Startup and Operation of SEE-THRU Nuclear Power Plant for Student Performance MP-SEE-THRU-01 Rev. 018

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1 Student Operating Procedure Millstone Station Startup and Operation of SEE-THRU Nuclear Power Plant for Student Performance Approval Date: 01/12/2011 Effective Date: 01/12/2011

2 TABLE OF CONTENTS 1. PURPOSE Objective Discussion Applicability PREREQUISITES General PRECAUTIONS Safety Precautions General Precautions Operating Limits INSTRUCTIONS Establish Initial Plant Conditions Plant Heatup Establishing Pressurizer Steam Bubble Heatup and Secondary Plant Startup of 18

3 1. PURPOSE 1.1 Objective This procedure provides instructions for the heat-up and power operation of the SEE- THRU Nuclear Power Plant. Students under the instruction of a qualified instructor may use this procedure. 1.2 Discussion This procedure provides instructions for drawing a pressurizer bubble, heating-up the reactor plant, and operating the turbine-generator and secondary plant of the SEE-THRU Nuclear Power Plant. The PYREX glass that is used for the pressure vessels of the SEE-THRU Nuclear Power Plant needs to be gradually heated up to prevent stress damage to the glass. Therefore, several hold points will be observed during the plant heat up to allow for thermal equalization of the glass. The reactor coolant system (pressurizer, reactor vessel, steam generators (primary side), and piping) will be water solid at the beginning of this exercise. When the reactor coolant system is in this condition, changes in temperature will result in pressure changes due to thermal expansion or contraction of primary system water. The water in the pressurizer is heated to a saturated condition with an electric heater. When the water in the pressurizer reaches saturation temperature, a steam bubble in the pressurizer is established by lowering pressurizer water level to approximately 50%. The reactor coolant is concurrently heated by electric heater rods (which simulate the reactor core) and is circulated, through two steam generators, via two reactor coolant pumps. As the reactor plant heat up continues, the water in the steam generators will begin to boil and the steam will be transported to the secondary plant. The heat input (reactor power) into the reactor coolant system is raised and the turbine-generator is started using the steam from the steam generators. 1.3 Applicability This procedure is applicable for student operation of the SEE-THRU Nuclear Power Plant. 3 of 18

4 2. PREREQUISITES 2.1 General The instructor has completed procedure Millstone Power Station SEE-THRU Nuclear Power Plant Preparation for Operation Students have reviewed the SEE-THRU Nuclear Power Plant layout and are familiar with the locations of the major plant components, operating controls, local valves, pumps and instrumentation indicators Students have reviewed and understand the safety precautions, general precautions and SEE-THRU Nuclear Power Plant operating limits The instructor has conducted a pre-job brief with all students for this activity. 4 of 18

5 3. PRECAUTIONS 3.1 Safety Precaution Always operate the SEE-THRU Nuclear Power Plant with the containment plexiglass (cylinder and dome) and component plexiglass covers in place to prevent scalding from hot water or steam in the event of a primary or secondary plant leak or rupture. The containment and component covers must also be in place to prevent serious lacerations or other injuries from broken/flying glass should a glass component break. 3.2 General Precautions When starting any pump, STOP it immediately if there is an abnormal noise or if an abnormal noise develops during operation Do NOT run any pump at a shutoff head for an extended period of time ENSURE that the pressurizer heaters and reactor vessel heaters are completely covered with water anytime the heaters are energized Do NOT allow the condenser to pump empty because this will cause air binding of the Condensate Pump and/or Feed Pump When the reactor coolant system is solid (no steam bubble in pressurizer), a small change in temperature can result in a significant change in system pressure Start up of SEE-THRU Nuclear Power Plant is NOT allowed if reactor coolant system Auto/Manual Relief Valve is NOT operational When shutting Feedwater Regulating Valves FW1 and FW2, Reactor Vessel Vent Valve RC-15, and Pressurizer PORV Isolation Valve RC-22, do NOT run them hard into their shut seat. This will prevent damaging the valves Do NOT allow Feedwater Outlet temperature to exceed 170 o F. 3.3 Operating Limits Ensure that the following operating limits are not exceeded: a. Reactor coolant system pressure is maintained less than 23 psi b. Reactor temperature is maintained less than 275 F c. Pressurizer temperature is maintained less than 275 F d. Condenser water level is maintained greater than 1/3 full e. Containment temperature is maintained less than 180 F 5 of 18

