Contents

1 Functions of AFW system................................................................................................................... 3

2 AFW System components ................................................................................................................... 4

2.1 System Design and Operation....................................................................................................... 4

2.2 AFW System Diagram .................................................................................................................... 6

2.3 List of Components ....................................................................................................................... 7

3 AFW System Component Details ...................................................................................................... 9

3.1 Valves ............................................................................................................................................ 9

3.1.1 Check Valves ....................................................................................................................... 9

3.2 Gate Valves ................................................................................................................................. 10

3.2.1 Globe Valves ...................................................................................................................... 10

3.2.2 Butterfly Valves ................................................................................................................. 10

3.2.3 Ball Valves ......................................................................................................................... 11

3.2.4 Trip and Throttle Valve ................................................................................................... 11

3.2.5 Relief Valves and Safety Valves ....................................................................................... 11

3.3 Motors......................................................................................................................................... 12

3.4 Pumps ......................................................................................................................................... 12

3.4.1 Motor-Driven Auxiliary Feedwater Pumps .................................................................... 12

3.4.2 Turbine-Driven Auxiliary Feedwater Pumps ................................................................. 13

3.5 Condensate Storage Tanks.......................................................................................................... 13

4 AFW System Fault Analysis............................................................................................................. 15

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4.1 System Boundaries...................................................................................................................... 15

4.2 Failure Modes ............................................................................................................................. 15

4.2.1 Major Failure Modes ........................................................................................................ 15

4.3 Classification of Failure Events.................................................................................................... 19

4.3.1 Primary, Secondary and Command Failures ................................................................. 19

4.3.2 Common Cause Failures .................................................................................................. 19

4.3.3 Human Errors ................................................................................................................... 20

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 AUXILIARY FEED WATER SYSTEM

1 Functions of AFW system

The Auxiliary Feed water System (AFW) is a key component in pressurized water reactor

designs. The AFW performs several functions within the reactors, however the primary function

is, provision of feedwater to the steam generators in order to maintain a heat sink. This is usually

in the event of, loss of the reactors main feedwater, loss of offsite power as a result of a reactor

trip or in the event of a small break loss of coolant accident [1].

The AFW system performs safety-related functions within the reactor. The system supplies

feedwater to the steam generators at high-pressure, in-order to provide a balance of the water

inventory that is required to remove heat energy from the reactor coolant system through

secondary side steam release [2]. This feedback system is usually used in the event of

inoperability or unavailability of the main feed water system. During such accidents, the AFW

system automatically starts and delivers adequate feedwater flow that maintains steam generator

levels thereby preventing the main steam safety valves from opening. This mechanism also helps

achieve cold shutdown conditions during accidents that require rapid reactor coolant system

cooldowns.

The AFW system also performs functions related to regulatory commitments within the reactor.

In scenarios of total blackout, the system automatically supplies sufficient feedwater that

removes decay heat from the units for up to one hour without reliance on AC power [2].

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 2 AFW System components

2.1 System Design and Operation

An ideal AFW system is configured with two separate mechanical divisions, independent of each

other with and with separate initiation and control functions designed to feed all the steam

generators. One of the divisions may consist of two electric motor-driven pumps whereas the

other may have one turbine driven pump.

The common design configurations of AFW systems are four-steam and two-steam generator

plants. In a four-steam generator plant, each of the electric-motor driven pump train has the

capacity to supply two steam generators whereas the turbine driven pump is capable of supplying

four steam generators. In a two-division two-train plants setup, both the pumps are aligned and

rated to supply all the steam generators.

Each of the steam generators is fed water through flow control valves. The valves regulate the

steam generator levels by open or closing to release feedwater. The flow control valves are

controlled either manually or automatically from the control rooms. The water supply to the

AFW system provides for redundancy, with the primary source being water from the condensate

storage tanks while the secondary feed is from the plant water system that are powered by diesel

generators. The condensate tanks will each have their water levels monitored to a capacity that

allows for up to 6 hours of system operation. The switchover in water supply from the primary to

the secondary source is initiated by conditions such as; low-suction pressure or power failure.

Each of the turbines is fitted with a hydraulic governor control valve and a trip and throttle valve

with motor reset capabilities. The governor valves open the steam isolation valve(s) that activate

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the turbines to the required operation speed. In order to maintain the turbine’s speed to match the

pump rated speeds, the governor modulates the control valves to meet the required speeds. The

governor controlled turbine speeds are either adjusted remotely from the control room or

manually at the governor. The throttle valves are used to stop the turbines, this is usually done

automatically from the control room or the remote shutdown panel. In instances where the

turbine speeds get to 115% of the rated speeds, the throttle valves are electrically tripped.

