifold is
equipped with normally closed directional valves, which are actuated
pneumatically. For operation of directional valves separate N2 pilot cylinders are
provided. In between N2 pilot cylinder and directional valve Solenoid valve is
provided to achieve proper activation of directional valve for the hazard under fire.
The directional valve valve when opened will release CO2 gas into the protected
area. In addition to that directional valve can be opened manually.

In cylinder bank those cylinder which are provided with release unit which
comprises of Electric actuating device and manual override is termed as Master
cylinder. Other remaining cylinders, which are not fitted with electric and manual
actuators, are termed as slave cylinders. The system is capable of electric and
manual activation and can be released by one or more of the following methods.

AUTOMATIC RELEASE

Automatic release is accomplished via detectors installed in the protected

area (detectors are installed and programmed on cross zone principle to avoid
accidental release of gas due to malfunction/false alarm).

As soon as fire is detected from both the detectors (i.e. one Ionization smoke
detector and Photo electric smoke detector), signal is sent to the Fire alarm and
CO2 release panel.

After a specified time delay of 2 minutes, energizes the solenoid valve

located on the CO2 cylinder valve assembly. Simultaneously, respective solenoid
valve on the piping between N2 cylinder is energized and directional valve is
opened pneumatically.

MANUAL REMOTE RELEASE (BREAK GLASS TYPE)

Remote release is accompanied by breaking glass and pressing the push

button at a “Manual Release Push Button Station” located outside the G2A/B/C
room. Once the button has been pressed, the system will be released as described
above.
MANUAL EMERGENCY RELEASE

In the unlikely event of power failure, the system can be actuated manually.
One N2 auxiliary cylinder is provided with additional valve to actuate master
cylinder and slave cylinders of both the banks by actuating N2 auxiliary cylinder
and opening discharge valve the system can be actuated. Required directional
Control valve shall be opened manually.

DETECTION OF FIRE

Each of the areas covered under CO2 Protection system is divided into two
fire detection zones. Each of the detection zones will have any one type of smoke
detectors (ISD or PSD) and one UV detector in the loop. In the event of fire in any
of the three areas the Ionization /Photoelectric/ Ultraviolet detector in its vicinity
will sense it and give signal to the fire alarm cum CO2 Control panel. If the panel
receives signal from both the zones in an area (i.e. if cross zoning of signal takes
place), the panel treats it as a certain “Fire” condition, gives alarm and actuates fire
protection system. In case CO2 flooding is required to be stopped before it is
initiated, the same can be done by pressing the Abort switch, installed at the
entrance of DG room.
DRG 233B
DRG 233C
DRG 233D
 Protective Coating & Colour Codes

1.5.1 Equipment Item:

Stationary Equipment Colour

Turbine-Generators Aircraft Grey (693) or ASA 61 grey.

Pumps - do –

Motors Control Centers - do –

Transformers - do –

Tanks & Heat Exchangers - do –

Emergency Diesel Generators - do –

Machine Tools - do –

Specification No. M-35-183 Rev.0

1.5.2 Moving Equipment Colour

Overhead Cranes Light Orange (557)

Gantry Cranes - do –

Chain hoists & trolleys - do –

Hooks - do –

Conveyors - do –

Cutting or Crushing hazards - do –

Control handles & levers on all machinery - do –

Exposed gears & pulleys - do –

Fire fighting equipment Signal Red (537)

First Aid equipment Brilliant Green (221)

2.5 Colour Code for piping:

Identification
Piping Description of System Overall Colour
System Band colour & No.

551 Primary Steam Aluminium Single band of red (538)

552 Secondary Steam Aluminium Double band of red (538)

553 Primary feed water Sky blue (101) Single band of white
554 Secondary feed water Sky blue (101) Double band of white

Feed pump recirc. to main

555 Sky blue (101) Single band of white
condenser

Turbine steam bypass to

556 Aluminium Single band of red (538)
condenser.

Secondary steam generator

557 Sky blue (101) Double band of red (538)
blowdown

558 Turbine extraction steam Aluminium Double band of red (538)

559 Condensate Sky blue (101) No bands

560 Off Gas piping White Single band of Yellow (309)

564 Turbine gland seal piping Aluminium Single band of red (538)

566 Lube oil Light brown Single band of white

567 Hydrogen White Single band of red (537)

Reactor building cooling Single band of verdigris green

568 French blue (166)
water (280)

568 Chilled water Grass green (218) Single band of white

Condenser recirc. water Oriental blue (174) No bands

569 Demineralised water French blue (166) No bands

570 French untreated water Grass green (218) No bands

 (Raw water)

Single band of Canary Yellow

570 Chlorinated domestic water Grass green (218)
(309)

571 Salt Service Water Oriental blue (174) Single band of white

Travelling water screen

572 Oriental blue (174) Single band of white
wash system

573 Service Air White No bands

573 Instrument Air White Single band of state (634)

575 Diesel Fuel Oil Light brown (410) No bands

Discharge piping from Colour code and bands same as the process piping
576
Misc. Relief Valves on which the Relief Valves are located

577 Chlorine System Yellow(309) No bands

 Identification
Piping Description of System Overall
System Colour Band colour & No.

578 Acid Light purple brown (449) No bands

578 Caustic Light salmon pink (442) No bands

Single band of golden brown

579 Carbon dioxide White
(414)

580 Fire water system Red (537) No bands

581 Uncontaminated drain Black No bands

581 Clean Radwaste Black Single band of white

581 Dirty Radwaste Black Double band of white

581 Oily Waste drain Black Single band of brown (410)

581 Decontamination drain Black Single band of yellow (309)

581 Liquid Radwaste CRW-Black Single band of white

Process piping CRW-Black Double band of white

Single band of traffic yellow

583 Control rod hydraulic French blue (166)
(368)

Control rod drive Double band of traffic yellow

583-A French blue (166)
hydraulic supply (368)

584 Reactor recirc. water French blue (166) Single band of crismon (540)

585 Liquid poison system Red (538) No bands

Emergency steam and

586 Aluminium Single band of red (538)
condensate piping

587 Reactor Cleanup French blue (166) Double band of crimson (540)

Suppression chamber Single band of light

French blue (166)
cooling bronze green (222)

588 Reactor shutdown French blue (166) Single band of light bronze
 green (222)

Single band of dark stone

589 Fuel pool cooling French blue (166)
(363)

Double band of light buff

590 Core spray water French blue (166)
(358)

Double band of light buff

591 Post incident system French blue (166)
(358)

Reactor shield cooling Double band of light bronze

592 French blue (166)
water system green (222)

Emergency condenser
597 Salmon Pink (443) No bands
shell vent to roof

Auxiliary steam for

598 Aluminium No bands
Radwaste concentrator

Double band of dark stone

Resin transfer piping French blue (166)
(363)

Cleaning filter piping French blue (166) No bands

Note: The Specification numbers indicated against each colour stated above
refers to the colour numbers given in Indian Standards Institution
Publication No. IS 5-1961.

Ref: Extracts from the Report No.TAPS/TSS/Report/249

Refueling Operation

During a refueling outage, there are more than 1000 separate activities that
may be necessary to be carried out by different sections. In Mechanical
Maintenance Turbine Group may be attending to 300 jobs and Reactor Group to
200 jobs. Electrical Maintenance may be attending to 250 activities and Instrument
Maintenance to 150, Operation, Technical Services and Civil Maintenance to 200.
These numbers are only an order of magnitude but they clearly illustrate that a
large number of important operations are involved. An efficient and safe refueling
depends upon proper planning, preparation and execution.