6 4. INSTRUCTIONS 4.1 Establish Initial Plant Conditions Circ Water Regulating Valve CW1 regulates domestic water supply pressure to the Containment Air Recirculation Cooling (CARC) unit and the Quench Tank. The domestic water supply pressure is not stable and periodic adjustment of the circulating water pressure may be required during operation of the SEE-THRU Nuclear Power Plant Initiate circulating water and containment cooling by performing the following: a. THROTTLE OPEN Circ Water Reg CW1 to obtain an initial reading of psi as read on CW system pressure gauge. 1) PERIODICALLY CHECK the CW system pressure gauge to ensure pressure is between 15 to 20 psi. b. VERIFY no leaks exist at the circulating water connections to and from the model. 1) IF leaks are present, NOTIFY instructor for further guidance. c. VERIFY circulating water sump pump starts as tank fills. d. START the Containment Air Recirculation Cooling (CARC) fan VERIFY the initial operating conditions of the following components: Pressurizer is water solid Reactor vessel is water solid Passive Accumulator tank level is approximately 1/3 full Passive Accumulator tank pressure is approximately 0 psi Condenser is 1/3 to 1/2 full Quench Tank / RWST is 1/2 to 2/3 full Steam Generator A Level approximately ½ to 1 inch above tube bundle Steam Generator B Level approximately ½ to 1 inch above tube bundle IF any of the initial operating conditions in step do not exist, ADJUST water level or pressure as directed by the instructor. 6 of 18

7 CAUTION When pressurizing the passive accumulator, do not exceed 9 psi on Passive Accumulator Pressure gauge. Over pressurization of the passive accumulator could result in damage to the passive accumulator Perform the following to pressurize the passive accumulator: a. START Safety Inj Pump - P1. b. OPEN Fill - SI5 valve. c. WHEN Passive Accumulator Pressure gauge indicates 6-8 psi, CLOSE Fill - SI5 valve. d. STOP Safety Inj Pump - P1. - End of Section of 18

8 CAUTION Monitor pressurizer pressure (Red LED) and reactor temperature (F2) during plant heatup. 1. The Master Display/Controller Function Keys are as follows: F1 Main Menu/Reactor Coolant Loop hot and cold leg temperatures F2 Pressurizer water, reactor and PORV tailpipe temperatures F3 Main steam and feedwater inlet and outlet temperatures F4 Quench Tank, Circulating Water inlet and outlet, and Containment temperatures F5 Pressurizer Control F6 Pressurizer Manual Control % Output Control F7 Pressurizer Manual to Automatic and Automatic to Manual control mode change F8 Pressurizer Automatic Pressure Control Setpoint 2. When using the Master Display/Controller, F1 must be used to return the display to the Main Menu in order to use the F2, F3, F4, F5 and F Plant Heatup START Reactor Coolant Pump P START Reactor Coolant Pump P Perform the following to start pressurizer heatup: a. PRESS F1 then F5 on the Master Display/Controller b. VERIFY 0% output is displayed. c. VERIFY Pressurizer Control is in MANUAL d. PLACE the Pressurizer Heater switch in the ON position. e. PRESS F6 On the Master Display/Controller f. ENTER 50% (TYPE in 50 and depress the enter key) g. VERIFY 50% output is displayed 8 of 18

9 h. PRESS F1 then F2 on the Master Display/Controller. To observe pressurizer heater performance, look directly at the pressurizer to observe the shimmering waves of convection currents as the pressurizer heater begins to heat the water. CAUTION When the reactor coolant system is solid (no steam bubble in pressurizer), a small change in temperature could result in a significant change in system pressure Perform the following steps to manually control reactor coolant system pressure during heatup: Dual Verification a. CLOSE valve RC-15 (manual valve downstream of valve RC-1) Performer Verifier (Dual) b. OPEN valve RC-1 (reactor vent). 1) VERIFY Pressurizer Pressure is not decreasing. 2) IF Pressurizer Pressure lowers after opening valve RC-1, PERFORM the following: a) CLOSE valve RC-1 b) OPEN valve RC-15 Independent Verification Performer Verifier (Independent) c) ESTABLISH alternate drain path as directed by instructor 1. The Low System Pressure alarm will clear when pressurizer pressure raises above 10 psi. 2. Step (reactor startup) can be started while plant pressure is being raised to the pressure band in step c. c. WHEN Pressurizer Pressure is >10 psi, THROTTLE valve RC-15 as necessary to maintain pressure between 10 and 13 psi. 9 of 18