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 2.2 AFW System Diagram

Fig 1. AFW System Diagram

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 2.3 List of Components

Compon Operating Failur Components Notes

ent failure e
rate(hrs) Proba
bility
Motor
Driven
Pump
Turbine
driven
pump
Check V1206A,V1203A/B,V2202B,V10
Valve 12B,V1014B,V1003B,V1007B,V
1008B,V1004B,V1020B,V1014A
,V1012A,V1007A,V1003A,V100
4A,V1020A,V1628

Globe
valve
AF
Insolatio
n
Valve(G
ate
valve)
Steam
insolatio
n/Steam
Globe
valve
Gate V1006A, V1005A,V1002A,
Valve V1001A, V1601, V1626, V1184,
V1185,
V105D,V1200,V1201,V1605,V1
610,V1700,V1220,V1205A,V120
4A/B,V1201A,V1603/V1616,V1
151
Governo V3011 E/H Operated
r Globe
Valve(E
/H)
Trip and V3009 Motor-operated by
Throttle demand
Valve

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Butterfl V1208
y Valve
Demi
Water
Storage
Tank
AF
Storage
Tank
A/B
Raw
Water
Storage
Tank
Condens
ate
Storage
Tank A
TKO1
Condens
ate
Storage
Tank B
TKO2
AF TDP PP01A/B, MDP PP02A/B
Pump
Pump PP31(A), PP31(B)
AF V0035,V0037
Modulat
ing
Valve
Gate V105 Motor operated, Fall
Valve locked
(Motor
Operate
d)
Gate V1623, V1627, V1621,V1622 Manual operated, All
Valve modes
(Manual
Operate
d)
Turbine AF Pump Turbine A TA01A All models
Orifice V1015, V1017

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 Steam PT 1013A, PT1013B, PT1013C,
Generat
or 1/2
Steam
Generat
or 2

3 AFW System Component Details

3.1 Valves

Valves are an integral part of the AFW system’s architecture, their main functionality being

control or stopping liquid flow along a pipe. The components of a valve include; the seat and

disk that function together to throttle system flow, the valve has a body that acts as a pressure

boundary and a bonnet that contains the packaging and provides support to the stem [3].

Valves are often positioned using a variety of methods based on their operation modes, this

include; hydraulic operated, manual operated, air operated and motor operated valves. To

identify direction of flow within valves, there are usually external markings on the valve’s body

that indicate directions of flow.

There are different valve designs each with different functionalities, this include; gate valves,

globe valves, butterfly valves, ball valves and check valves among others.

3.1.1 Check Valves

Check valves are designed to allow flows only in one direction. There is minimal resistance of

flow when the valve is open and they automatically close when system flow reverses.

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There are different designs of check valves such as lift check valves and stop check valves, the

most common being Swing check valves.

3.2 Gate Valves

Gate valves are often used for isolation. They can be operated either in fully open or fully closed

modes. In a fully closed mode, the gate exerts force on the seat thereby creating a tight seal

whereas in the fully open mode the gate is out of the flow path.

3.2.1 Globe Valves

Globe valves are primarily used in regulation or throttling flow, but then can also be used for

isolation. They have a rounded disk and tapered seat. The seat and disks of the globe valves are

usually not as damaged compared to gate valves when the valves are used to regulate flow.

Globe valves are typically configured as either Angle globe valves or Needle glove valves, the

former designed to serve both as an isolation, throttle valve and a 90 degree piping elbow.

Needle glove valves on the other hand are used for fine flow control in small diameter pipes,

they have sharp pointed conical disk and matching seats that make that a possibility.

3.2.2 Butterfly Valves

Butterfly valves are used for isolation, they are light weight and are commonly used in low

pressure low flow systems with large diameter piping (Agency, 2019, p. 35). The valves are

usually unable to seal tightly if there are high pressure differences across the valve’s disk.

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Butterfly valves perform a 90-degree operation, for the disk to position from a fully open to fully

closed state it goes through a one quarter turn (90 degrees).

3.2.3 Ball Valves

Similar to Butterfly valves, Ball valves are also used for isolation, and they perform a 90-degree

operation. They are commonly used in high pressure systems (Agency, 2019, p. 36).

3.2.4 Trip and Throttle Valve

The trip and throttle valve is designed to control steam flow and prevent catastrophic failure, it is

therefore a critical safety device on a steam turbine. When operating as throttle valves, they

regulate flow of steam and gas in large high-pressure pipe lines, whereas when operating as trip

valves they act as safety measures by tripping to protect valuable equipment.

The trip throttle valve can be remotely shutdown from the control room to stop the turbine. The

valves are automatically tripped if the turbines over speed to a tune of 115% of the rated speed.