Planning:

Months before each refueling outage, specific tasks are designated for each
section and a detailed schedule is made indicating critical path jobs, and activities
of each section and number of days required for each activity are also shown. With
each outage; as experience is gained, job sequences are refined to provide the
safest and most efficient method of performing the function. Planning also includes
pre-refueling equipment inspection and periodic checks of equipment during
operation. For example, refueling grapple is thoroughly checked before using it for
handling fuel bundles etc. and is checked periodically during its use.

Preparation:

Cutting down refueling outage is necessary, but speed alone is not the
primary objective. Safety is the first consideration as a single accident could result
in loss of considerable amount of time and man-rem. Efficient and safe operation
depends upon careful preparation before the start of the operation to be performed.

Execution:

Equipment operator is responsible for a safety and speed more than any
other single factor. He is trained and made thoroughly familiar with equipment, its
proper use, function and its limitations. Jobs are performed in a specified order and
with specified duties by organised teams of men with a leader.
 Work is stopped and inspection performed when equipment operators notice
any indication of malfunction. This is particularly important for equipment with
motor drives and hoists, such as CRD removal and installation tool or refueling
grapple. Operations are carried out in a planned way and in the specified sequence.

Refueling Works:

After opening generator breaker and performing turbine test such as

Governor low speed stop, high speed stop, Turbine over speed trip and backup
over speed trip, reactor is shutdown and cooled. During shutting down CRD
indication deficiencies are noted. While shutting down and cooling of reactor is in
progress, cavity shield blocks and drywell head are removed and cavity vent lines
are blinded. Initial reactor hydro is performed and leak inspection in drywell is
done. Rubber Bellow Seal in between Drywell and Reactor building is replaced.
Vessel head is unbolted, Cavity vent plugs are installed and manhole closed. Leaks
are checked by filling cavity upto 4 ft. and fixed, if found any. 5 studs are removed
and stud holes are plugged. Pressure piping is removed. Mirror insulation is
removed and vessel head thermocouples are disconnected and removed.
Condensing chamber is removed and line blind flanged. Vessel head is removed.
Dryer-separator is unbolted and inspected. It is slung to reactor building crane after
removing fuel pool pit plugs. Cavity is flooded and Dryer separator is removed.

When above cavity works are in progress IRM detectors are removed and
TIP tubes are disconnected. SRMs are connected in non-coincident mode scram.

Initial Core inspection is carried out after clarity improves and In-core
sipping is done to identify the failed fuel assemblies. The sipper head which
positions over the fuel cell isolate the four fuel bundles from the rest of core.
Continuous air flow in the sipper establishes and air pocket above the fuel that
blocks flow out of the channels and prevents water sample contamination and
cross-mixing from surrounding fuel channels. After 20 minutes of soaking time to
allow for fission products build up, water sample is withdrawn from each of the
fuel bundles and samples are analyzed in Chemical Lab. Samples from failed fuel
bundles will show higher activity.
 Fuel pool gates are removed after completing In-core sipping. Out of core
sipping is done for fuel bundles which due to any reason could not be sipped in the
core or suspect fuel bundles.

While out of core sipping is in progress replacement of control rod drive is

taken up. For the drive to be replaced the control rod is withdrawn to full out
position and uncoupled from the top and after verifying rod drive over travel
alarm, the drive is valve out. After completing removal and reinstallation of the
drive at CRD housing the drive is coupled to the control rod and coupling integrity
is checked many times by fully exercising the drive. Replacement of LPRMs and
control rods is carried out from 200 ft. elev. For LPRM replacement 7 fuel bundles
are unloaded and the spacer coming in the way of the LPRM tool rotation is
removed. Old LPRM is removed and stored in fuel pool and a new LPRM is
installed. For CRD removal, the cell is emptied and old blade removed and new
blade is installed.

Orifices are inspected and the displaced ones are seated properly or new
ones are installed. Now a days all fuel bundles are coming with welded loose
orifices. The peripheral fuel bundles locations are having adopter orifice as a
substitute for tight orifice.

New fuel bundles, after inspections are channeled with either new channels
or with irradiated channels with new channel fasteners. Approximately 100 nos. of
fresh fuel bundles are loaded in the core to take care of 18 months of refueling
cycle. The irradiated channels are inspected for any bulging out before using for
channeling a new bundle. Reshuffling of fuel bundles and loading of the core with
new fuel bundles is done using refueling grapple. All core work is done under
water standing on the refueling bridge.

Some of the tools used during refueling are:

1) CRD blade removal tool

2) LPRM tool
3) Romer’s tool
4) Erickson tool
5) Telescopic refueling grapple
6) J-hook
 Refueling interlock system is provided to prevent rod withdrawal when fuel
is being handled over a reactor and to prevent handling fuel over a reactor when
control rods are withdrawn. This interlock is provided to prevent withdrawal of
control rod from control room when fuel movement operation is on.

Fuel Hoist Fuel on Fuel on Fuel on

Not full up Aux. Hoist
Fuel hoist Aux. Hoist

Refueling Platform
Over Reactor No. 1

Block Rod withdrawal

Reactor No. 1

Fuel Hoist Fuel on Fuel on Fuel on

Not full Fuel hoist Aux. Hoist Aux. Hoist

Refueling Platform
Over Reactor No. 2

Block Rod withdrawal

Reactor No. 2
Rods out
Fuel on Fuel Hoist or Rods out
Reactor No. 1 Fuel Hoist not full up Reactor No. 2

Block fuel hoist power

Trolley Mounted Aux. Hoist

Fuel on Hoist

Rods out Rods out

Reactor No. 1 Reactor No. 2

Platform over Platform over

Reactor No. 1 Reactor No. 2

Block Hoist Power

Frame Mounted Aux. Hoist

Fuel on Hoist

Rods out Rods out

Reactor No. 1 Reactor No. 2

Platform over Platform over

Reactor No. 1 Reactor No. 2

Block Hoist Power

 Fuel on any Hoist or
Fuel Hoist not full up

Rods out Rods out

Reactor No. 1 Reactor No. 2

Platform approaching Platform approaching

Reactor No. 1 Reactor No. 1

Block platform travel in Block platform travel in

direction of reactor No. 1 direction of reactor No. 2
from fuel pools from fuel pools
 There is a “Jam” Interlock on the fuel hoist at 1000 lbs. to prevent damage in
case a fuel element is stuck in the core.

A “Slack Cable” interlock has also been provided on the fuel hoist.

After fully constituting the new core, core verification in the presence of
IAEA representatives by CCTV camera is done. Final works in the cavity are done
for installation of dryer separator, vessel head, drywell head and pit plugs etc. Then
the unit is started as per guidelines given by Reactor Physics .All the mandatory
tests are conducted and unit is synchronized to the grid. Further power raise is done
as per the guide lines given by Pre-Conditioning Interim Operation Management
Review recommendations up to full power.

During refueling outage Mechanical Maintenance–Turbine Group inspects

and repairs CW headers, Condenser tube leaks, feed water heaters, LCVs, Primary
feed pumps, Condensate pumps, Turbine compound control mechanism, Turbine
PCVs, bypass valves, Turbine lube oil system, hot well, area cooler fans etc.

Mechanical Maintenance – Reactor Group inspect and repair primary system

pipes and MOV’s, re-circulation pump seals, drywell sump pumps, re-
circulation MOVs, drywell cooler fans, condensate demineraliser CVs etc.
Electrical Maintenance inspects, repairs and perform annual maintenance of
AO buses, BO buses, MCCs, Load center transformers, Main/Auxiliary and Start
up transformers. Annual maintenance on Generator, exciter, amplidyne and
Reactor protection system relays etc.

Instrument Maintenance check and do annual maintenance of reactor

protection system instruments, CRD scram CVs, LCVs, reactor level and pressure
indicating instruments etc. Instrument Maintenance also do annual maintenance of
neutron monitoring instruments.