10 4.2.5 Initiate reactor startup and heat up of the reactor coolant system as follows: a. PRESS the Reactor Trip push button to reset the reactor trip. b. VERIFY Reactor Trip button red light is not lit and Reactor Trip alarm has cleared. c. RAISE Reactor Power to 10 amperes. d. WHEN Pressurizer Water Temperature is >125 o F, RAISE Reactor Power to 18 amperes. The PYREX glass that is used for the pressure vessels of the SEE- THRU Nuclear Power Plant needs to gradually heat up to prevent stress damage to the glass. There are several hold points during the plant heatup to allow for thermal equalization of the glass WHEN Reactor Temperature indication reaches 120 F: a. LOWER Reactor Power to between 6 and 10 amperes. b. MAINTAIN Reactor Temperature at approximately 120 F for >5 minutes WHEN the 5-minute temperature hold is complete, RAISE Reactor Power to 18 amperes WHEN Reactor Temperature indication reaches 135 F: a. LOWER Reactor Power to between 6 and 10 amperes. b. MAINTAIN Reactor Temperature at approximately 135 F for >5 minutes WHEN the 5-minute temperature hold is complete, RAISE Reactor Power to 18 amperes WHEN Reactor Temperature indication reaches 150 F: a. LOWER Reactor Power to between 6 and 10 amperes. b. MAINTAIN Reactor Temperature at approximately 150 F for >5 minutes WHEN the 5-minute temperature hold is complete, RAISE Reactor Power to 18 amperes. 10 of 18

11 Step (increasing pressurizer heatup rate) can be performed while plant pressure is being raised to the pressure band in step RAISE Pressurizer Pressure to between 17 and 18.5 psi as follows: a. CLOSE valve RC-15. b. WHEN Pressurizer Pressure is between 17 and 18.5 psi, THROTTLE RC-15 as necessary to maintain pressure between 17 and 18.5 psi RAISE pressurizer heat up rate as follows: a. PRESS F1 then F5 On the Master Display/Controller b. VERIFY 50% output is displayed. c. PRESS F6 On the Master Display/Controller d. ENTER 70% (TYPE in 70 and depress the enter key). e. VERIFY 70% output is displayed. f. PRESS F1 then F2 on the Master Display/Controller WHEN Reactor Temperature indication reaches 180 F, LOWER Reactor Power to between 6 and 10 amperes. - End of Section of 18

12 4.3 Establishing Pressurizer Steam Bubble CAUTION Do NOT allow pressurizer level to lower to below 40% or pressurizer pressure to exceed 23 psi WHEN Pressurizer Water temperature is >250 F: a. VERIFY Pressurizer Level is >50%. b. SLOWLY OPEN valve RC-15 to create a steam bubble in the pressurizer. 1) WHILE lowering pressurizer level, MAINTAIN pressurizer pressure above 16 psi. c. CLOSE valve RC-15 when pressurizer level has lowered to approximately 50%. d. CYCLE valve Pressurizer Spray -RC4 as necessary to maintain pressurizer pressure between 19 and 21 psi. Pressurizer pressure may be momentarily erratic when the Pressure Control is initially placed in Automatic mode ESTABLISH automatic pressurizer pressure control as follows: a. PRESS F1 then F5 on the Master Display/Controller b. PRESS F7 to switch from Manual to Automatic pressure control mode. c. IF open, SHUT valve Pressurizer Spray-RC4. d. VERIFY Pressurizer Pressure is stable between 19 and 21 psi WHEN Pressurizer Pressure is stable between 19 and 21 psi: a. PLACE the Injection SI1 key switch to Normal (key in vertical position - ¼ turn COUNTER CLOCKWISE). b. OPEN valve Flood SI2 to create a flow path from the passive accumulator. c. VERIFY passive accumulator level and pressure are stable. 12 of 18

13 Independent Verification CLOSE Reactor Vent valve RC FULLY OPEN valve RC-15. Performer Verifier (Independent) a. VERIFY pressurizer level is stable at approximately 50%. - End of Section of 18

14 4.4 Heatup and Secondary Plant Startup Do not allow loop T H (F1) to exceed 242 o F Perform the following steps to heatup the reactor coolant system: a. MONITOR reactor coolant loop (F1) and main steam (F3) temperatures during the plant heat up. b. RAISE Reactor Power to 18 amperes WHEN Loop Temperature indication reaches 210 F: a. LOWER Reactor Power to between 9 and 11 amperes. b. MAINTAIN Loop Temperature at approximately 210 F for >2 minutes. c. OPEN valve Pressurizer Spray RC4 to initiate pressurizer spray. d. VERIFY Pressurizer Pressure is stable between 19 and 21 psi. Because of its design, starting and stopping the turning gear several times may be necessary in order to obtain proper rotational direction (counter-clockwise as viewed from the turbine end) START the Turbine Generator Turning Gear IF Steam Generator water levels are greater than 1 inch above the U-tubes, RAISE Reactor Power to 28 amperes. CAUTION When shutting Feedwater Regulating Valves FW1 and FW2, do not run them hard into their shut seats. This will damage the valves VERIFY the following parameters: a. Valves MSIV-MS1 and MSIV-MS2 are OPEN b. Valve Bypass-MS3 (Steam Dump to the Condenser) is OPEN. c. Feedwater Regulating Valve FW1 is CLOSED d. Feedwater Regulating Valve FW2 is CLOSED. 14 of 18