("NRC: Auxiliary Feedwater (AFW) System," n.d.)

3.2.5 Relief Valves and Safety Valves

These valves are used to prevent system pressure from exceeding specific defined values, this in

turn prevents equipment damage due to high pressure conditions.

A relief valve maintains pressure by gradually opening as pressure exceeds a defined setpoint

and gradually closing as the pressure drop below the particular setpoint. (Agency, 2019, p. 37).

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 3.3 Motors

Motors are instrumental in the operation of many equipment within the AFW system, including

pumps, fans, compressors and valves. They convert electrical energy either from AC or Dc to

mechanical rotational energy.

Motors have temperature and vibration detection systems, cooling and lubricating systems,

bearings and other support systems that must operate optimally for motors to perform their

intended functions.

3.4 Pumps

Pumps are mechanical devices that are used to move fluids, either liquid or gas. Most pumps are

motor-driven, but in some cases they are powered by either steam turbines or diesel engines.

Pumps have support systems such as temperature and vibration detection systems, cooling and

lubricating systems that must operate correctly for pumps to perform their intended functions.

(Agency, 2019, p. 38). Within the AFW system, there are two types of pumps; Motor-Driven

Auxiliary Pumps and turbine-Driven Auxiliary Pumps.

3.4.1 Motor-Driven Auxiliary Feedwater Pumps

The motor-driven pumps are multistage, horizontal, centrifugal pumps, they supply up to 440

gpm at discharge pressure of about 1300 psig. The motor-driven pumps are powered by 4.16-

kVac Class IE vital distribution boards [5].

The Pumps are automatically started during either of this conditions

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  Low-low water level in any single steam generator

 Loss of one main feed pump (MFP) if power is greater than 80 percent

 Loss of both main feed pumps (MFPs) at any power level.

 Loss of power to a Class IE power distribution system

 When a safety injection actuation signal is received.

3.4.2 Turbine-Driven Auxiliary Feedwater Pumps

The turbine driven pumps are multistage, horizontal, centrifugal pumps capable of delivering 880

gpm at a discharge pressure of approximately 1200 psig [5].

The automatic start signals for the turbine driven auxiliary feed pumps include;

 Low-low steam generator levels in 2 of 4 generators

 Loss of main feed pump (MFP) if power is greater than 80 percent

 Loss of both MFPs at any power level

 Loss of power in either of the Class IE distribution system.

3.5 Condensate Storage Tanks

The condensate storage tanks provide water to the suctions of the auxiliary feedwater pumps for

supplying AFW to the Steam Generators. The tanks also provide usable water volume for plant

start-up including transient demands. The tanks always have water capacity required for safe

shutdown of the plant, this level always maintained by the height of the tank penetrations.

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The condensate storage tank has a capacity of 480,000 gallons, and it is designed to maintain a

minimum level of 66% (340,000 gallons). The minimum water level satisfies the grade cold

shutdown capability that enables the plant to operate in the hot standby mode for 4 hours

followed by a 5 hour orderly plant cooldown ("NRC: Auxiliary Feedwater (AFW) System," n.d.)

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 4 AFW System Fault Analysis

4.1 System Boundaries

Variations in components boundaries are considered one of primary reasons for susceptibility to

failures. Individual component boundaries highly influence failure rates depending on particular

components and system designs. Each component has a boundary and points of interference with

other systems.

4.2 Failure Modes

A system can be broken down into their subsystems and components for fault analysis, an

understanding of components interaction is necessary to determine possible combinations of

failure events that may result into entire system failures. It is common that systems that function

dynamically are more prone to failure that static system components (Lee & McCormick, 2012,

p.143).

4.2.1 Major Failure Modes

4.2.1.1 All Modes

This refers to any failure that could possibly occur on components. All modes is used in

instances where detailed data for a particular failure mode is unavailable, thereby implying that

the particular component should be taken out of service under normal operation conditions.

4.2.1.2 Degraded

This refers to any failure that causes a component not to perform their function accurately, in the

expected capacity.

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 4.2.1.3 Failure to Change position

This refers to instances where components fail to move to a new required position. It is common

to components that perform their functions by moving from one state to another such as valves

and breakers.

4.2.1.4 Failure to remain in position

This refers to instances where components fail to remain in a required position, it is applicable to

components that operate by changing state between two positions. Failure typically causes

components to move in opposite directions to those designated.

4.2.1.5 Fail to close

This is a subset of failure to change position mode, it is characterized by components failing to

move to a new, closed position. Used where components operate by moving from one position to

another, and being in a closed state is necessary to complete its operation.