CRDs friction checks and scram checks are also performed.

Two units outage is availed and total loss of power test is conducted to
check the performance of diesel generators and associated switch gears as well as
the performance of EMTR’s and performance of Core spray and Post incident
system equipments is also done. Checks and inspection cum repairs of common
systems such as SSW, RBCW, TBCW etc. are done.
 Surveillance checks such as ISI of primary system piping, welding integrity
checks of critical equipment are done during refueling outage. Functional checks
such as manual scram push button, emergency condenser pipe way high
temperature switches, main steam line high temperature switches, poison system
squib valve firing and liquid poison sparger through ness, drywell cardox puff test,
core spray sparger through ness, drywell spray nozzles through ness tests, and
drywell sump pump performance checks etc. are also performed.
 Acid and Caustic System

Purpose of the system is to provide adequate supply of Sulphuric acid and

Sodium hydroxide (NaOH) for resins regeneration at Make up demineralizer
system and at regeneration facility. It also supplies acid/caustic to radwaste system
for neutralization of the liquid waste before its processing.

There are two storage tanks one for acid (T-34) and one for caustic (T-35)
each of about 22,100 liters capacity, located in front of Mechanical Workshop.
Concentrated Sulphuric acid (98% concentration) and concentrated caustic as
Sodium hydroxide (NaOH) (48% concentration) is received separately from the
outside suppliers in tanker and these tankers are unloaded in the respective storage
tanks. Received acid/caustic tanker samples are first analyzed and then only
tankers are unloaded in acid /caustic tanks.

On the acid storage tank acid transfer pumps (P-23A and P-23B) and on
caustic storage tank caustic transfer pumps (P-22A and P-22B) are provided. The
pumps are having selector switches near the pump. The pumps can be tested by
local push buttons provided near the pump. There are bubbler type level indicators
provided which indicate the level in centimeters. On the acid tank the vent line is
provided with silica gel breather to avoid ingress of moisture where as on caustic
line only vent line is provided. The pump capacity is 20 gpm. These pumps are
provided with minimum recirculation line for pump protection. On the discharge of
the acid and caustic pumps a filter is provided and down stream of the filter acid
and caustic is supplied at three places. A separate acid line is provided for Make up
demin. and regeneration facility from outside the building.

a) Regeneration facility with CV-AR2 for acid supply and

CV-CR2 for caustic supply.

b) For Makeup demineralizers, acid is supplied through CV-830 and

caustic is supplied through CV-828.

c) For chemical addition tank in radwaste building acid is supplied

through CV-831 (which is now blind flanged) and caustic is supplied
through CV-829.
 The interlocks are provided in operation of CVs such that acid/caustic
supply to regeneration facility is given priority. The acid/caustic CVs supplying to
radwaste or make-up demin. systems cannot be opened if acid/caustic CV
supplying regeneration facility is open. Further, CVs supplying acid/caustic to
radwaste and Makeup demin. systems cannot be opened simultaneously.

The selector switches for acid/caustic pumps are provided near pumps. The
pumps control switches are provided on regeneration facility control panel, Make-
up demin. control panel and radwaste control panel. The selected pump can be
started from Make-up demin. panel only if CV for makeup demin. system is open.
Similarly selected pump can be started from radwaste panel if CV for radwaste
system is open. There is no interlock for starting pump from regeneration facility
panel.

Acid and Caustic storage tank low level alarms are provided on regeneration
facility panel. Safety showers and eye washers are provided at acid/caustic storage
tanks area, Make demin. system area, radwaste system area and regeneration
facility area.

One separate pump is provided each for acid and caustic tanker unloading.
The tanker unloading is done by using these pumps only. While unloading tanker
sample is analyzed by chemist. All the safety precautions are taken while
unloading acid and caustic tanker.
DRG 246A
 Radioactive Waste Disposal

Purpose:

Three types of radioactive wastes i.e. Solid, Liquid and Gaseous wastes are
generated as a part of normal operation of the plant. The purpose of the radwaste
system is to collect process and dispose off the radioactive waste in an efficient
manner without limiting station operation and without exceeding prescribed limits
on release of radioactivity to environs.

Description:

1) Solid Radwaste System :

The solid waste generated consists of filter sludge, spent resins and assorted
waste. Filter sludge is received in sludge tanks in the form of slurry. The
slurry is processed by centrifuge to separate solids from liquid. The
separated solids collect in a 200 liters drum and the liquid is returned to
liquid radwaste system. Remote operated hoists and conveyor system is
provided to handle the drums containing radioactive solid waste. After a
drum gets full, it is capped remotely and then transferred to concrete cask for
transportion to burial ground. At burial ground the drums are disposed off in
underground concrete trenches.

Spent resin: Now-a-days spent resins are not processed but it is transferred
to large underground storage tank known as SPERT for temporary storage.
However, the facility of processing spent resins using centrifuge exists.

Assorted waste: Assorted waste arises from cotton rags, used filter
elements, used insulation, used pipes, active scrap and other miscellaneous
items. The assorted waste is straight way transferred to burial ground after
proper packing. A hydraulic press is provided to compress the bulky
assorted waste as required.
2) Liquid Waste:

The liquid radwaste arises from system leaks, isolation and draining of
equipments for maintenance jobs, equipment drains, regenerants of
demineralisers, decontamination centre and laundry drains etc. The liquid
wastes are classified depending on their chemical purity. The classification
of waste is shown below:

Liquid Radwaste

Low conductivity waste High conductivity waste

OR OR
Clean radwaste (CRW) Dirty Radwaste (DRW)

Sources High activity waste Sources

Equipment drains Sources
SSGs blow down i) Regeneration of resins All floor drains

Rinsing water from ii) Decant from

centrifuge Laundrywaste Laundry
waste

The treatment of individual waste stream is done as below. The processing is

done on a batch basis to ensure proper control.

CRW: All clean radwaste coming to CRW sumps at various locations in the plant
is pumped out to waste collector tank (T-38). The sump pumps are automatically
controlled by sump level switches.

The waste collector tank has been provided with a cooling coil to cool the water so
that it does not damage ion exchange resins while processing through
demineralizer.

The CRW is first passed through filter (F-4) to remove insoluble impurities and
then through demineralizer (T-51) to remove soluble impurities. The water thus
processed is collected in waste sample tank (T-50). After processing the water is
analyzed and transferred to condensate storage tanks for reuse.

DRW:

a) Low Active Waste :

All floor drains coming to DRW sumps at various locations in the plant is
pumped out to floor drain collector tank (T-46). The sump pumps are
automatically controlled by sump level switches.

The water from floor drain collector tank is neutralized to a pH of 9 to 10

and settled for 3 to 4 hrs. After settling the muck accumulated at tank bottom
is directly drained to filter sludge tank. The water is then processed through
a pressure pre-coat type filter (F-5) to one of the floor drain sample tanks.
(T-49A/B) to remove all the insoluble impurities. Precoat material used is
fine cellulose powder known as Solca-floc.

After processing of a batch is over the sample tank water is analyzed for
pH, radioactivity and is then transferred to TRAP (Tarapur Radwaste
Augmentation Plant) for further activity reduction by chemical processing
and decay. After providing maximum possible decay the water is discharged
to sea after analyzing the water through TAPS discharge line.

b) High Active Waste :

The high active waste is collected in waste neutralizer tanks (T-

48A/B). Before processing the waste is neutralized to a pH of 9 to 10 and
tank is allowed to settle for 3-4 hrs. After settling the muck accumulated at
tank bottom is directly drained to filter sludge tank.