15 e. Demineralizer Inlet valve MS-19 is OPEN f. Demineralizer Outlet valve MS-20 is THROTTLED 1/2 OPEN. g. Condenser water level is 1/3 to 1/2 full STARTUP the secondary plant as follows: a. START Condensate Pump P4. 1) VERIFY Feedwater System Pressure raises to between 3 and 10 psi. 2) IF Feedwater System Pressure did NOT raise when condensate pump was started, NOTIFY instructor that system may be air bound. b. START Feed Pump P3. 1) VERIFY Feedwater System Pressure raises to between 10 and 15 psi. 2) IF Feedwater System Pressure did NOT raise when feed pump was started, NOTIFY instructor that system may be air bound ESTABLISH feedwater flow to the steam generators as follows: a. OPEN Feedwater Regulating Valves FW1 and FW2 to float the rotometer balls to an initial setting of approximately 5 on the vertical feedwater flow gauges. b. THROTTLE, as necessary, FW1 and FW2 to maintain a water level of approximately ½ to 2 above the S/G U-tubes IF not performed previously, RAISE Reactor Power to 28 amperes. CAUTION The Turbine Generator Turning Gear must be stopped expeditiously after closing Bypass-MS3 to avoid damage to the Turbine Generator Turning Gear WHEN Main Steam Pressure is >1.5 psi on gauge PI-5, perform the following to startup the steam turbine: a. OPEN valve TSV-MS4 (Steam to the Main Turbine). b. VERIFY Turbine Trip annunciator light is NOT lit. c. CLOSE valve Bypass-MS3 (Steam Dump to the Condenser). 15 of 18

16 d. IMMEDIATELY STOP the Turbine Generator Turning Gear. e. VERIFY that the Main Turbine is rotating by observing the Turbine Speed LED. 1) MONITOR Turbine Speed to ensure it remains < 3400 RPM. 2) IF turbine speed exceeds 3380 RPM, CYCLE valve Bypass-MS3 (Steam Dump to the Condenser) as necessary to maintain turbine speed <3400 RPM. f. TURN the black Turbine Generator Exciter potentiometer to the fully counter-clockwise (minimum) position. g. WHEN Turbine Speed exceeds 1800 rpm, TURN ON the Turbine Generator Exciter switch. h. While MONITORING the Generator Output Power meter, RAISE the turbine generator output by turning the Turbine Generator Exciter potentiometer clockwise to its maximum position, not to exceed 750 watts, as read on the Generator Output Power meter LOWER Reactor Power to 26 amperes MAINTAIN the following parameters: Reactor Power = 23 to 26 amperes Primary Temp = Loop T H <242 o F Primary Pressure = 19 to 21 psi Pressurizer Level = approximately 50% Condenser Level = 1/3 to 1/2 full S/G Levels = visible level above the U-tubes Turbine Speed = < 3400 rpm Containment Temp = <180 o F 16 of 18

17 CAUTION Do NOT allow the feedwater outlet temperature to exceed 170 F when performing step The feedwater heater condensate level should be maintained slightly above the drain orifice to prevent the steam from bypassing directly to the condenser IF desired, perform the following steps to place the feedwater heater in operation: a. VERIFY Main Steam Pressure PI5 is greater than 2 psi. b. VERIFY CLOSED manual isolation valves MS-9 and MS-16. c. OPEN valve Feedwater Supply MS5. d. OPEN valve Feedwater Heater Drain MS6. e. Slowly OPEN manual valve MS-16 to pressurize the feedwater heater. f. THROTTLE OPEN feedwater heater drain manual isolation valve MS-9 as necessary to maintain desired condensate level (about 1/3 full). g. PRESS F1 then F3 On the Master Display/Controller to display Feedwater Temperature. h. THROTTLE manual isolation valve MS-16 as necessary to maintain Feedwater Outlet temperature < 170 F. The vacuum pump should NOT be operated continuously for more than 5 minutes. The pump should only run for short periods to demonstrate the improved efficiency of the steam cycle with a lower condenser vacuum IF desired, perform the following steps to place the vacuum pump in operation: a. OPEN manual isolation valve MS-12. b. CLOSE manual isolation valve MS-13. c. START Vacuum Pump P5. d. VERIFY proper operation by noting a lower in condenser pressure as read on the Condenser Vacuum Gauge PI of 18

18 e. After 5 minutes or less, STOP Vacuum Pump-P5. f. OPEN manual isolation valve MS-13. g. CLOSE manual isolation valve MS End of Section of 18

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