4.2.1.6 Fail to Open

Also a subset of failure to change position mode, characterized by a components failure to move

to a new, open position. Applicable to components whose performance are subjective to moving

from one station to another whenever opening is necessary.

4.2.1.7 Fail to Function

This failure mode is applicable to components that do not move in order to perform their

functions, it’s characterized by components failing to perform optimally either continuously or

when demanded. This failure mode is also applicable as a composite failure mode for a pump not

able to perform its function.

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 4.2.1.8 Short to Ground

The short to ground failure mode characterizes ground connections of any component where

electric current is isolated on higher-than-ground-voltage. It is used in components that are

unable to perform their functions when isolation to ground is broken and a power to ground

circuit formed.

4.2.1.9 Short Circuit

Applicable to all electrical components, it refers to a connection established between two or

more conductors that are normally isolated.

4.2.1.10 Open Circuit

Refers to a scenario where there is an electric circuit disconnection. It is applicable to all

electrical and I&C components.

4.2.1.11 Plug/Rupture

This is a failure mode unique to piping that is characteristic of rupture to a pipe segment that

prevents flow in a required direction.

4.2.1.12 Fail to run

This refers to a component failing to continue operation (rotational movement) when required. It

is applicable to components that operate by continuous movement.

4.2.1.13 Fail to start

Refers to component fail to start when demanded, applicable to all the components that operate

by starting and subsequently continuously rotating.

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 4.2.1.14 Spurious Function

Refers to failure of components to retain their current status, such as change state without any

trigger to dos so. It is used for components that perform their functions by existing in a particular

state, and any failure causes a change in state.

4.2.1.15 Rupture

Rupture characterizes inability to retain liquid boundaries. It is applicable to all components that

retain liquid. Rupture is considered a catastrophic component failure.

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 4.3 Classification of Failure Events

Failure events can largely be classified as either common cause failures,

primary/secondary/command failures or failures due to human errors (Lee & McCormick, 2012,

p.144).

4.3.1 Primary, Secondary and Command Failures

This are faults that arise when a system components perform their intended functions but fail due

to basic mode events such as structural faults. Primary faults often occur as a result of wear; high

performance systems experience primary faults arise from wear due to improper maintenance of

replacement of components or component part. Wears can also arise from poor designs or

fabrications, however this is common in lower performance systems (Lee & McCormick, 2012,

p.144).

A system is likely to experience a fault in instances where it is subjected to a load or an operating

environment other than the one it was designed for. Such faults are known as Secondary faults.

Command faults on the other hand arise from components operating at the wrong place or time,

an example is a pressure vessel failing because of an operator incorrectly closing a valve. (Lee &

McCormick, 2012, p.144).

4.3.2 Common Cause Failures

Common cause failures (CCF) are described as failures that result from two or more component

failures arising from the same inherent flaw in design, manufacture, operation or maintenance of

the components. Common cause failures occurring on multiple system components significantly

affect the overall system failure probability.

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In order to classify an event as resulting from a common cause failure, the following conditions

must have been met:

 The component failures or degradations must result from a single shared cause

and coupling mechanism.

 Two or more individual components must fail or be degraded in a select period of

time.

 Two or more individual components must fail or be degraded during demand, in-

service testing or from deficiencies that would have resulted in a failure had the demand

signal been received.

 The component failures are not due to the failure of equipment outside the

established component boundary.

Common cause failures often result from concurrent existence of two factors; components

susceptibility to failure due to a particular cause of failure and a coupling factor that results into a

condition where multiple components are affected by the same cause (Lee & McCormick, 2012,

p.147).

4.3.3 Human Errors

Human errors can be generally classified into either omission errors or errors of commission in

human reliability analysis. Omission errors refer to scenarios where operators do not take any

action or where action taken does not make any significant difference with lack of action (Lee &

McCormick, 2012, p.148), whereas errors of commission refer to actions taken that significantly

increase the severity of the existing event.

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Human interaction with the nuclear plant are majorly during routine operations, testing, and

maintenance and plant safety issues. Human response to accidents are mostly always under

stress, the stress levels dependent on the type of intervention required.

21
 References

Agency, I. A. (1992). Procedures for conducting probabilistic safety assessments of

nuclear power plants (level 1): a safety practice.

Agency, I. A. (2019). Handbook for Regulatory Inspectors of Nuclear Power Plants.

International Atomic Energy Agency.

Lee, J. C., & McCormick, N. J. (2012). Risk and Safety Analysis of Nuclear Systems.

Hoboken, NJ: John Wiley & Sons.

NRC: Auxiliary Feedwater (AFW) System. (n.d.). Retrieved from

https://nrcoe.inl.gov/resultsdb/SysStudy/AFW.aspx

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