The waste from (T-48A/B) is then passed through filter (F-5) to one of the
floor drain sample tanks (T-49A/B).After the processing of the batch is over
the tank is analyzed for radioactivity and transferred to TRAP. At TRAP, the
waste is processed using chemicals to remove long lived radioactive
nuclides. After providing maximum possible decay the water is discharged
to sea after analyzing the water through TAPS discharge line.
c) The Laundry Waste is discharged to sea without any processing.

The liquid waste is discharged into discharge canal of circulating water

system so that it is diluted by circulating water flow. The activity that can be
discharged is controlled by limit on radioactivity concentration in discharge
canal of circulating water system.

Gaseous Waste:

The basic source of the radioactive gases is the reactor. In the reactor, certain
gaseous activation products are continuously formed due to radiolysis of reactor
water. Also the reactor water undergoes some decomposition to form gaseous
hydrogen and oxygen. Some fission gases are also released in the reactor from
leaky fuel assemblies. The systems which handle gaseous waste are Air ejector off
gas system and gland seal system.

The non-condensible gases from the reactor pass through the steam lines to
the turbine and then to main condenser. A small fraction of gases leave the turbine
via gland seal system.

Air ejector off gas system:

The air ejector off gas system consists of hold up line of sufficient volume to
provide 30 minutes decay time between the air ejector and the plant stack.

A high efficiency particulate filter has been provided at the end of hold up
line to remove particulate decay products of fission gases. The particulate removal
efficiency of filter is 99.97% for 0.5 micron and larger size particulate. Two Off
Gas radiation monitors are provided to monitor the discharged gases. The Off gas
line is also designed for automatic isolation in case of high activity release.

Provision of automatic isolation exists in case of explosion in off gas holdup

line. As the off gas contains hydrogen and oxygen gases from decomposition of
water, the possibility of explosion exists.
 The piping of the system is designed to withstand the explosion. The non-
condensible gases from the condenser are extracted by air ejectors, passed through
30 min. hold up line and a particulate filter and then released to atmosphere
through a stack. The gaseous radioactivity is diluted with plant exhaust air before
release from the stack.

Gland Seal System:

The non condensible gases coming to turbine gland seal system are extracted
by gland seal exhauster, passed through a 1.75 min. hold up line and then released
to atmosphere through stack.

Permissible limits for release of radioactivity to environment:

Liquid: The annual average concentration of radioactivity in discharge canal shall

not exceed 1.5 x 10-7 uci/ml or 5.5 Bq/l.

Gases: The annual average release rate of radioactivity from station stack shall not
exceed 65 mci/sec.
DRG 251A
DRG 251B
DRG 251C
DRG 251D
DRG 251E
 Diesel Oil System
The purpose of this system is to store and supply sufficient diesel oil to meet
the requirements of three Emergency Diesel Generators, One Station Black Out
Diesel Generator and One Diesel Fire Pump. The diesel oil system consists of the
diesel oil storage tanks, diesel oil transfer pumps, three over head day tanks
associated with each emergency diesel generator, over head day tank for Station
Black out Diesel Generator, under ground day tank for diesel fire pump and the
necessary valves and instrumentation.

The diesel oil bulk storage tank T12A is having a capacity of 76,000 liters.
The low level alarm appears in the main control room when the quantity of diesel
oil in the tank falls below 40,000 liters which is well above the requirement of one
diesel to run at rated load continuously for seven days.

The second diesel oil bulk storage tank T12B is having a capacity of 55,000
liters. The low level alarm appears in the main control room when the quantity of
diesel oil in the tank falls below 40,000 liters.

Each emergency diesel generator is provided with a 3000 liters capacity

high-speed diesel storage day tank installed over the ground. The day tanks diesel
supply lines are dedicated from the diesel oil transfer pumps. Each day tank over
flow line goes to a separate open pit for collection of the spilled diesel.

Each tank is provided with a level indicator and a level switch with alarms at
high and low level. Manual starting of one of the two-diesel oil transfer pumps P-
20A or P-20B does filling of the day tanks. Starting of diesel oil transfer pumps
from the respective DG day tank instrument panel can fill the day tanks. In case of
high level in any one of the three day tanks, the diesel oil transfer pump shall stop
automatically.

One motor operated discharge valve has been provided for diesel oil transfer
pump P20A. The valve opens automatically, when the pump is started and closes
when the pump is stopped.
 P20A & B has got control on EDG MCC and two local areas i.e. at the
Storage tank areas. There is a high level trip for the pump from the individual over
ground day tanks level switches which is effective only when the pump is started
from the corresponding local switch.

Diesel transfer pump P20A takes suction from diesel oil bulk storage tank
T12A and pump P20B takes suction from diesel oil bulk storage tank T12B. Power
supply to the diesel transfer pumps P20A and P20B is derived from G2A and G2B
local MCC panel respectively. Pump control switches are provided on each DG
local MCC panel and near the day tanks. The switches near day tanks override the
high level pump interlock. It is possible to transfer the oil from diesel oil bulk
storage tank to day tanks by gravity. The operability of diesel oil transfer pump is
checked once in a week.
DRG 253A
 Neutron Monitoring System

Nuclear And Radiation Monitoring Instruments:

First aim of these instrumentation system is to keep continuous monitoring

on the nuclear reactions taking place in the reactor so that not only it generates
desired power but also sees that the fission reaction is under control and no harm
comes to the nuclear process and the reactor internals. Purpose of system is to
detect changes in neutron flux in time and reduce the extent of damage and to
continuously keep a watch on the process such that in case of unwanted flux
changes corrective action in the plant operation can be taken before the events
cross stipulated limits.

Nuclear reactor instruments are designed to monitor neutron flux within

core, right from the start-up to full power. The same instrumentation can be used
with more sensitive detectors to monitor very low neutron flux levels during
loading and unloading of all the bundles from the reactor core. These are three
ranges of monitors deployed to measure neutron flux. For reactor shutdown and
start-up monitors are called start-up source range monitor (SRM). The transition
stage neutron monitoring from start-up range to power range is done by four
Intermediate Range Monitor (IRM). When reactor comes to heating power
onwards six Power Range Monitor’s (PRM) take over.

These three (i.e. SRM, IRM and PRM) have enough overlap (See
Fig.61) for reliable reactor protection. One channel of each of the three can be
bypassed for maintenance. In addition to the protection instrumentation there are
other two neutron monitoring systems namely “Local Power Range Monitors”
(LPRM) and Traversing In core Probe (TIP) system. LPRMs do not play as
important in reactor protection, but, are very important to reactor operator. LPRMs
indicate the effect of Control Rod Drive (CRD) movement immediately and helps
the operator to visualize the axial and radial neutron flux/heat flux distribution. TIP
system is used for calibration of LPRM monitors.
Source Range Monitors (SRM):

Reactor core is effectively monitored for neutron flux by three SRMs

detector which are located inside the reactor core. Fig. 61 gives the range of flux
coverage and Fig.61B illustrates the scheme. The detectors are miniature fission
chambers having sensitivity of 10-4 counts/nv of thermal neutrons. Detectors can be
positioned almost anywhere within the reactor core. The detector assembly shuttles
inside a dry tube extending inside the core. The position in controlled remotely
from the control room. SRMs are pulse counting systems with pulse height
discrimination facility. These process the signal from SRM detectors which is a
measure of neutron flux.

Detector construction gives high degree of discrimination between signal

due to thermal neutron flux and noise due to gamma flux. The discriminated pulses
are amplified and counted on a logarithmic Analog meter, which can read from 0.1
cps to 106 cps. Derivative of the log count rate meter is used to give an alarm in
control room to alert the operator against high rate of increase of the neutron flux
i.e. Period. Reactor Period means it is the time required to change the neutron flux
by a factor of “e” (e = 2.718). Reactor period alarm comes when it is 20 seconds
or lower. Generally reactor period is from 50 to 150 sec. at the time of criticality.
SRM’s do not initiate reactor scram instead they block CRD withdrawal (reactivity
addition) on high flux (count rate).

When reactor goes to heating power the detectors are moved down from (out
of) the active core (i.e. retracted) to increase detectors life as IRM’s and PRM’s get
picked up.

Intermediate Range Monitors (IRMs):

There are four IRMs like they too have retractable detectors located inside
reactor. These detectors are miniature fission chambers similar to those of SRMs
but the principle used for computation of flux is different. It is observed that mean
of the squares of the a.c. ripple of voltage of the fission chamber output is
proportional to the thermal neutron flux in the reactor core. This observation is
used to compute the neutron flux or reactor power. It is not logarithmic device
hence flux is monitored in the working range by making use of range switches.

The signal is received at the monitor after getting amplified at the pre-
amplifier. It is also observed that the frequency of output signal ripple changes
from about 8 kc/s to 16 kc/s band at lower flux to about 300 kc/s 600 kc/s band at
higher reactor flux. This change over is achieved through diode logic after
particular position of the range switch. This monitor gives “On Scale” control rod
withdraw interlock, Rx. high flux alarm and Rx. high flux “SCRAM”. When the
reactor power exceeds 10% the detectors are retracted below the active core to
avoid detectors from getting burnt up.

Power Range Monitors (PRMs):

In contrast to SRM/IRM monitors using in core fission chambers these are

six out of core monitors using Gamma compensated Boron coated ion chamber
detectors. These need to be more rugged and reliable system since these controls
the reactors when the station is generating electricity at full power. The detectors
are situated inside the Biological shield. Signal from the chamber is quite large and
it does not need any pre amplification in field (Ref. Fig.61E). The monitor is a
linear DC amplifier system with 12 position range switch between 0.0001% to
125% of full power. PRMs give on-scale CRD withdraw interlock, high flux alarm
and Rx. high flux “SCRAM”.

Local Power Range Monitors (LPRMs):

This system is used to monitor neutron flux at a fixed point location inside
the reactor core. This gives an idea of axial and radial neutron flux distribution
pattern inside core and helps in indicating heat generation pattern and in avoiding
hot spots on fuel bundles.

There are 13 LPRM assemblies symmetrically located at fixed positions

through out the core. Each assembly has 4 miniature fission chambers mounted at
3 ft. intervals on one closed guide tube for the TIP detector. Fig.61D illustrate the
system and the LPRM assembly respectively. Control room has one panel
displaying core map. LPRM indicators are located on this map at locations which
are exact replica of their location in the core along with the CRD position
indications.

Traversing In core Probe Systems (TIP):

Traversing In-core Probe calibration system is designed to permit rapid and

accurate calibration of LPRM system. The system is identical to
that of LPRM in construction except that its miniature fission chamber has a
flexible graduated coaxial cable. This chamber not only be driven in and out of
core but also can be withdrawn to safe shielded position outside the drywell (TIP
Room). There are two such systems per reactor. Each system covers 6 LPRM
locations independently and the balance 13th location is covered by both the
systems. This seventh common TIP location provides for cross calibration of both
TIP systems monitors so that all 52 LPRMs are calibrated to common reference.
Refer Fig.61C for the block diagrams.

Control Rod Drive (CRD) Position Indication System:

Control Rods are used in TAPS to control the reactor power. It is necessary
to know the positions of control rod blades (the neutron absorber) with respect to
the fuel bundles. Drive assembly is a hydraulically operated position piston device.
CRD position indication of each drive is transmitted to control room with the help
of a position indication probe housed inside the drive.

This probe consists of 52 magnetic read switches mounted axially at an

internal of 3 inch inside the dry annulus of the drive. A magnet which is housed on
the drive piston actuates the reed switches. The 104 leads of these switches are
connected in a logic to give digital display of CRD positions from 00 to 48 on
CRD indication panel in control room. Full IN (00) indication is displayed in
green background and full out (48) indication is displayed in Red background.

In addition each CRD position indication probe has a thermocouple mounted

on it which monitors drive temperature and transmits the temperature to control
room. A recorder scans, displays and records CRD drive temperature continuously
as well as gives alarm whenever drive temperature exceeds 120oC.

Radiation Monitor:

All the instruments described above were directly monitoring the primary
process i.e. the Nuclear Reaction. System here after will be of
secondary nature i.e. monitoring the effects of the reactor operation. This part of
discussion explains important instrumentation which monitors integrity of the
primary systems, aspects affecting plant personnel and the population at large.
These systems are treated under each sub-heading.

Process Radiation Monitoring System:

These systems monitor the process fluids and gases coming out of reactor or
reactor auxiliary systems. This indicates about system integrity and radioactivity
releases either qualitatively or quantitatively. They are:
1) Radwaste Demin. Effluent 9)Cleanup demin. effluent
2) Drywell purge discharge 10)RBCW cooling water
3) Reactor Bldg. Ventilation Disch. 11)Service Water Disch.
4) Emergency condenser Disch. 12)Circulating water Disch.
5) Emergency cleanup fan Disch. 13)Sample tanks to Disch.
6) Condensate DM Influent 14)Stack gas monitor
7) Condensate DM effluent 15)Primary steam line
8) Off gas radiation monitors radiation monitors.

Five of these are logarithmic gamma monitors are using sodium iodide
scintillates along with photo multiplier tubes. All the monitors are inter-changeable
with some modifications. As in other systems, the monitors are mounted on panels
in the control room whereas the detectors are mounted in field.

In stack gas monitoring system the part of the total gaseous discharge is
drawn as a sample at a constant flow rate through an iso- kinetic probe. It is made
to pass through iodine and particulate filters. Sodium Iodine crystal detector feeds
signals to two monitors. One is the gross count rate activity monitor (Channel “B”)
and the other is a single channel (Channel “A”) analyzer counting all gamma
emitting radio nucleons above 400 Kev contribution by Cs, Co, Noble radioactive
gases etc.

Primary steam line and off gas monitors use ion chamber detectors.
Detectors for the former mounted on the steam lines between reactor and turbine
and initiate primary steam isolation valve closure and SCRAM when preset value
of activity is exceeded. The latter monitors effluents from condenser i.e. non
condensable gases discharged by air ejector after a delay of about 2 minutes.

This monitor initiates closure of off gas discharge valves after a time delay if
pre set value of radiation level is exceeded. This system set point is calculated by
collecting grab sample of “Off-gases” counting it in laboratory and calculating the
values of activity release.

Area Radiation and Environment Monitoring System:

Area radiation monitoring is a name attributed to the general gamma

background monitoring systems, these are judiciously located in various areas in
the plant.
 There are total of 33 monitors using plastic scintillation detectors which are
optically coupled to photo multipliers which feed signal to DC log amplifier in
control room. Thermo-electric coolers are installed on the detector where ever
necessary so as to limit contribution due to dark current.

Three gamma detectors are located at a radius of 1 km. from the plant to
monitor and record the effect of plant operation on the environs.

Health Physics and Chemical Lab. Instrument:

Most of these are conventional radiation monitoring instruments common to

all nuclear power stations. Hence, these are not discussed here.

In Chemical Laboratory equipment the most important one is a multi-

channel analyzer with Ce-Li crystal. This equipment is used normally to analyze
samples of liquid effluents being discharged from radwaste system. During
refueling work it is used to analyze the samples of water drawn from fuel bundles
inside the reactor. During the analysis concentration of I-131 and I-133 is used to
identify the fuel bundles in the core having fuel failures. This data is used to
replace the leaky fuel bundles.
 Glossary of Observations

SRM :Source Range Neutron Monitor

IRM :Intermediate Range Neutron Monitor
PRM :Power Range Neutron Monitor
LPRM :Local Power Range Neutron Monitor
TIP :Traversing Incore Probe Neutron Monitor
SCRAM :Safety Control Rod Accelerated Movement
(To shutdown the reactor)
CRD :Control Rod Drive
LCRM :Log Count Ratio Meter
LRM :Log Radiation Monitor
DRG 260A
DRG 260B
DRG 260C
DRG 260D
DRG 260E
 Supplementry Control Room
Supplementary Control Room (SCR) is provided for the purpose of
achieving certain basic safety control functions like shutting down of the reactor
and maintaining the reactor in a safe shutdown state, in the event of an emergency
situation in which main control room becomes uninhabitable. From the
supplementary control room, it will be possible for the operator to shut down the
reactor and monitor all the essential process parameters so as to ensure that the
reactor is in safe shut down condition. It will also be possible to initiate and
maintain long term cooling of the reactor core.

Supplementary Control Room for Unit-1 is provided in Unit-1 Reactor

Instrument Vault RKO1 located in Reactor Building 103’ Elevation in the north
side.

Supplementary Control Room for Unit-2 is provided in Unit-2 Reactor

Instrument Vault RK11 located in Reactor Building 103’ Elevation in the south
side.

For the purpose of initiating and maintaining long term core cooling
additional control points are identified from where some of the pumps and motor
operated valves can be operated. These are basically motor control centers and
circuit breaker panels and are termed as Supplementary Control Points.

The Back Up Control Room functions are achieved by the provision of

Supplementary Control Room working in tandem with the Supplementary Control
Points.
ACTIONS ASSOCIATED WITH SCR:

In the Supplementary Control Room provisions has been made for following
controls/indications

i. Tripping of the reactor by SCRAM

ii. Initiating core cooling by use of Emergency Condenser
iii. Initiating Shutdown cooling for long-term residual decay heat
removal.

iv. Ensuring that Primary Containment isolation has taken place.

v. Monitoring of vital parameters of Reactor.
vi. Monitoring of control rod positions.
vii. Monitoring of neutron flux.

From Supplementary Control Points located at different elevations in

Reactor Building and Service Building following controls can be achieved:

I. Initiating core cooling by use of Emergency Condenser

II. Initiating Shutdown cooling for long term residual heat removal
DRG 262A
 Chillers and CTPH

Purpose:

Chillers are used to provide continuous supply of low temperature cooling water of
@ 8°C to various air conditionings and other equipments for cooling various
zones.

General Description:

The chilled water system provides circulating coolant which is used in conjunction
with the plant ventilation system to remove heat from certain areas in the service
building, reactor building, containment cooling building, administration building
and also provide chilled air to drywell.

Demineralized, inhibited water is circulated within a closed loop by one of two full
capacity pumps. This passes through the cooler section of two chillers. (During
normal operation two chillers are in operation and one in standby condition).

It is important that the chilled water system remain in operation at all times to
prevent overheating of electrical equipment through the plant. This is not required
as an emergency system however.

Chilled water system equipment:

1. Air conditioner chillers 1K4-K4-2K4.

2. Chilled water circulating pumps P74A and P74B.
3. Chilled water Compression tank T-75.
4. Chemical feeder T-76.
5. Ventilation system cooling coils.
DESCRIPTION AND GENERAL INFORMATION WITH IMPORTANT
OPERATING PARAMETERS:

The Kirloskar Mcquay Ltd., Pune make 280 tons centrifugal chiller is a complete,
self contained, automatically controlled water chilling unit. The chiller consists of
a compressor connected to a condenser and a evaporator. The chiller uses R-134a
refrigerant gas (CH2FCF3-Tetrafluoroethane) at a positive pressure over the entire
range of operation, which reduces size and weight of the chiller package, compared
to negative pressure refrigerant chillers. Thus problem of air ingress and purging
has been eliminated as encountered in previous carrier chillers which operate under
negative pressure in evaporator.

DESCRIPTION OF KIRLOSKAR MCQUAY MAKE (MODEL PHE063)

Following are the main components of Chiller.

(a) Centrifugal compressor and motor.

(b) Condenser.
(c) Evaporator.
(d) Expansion Device
(e) Lube oil supply
(f) Micro Tech control panel.
(g) Hot Gas Bypass

a) CENTRIFUGAL COMPRESSOR AND MOTOR:

The chiller-compressor is run by a 242 HP (190KW), 415V, 50 Hz, 2960

RPM, 3 φ Motor of (F- insulation class). It is a hermetically sealed squirrel
cage induction motor. Motor full load current is 308 Amps. The motor is
cooled by R-134a gas which is taken from condenser.

Motor shaft is connected to centrifugal compressor through a 8:16helical

gear ratio assembly. Guide vanes are located at the inlet to impeller and are
used to modulate the flow of gas to compressor. The vanes are operated
hydraulically by piston via solenoid valves for capacity control.
 The SV’s operate automatically depending on motor current and chilled
water temperature set point. During manual shut down of chiller (done
through toggle switch located on MicroTech panel) the vanes get closed up
to 30% open position and then tripping of chiller takes place.

The compressor is single stage, made of high strength aluminum alloy (cast)
and is 254 mm in diameter. The capacity of compressor is 280 Tons of
Refrigeration at design condition. Compressor is rotated at 24,846 RPM.
Compressor outlet discharge pressure is 9.4 Kg/cm². Total five bearings are
provided in the compressor.

High speed bearings – three numbers

One in the rear end of high speed assembly and two in the front end of high
speed assembly of compressor.

Low speed bearings – two numbers

One on the motor end and one on the compressor end of low speed shaft.

Lubricating oil under pressure is fed to the bearings for cooling bearings. For
this a separately mounted oil pump and a plate type heat exchanger is used.

2 no. of 250W, 115V AC crank case heaters are provided. These heaters get
switched “ON” whenever Chiller is in stopped condition. This is to reduce
the absorption of refrigerant in the oil.

(b) CONDENSER:

Condenser is a horizontal, double pass, shell and tube type, heat exchanger.
Hot refrigerant flows on shell side and raw water flows on the tube side. The
tubes are 19mm dia copper material and shell is MS as per IS2002 Gr-2. The
design raw water inlet & outlet temperatures are 31°C & 38.0°C. The design
cooling water flow rate is 155 m³/hr (680 gpm – 25 % flow). The design raw
water pressure drop across condenser tubes is 9.2 FT of WG.
 The refrigerant discharged by the compressor condenses on the outside of
the condenser tubes, when the latent heat is removed from the refrigerant
vapors by condenser raw water cooling water. The liquid refrigerant
condition at outlet of condenser is 35.9°C & 9.4 Kg/cm². The refrigerant in
liquid form will be fed to evaporator through the pilot thermal expansion
valve. The condenser has two relief valve separated by a three way shut off
valve. This valve allows any one of the relief valve to be isolated (in case of
RV is leaking). Both RV’s can not be isolated at the same time.

EVAPORATOR:

Evaporator is of horizontal two pass shell and tube type heat exchanger.
Evaporator has 19 mm dia copper tubes. Chilled water flows on tube side and
refrigerant flows on the shell side of evaporator.

The design chilled water temperature at evaporator inlet & outlet are 13. 3°C
& 6.6°C respectively for a chilled water flow rate of 128 m³/hr (560 gpm - 61%
flow). The design chilled water pressure drop across evaporator tubes is 9.2 FT of
WG. The evaporated gas at the outlet of evaporator goes to suction of centrifugal
compressor, at a pressure of 2.5 Kg/cm² and temperature of 4.4°C.

Expansion Device:

After the refrigerant condenses to a liquid in condenser it passes through a

pressure reducing device. This can as simple as an orifice plate or as complicated
as a electronic modulating thermal expansion valve.

LUBE OIL SUPPLY UNIT:

The oil system provides lubrication and heat removal for compressor
bearings and internal parts. In addition to above, the system provides oil under
pressure to hydraulically operate the loading and unloading piston, for positioning
the compressor inlet guide vane, for achieving the desired chiller capacity control.

The oil system consists of motor, pump, oil heater, oil cooler and oil
reservoir. Oil reservoir has 30 liters oil capacity. The oil pump is driven by a 2 HP
(1.5 KW), 3000 RPM, 115V AC single phase motor.
 The oil pump develops a maximum pressure of 14 Kg/cm² and a continuous
flow rate of 16 US gpm. The oil is pumped through a oil filter in to a plate type
heat exchanger. Oil is cooled by chilled water taken from the chilled water inlet
line to evaporator and oil cooler outlet is connected to chilled water circulating
pump suction header.

One SV is provided in the chilled water inlet line to oil cooler, which opens
on chiller starting. The oil temperature is maintained between 32°C -38°C (90-
100°F) during normal operation by chilled water flow control through a
thermostatic valve at the cooler outlet line. The chilled water to oil cooler also has
isolating valve and a 40 mesh strainer. During lube oil pump power supply failure
condition, lube oil requirement during coast down of chiller is accomplished by a
spring loaded piston. When the oil pump is started, the piston is forced back by the
oil pressure. This compresses the spring and filling the piston cavity with oil.
When oil pump stops, the spring pressure on the piston, forces the oil out to the
bearings, hence ensuring lube oil during chiller coast down period.

The oil reservoir has two numbers of 250 watts (each) electric heaters for
maintaining the oil temperature. These heaters get switched ON when the chiller is
not running. Out of this one of the heater remains continuously ON and the other
cuts in and cuts out to maintain oil reservoir temperature. Oil temperature is
maintained to reduce the absorption of refrigerant in the oil.

CAPACITY CONTROL SYSTEM:

The compressor capacity is controlled by the movement of the inlet vanes,

opening or closing to permit the correct quantity of refrigerant to enter the
impeller. The vane movement occurs in response to oil flow from the SA or SB
solenoid valves as per the signal from control module. This oil flow activates a
piston to rotate the vanes.

VANE OPERATIONS:

The hydraulic system for the inlet guide vane operation consists of a 4-way
normally open SV. Oil under pressure is directed by the 4-way valve to either or
both sides of the piston, depending on whether the control signal is to load, unload
or hold the load on chiller.
 To open the vanes (load the compressor) solenoid SA is de-energized and
solenoid SB is energised, allowing oil flow from port SA to one side of piston then
drain through port SB.

To close the vanes (unload compressor) valve SB is de-energized and valve

SA is energised to move the piston and vane towards the unload position.

When both SA & SB solenoid valves are de-energized, full oil pressure is
directed to both sides of the piston through port SA & SB, thus the vanes are held
in that position. Also both SVs can not be energised simultaneously. The speed at
which the capacity control vanes are opened or closed can be adjusted to suit
system operating requirements. Adjustable needle valve in the oil drain lines are
used to control the rate of bleed-off and consequently the “vane speed”. The needle
valves are part of the 4-way SV assembly located in the compressor lube box.

HOT GAS BYPASS:

The hot gas bypass system used to feed discharge gas directly into the evaporator
when the system load falls below a predetermined minimum compressor capacity.

Light load conditions are signaled by measurement of a set percentage of RLA

amps by the Micro-Tech control panel. When the RLA drops to the set point the
hot gas bypass solenoid is energized making hot gas bypass available for use. This
bypass system provides a stable refrigerant flow and keeps the chiller from short
cycling under light load conditions. It also prevents surge during heat recovery
operation.

MICRO-TECH PANEL DESCRIPTION:

The MicroTech-II unit controller is a Micro-processor based control panel

designed to initiate the step-by-step start functions of its centrifugal compressor
unit, monitor and regulate the compressor capacity, protect it and sequence the
compressor shut down.

The Microtech II control system consists of the following components:

Operator Interface Touch Screen (OITS) - provides unit information and is the
primary set point input instrument. It has no control function.

Unit Controller – controls unit function and communicates with all other
controllers. It is the secondary location for set point input if the OITS is
inoperative.

Compressor Controller – controls compressor functions and can operate a

compressor without the unit controller or OITS.

The controller is located in a panel adjacent to the compressor. If a fault develops,

the controller will shutdown the machine and activates an alarm output. The alarm
condition occurs are retained in the controller memory to aid in the troubleshooting
and fault analysis.

Operator Interface Touch Screen:

It is the primary device by which commands and entries into the control system are
made. It displays all controller data and information on a series of graphic screens.
The side of the OITS contains a floppy disc drive that can be used for loading
information to and from the control system. The screen is reactivated by touching
it anywhere.

Unit Controller:

The unit controller primary function is processing data to the entire chiller unit
operation as compared to data relating to the compressor operation. The unit
controller processes information and sends data to other controllers and devices
and relays information to the OITS for graphic display. It has a 4*20 LCD display
and keys for accessing data and changing set points. The LCD can display most of
the same information as the OITS and can operate the chiller independently if the
OITS is not available. The Unit and Compressor ON/OFF switches are mounted
inside the Unit controller.
Compressor Controller:

The compressor controller primary function is controlling and protecting the

compressor. No set points inputs are made with it. The compressor controller
receives processes and sends to other controllers and devices and to the compressor
starter or variable frequency drive (VFD).
IMPORTANT FEATURES OF MICROTECH PANEL:

• Precise control of chilled water outlet temperature within a ± 0.1°C (± 0.2°F)

control band.

Readout of all temperature and pressure readings.

• Operator can log chiller operating conditions from a single key pad / display
instead of reading gauges, thermometers, pots etc.

• Auto logging feature will log chiller functions at the time of peak load. The
controller will store and display up to six weeks of accumulated data.

• Three levels security protection against unauthorized changing of set points and
other control parameters.

• Complete warning and fault diagnostics (along with date and time) to inform
operator of any abnormality. In addition the operating conditions that exist
prior to shut down can be recalled to aid in identifying the cause of problem.

• Twenty-five previous faults and related operating conditions are available for
display.

Remote input signals for chilled water reset, demand limiting, unit enable.

• History trend feature will constantly log chiller functions and set points. The
controller will store and display all accumulated data for recall in a graphic
format on the screen.

• Communication capabilities for remote monitoring, changing of set points,

trend logging, remote reset, alarm and event detection through a PC.

CHILLER- PH-063MCONTROL PANEL:

Chiller-PH-063M has two control panels. They are Micro-Tech panel and local
starter panel.
(1) Micro-Tech panel has STOP/AUTO toggle switch, 18 pressure sensitive key
pads and display unit.

(2) Starter panel has breaker healthy indication, motor current and emergency
trip PB.

HAZARDS AND PRECAUTIONS DURING OPERATING AND

SHUTDOWN STAGES:

(1) Lub oil heater is always kept ON (through logic) when chiller is not running.
The oil sump temperature shall maintain between 50-54°C (125-130°F).
This is to avoid mixing of refrigerant into lub oil.

(2) Chilled water outlet temperature should not be lower than 5°C, to avoid
chiller tripping and not greater than 15°C to prevent area heating.

(3) Lub oil level in the oil reservoir shall be maintained at around 50% during
chiller startup, chiller operation and after chiller trip.

(4) Whenever chiller trips, ensure the control supply to Micro-Tech panel is in
energized condition by checking MCB-1 / MCB-2/ MCB-3 and MCB-4
inside local Starter panel is ON. This is to ensure that oil heater is ON

DESCRIPTION OF SHUT DOWN STATE:

When the chiller is under shut down, the status of system will be as follows,

(1) Chilled water flow to chiller evaporator is stopped by closure of its isolating
valves

(2) Raw water flow to chiller condenser is stopped by closure of its isolating
valves.

These TRIPS/FAULTS must be cleared manually to restart the unit Chiller will be
shutdown by Micro-Tech panel in response to any of the following TRIP/FAULT
condition.
SL
DESCRIPTION OF TRIP PARAMETER
NO
1. Low Evaporator Pressure
2. Low oil Delta Pressure
3. Low Oil Feed Temperature
4. High Oil Feed Temperature
5. Low Motor Current
6. Motor Protection Trip
7. High Discharge Line Temperature
8. High Condenser Pressure
9. Refrigerant high pressure at compressor outlet line
10. High Motor Temperature
11. High Suction Super Heat
12. Low Chilled Water Flow
13. Low Raw water Flow
14. Evaporator Outlet Temperature Sensor Fail
15. Evaporator Pressure Sensor Fail
16. Condenser Inlet Water Temperature Fail
17. Compressor Suction Temperature Sensor Fail
18. Compressor Discharge Temperature Sensor Fail
19. Condenser Pressure Sensor Fail
20. Oil Feed Temperature Sensor Fail
21. Oil Sump Temperature Sensor Fail
Cooling Tower Pump House

Purpose of the cooling tower pump house is to cool the return water from
chiller condenser by giving its heat to the environment so the cool water can be re
used for chiller condenser cooling. CTPH is of cross flow induced draft type.
CTPH is divided in to two separate compartments. Each compartment is having a
fan. Return water from Chiller condenser is broken in to fine particles (atomized)
by spray nozzles while traveling downwards in cooling tower. The air flow which
enters cross flow and travels upwards cool the fine water particles and picks up the
heat from the water.

The heat transfer takes place by latent heat transfer method. The hot air
which has picked up the heat is discharged to the environment by the running fans.
The cool water is collected in the sump which is divided in to two parts. Pumps P-
104 A/B/C takes suction from the sump and discharges in to common discharge
header. The pumps are protected by Y strainer in the suction. Normally two pumps
are running while third remains standby. During normal operation one
compartment can be isolated and cleaned.

The system consists of cooling tower, three horizontal centrifugal pumps of

40 HP each, two induced draft fans V-50 A/B of 20 HP each, chemical feeder,
instrumentation and controls. The CTPH equipments receive power supply from
local MCC which is supplied by 1MVA substation. The CTPH equipments can be
operated from locally as well as remotely from a panel near Chillers. Eco friendly
chemicals are being added on daily basis in CTPH sump to prevent algae growth
and to maintain water chemistry. This is done to prevent fouling of Chiller
condenser tubes. Continuous CTPH blow down of 4 gpm is required to maintain
water quality.
DRG 273A
DRG 273B
 AFR Fuel Pool Cooling and Polishing System

AFR is designed to store the irradiated fuel bundles which have been cooled
in TAPS fuel pool for at least 10 years. Irradiated fuel bundles from TAPS fuel
pool are transported to AFR fuel pool in approved dry transportation fuel cask.

The system serves two purposes:

(a) To remove the decay heat generated by stored spent fuels. The expected
generation of heat is at the rate of 0.1 KW per bundle. The fuel pool water
temperature should be maintained less than equal to 42oC. In no case the
temperature should increase more than 60oC.

(b) To provide filtering and polishing of pool water to remove radioactivity

build up in the pool.

General Description:

1. Fuel Pool:

The size of the pool is 9M x 13M x 13M depth and is lined with SS -304 L 6
mm thick up to 5 meters from bottom, then onwards it is 3 mm. Cask
handling area with 25 mm thick SS plates is also provided. The pool is
designed to store 2000 TAPS fuel bundles or equivalent with a provision to
augment for storage of 3312 bundles. Total water volume in the pool is 1376
M3 .

2. Heat Exchangers:

For normal operation two plate type heat exchanger are used to maintain the
pool water temperature less than equal to 42oC. Primary and secondary
cooling water flow rates are 30 M3/ hr.

3. Pumps:

Two full capacity centrifugal pumps are provided for circulating pool water.
Pump discharge pressure is 9.0 Kg/cm2.
4. Filters:

Two full capacity cartridge filters of efficiency up to 10 microns are used for
removal of accumulated crud in the fuel pool released during fuel handling.

5. Strong acidic Cation Bed:

One full capacity bed of resins volume 1.8 M3 is used to trap radio Cs
isotopes.

6. Mixed Bed:

One full capacity bed of anion to cation resins in the ratio of 3:2 is used to
maintain the pool water quality.

Mixed bed outlet water quality: Silica < 0.02 ppm and conductivity < 1.0
micro mho/cm.

7. Cooling Tower:

Total heat load is 190 x 10 3 Kcal/ hr. Heat extracted from circulating water
(i.e. fuel pool water) in the heat exchanger by raw water which is cooled by
cooling tower to atmosphere.

8. Cooling Water pump:

Two full capacity pump of discharge pressure 3.5 Kg/cm2 is used for
circulating cooling water from cooling tower to heat exchanger and back to
cooling tower.

AFR Power Supply:

AFR facility is provided power supply with two different sources. Normal
415 V power supply required for AFR equipments is supplied by a 3.3 KV/415V
transformer of capacity 630 KVA. The transformer is getting power supply from
TAPS Zone-III 33 KV feeder No.5.
 The feeder supplies via a 33KV/3.3KV transformer of 2 MVA capacity
through underground cable. The AFR transformer feeds to both the 415 V MCC’s
namely MC1 and MC2. An alternate power supply is provided to MC2 for
essential equipments through TRAP. 1MVA substation provides power supply to
TRAP. The change over from normal to alternate power supply takes place
automatically.

Un-interruptible Power Supply (UPS):

UPS System is provided by IAEA for reliable power supply to the lights in the fuel
pool area. There are two UPSs i.e. UPS#1 and UPS#2 having capacity 1.5 KW
each. The UPS System supplies four nos. of tube lights of rating 14 Watts each.
Each UPS is supplying to two diagonally opposite tube lights. Four spare lights are
also available on the fixture, which can be connected if any one fails. The UPS can
provide power supply to the tube lights for two days even if the AC supply fails.
The maintenance of the UPS and the tube lights will be done by IAEA only. Hence
if the UPS or any tube light fails, it should be informed to IAEA at the earliest.

AC Supply to the UPS is from MC-2 (LM panel breaker 14 -Y). In addition to the
UPS, this also provides supply to the three nos. of IAEA cameras. A voltmeter is
provided in the Control room to monitor this AC voltage. Also, if the AC supply
fails, under voltage alarm will appear on control room alarm panel. Even if the AC
supply fails, the cameras will have power supply from their built in batteries for 6
days. If the AC supply fails, it should be rectified within 24 hrs. Any failure of the
AC supply has to be informed to the IAEA at the earliest.

At least, once in 4 hrs. the AFR operator should monitor that all the 4 tube lights
are glowing. He should also ensure that AC supply to the UPS and cameras is
available. If failure of AC supply, UPS, or any tube light is noticed it should be
informed to SCE/ASCE at the earliest. There are 3 nos. of IAEA emergency lamps
kept at the fuel pool area. Every month E/M and operation should check their
healthiness.

DRG 276A