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CHASHMA NUCLEAR POWER PLANT PROJECT
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Title CONTROL ROD CONTROL
SYSTEM MANUAL
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CONTROL ROD CONTROL
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PCa 03-01
CONTROL ROD CONTROL SYSTEM MANUAL Rev. Bo EI~1
1 Summary
1.1 General
This manual states the function, design bases, system description and conirol bases of
the control red control system(CCR), which includes trip breaker cabinets.
Only one set of CCR system equipement is provided for the plant.
1.2 Contents
Chapter Title Reference Revisio
n
1 Summary PC217CCRO01S04045GN B
Ll General
1.2 Contents
13 Updated revision
Function PC217CCRO02804045GN B
21 General function
22 Safety function
3 General design PC217CCRO02804045GN B
3.1 Design bases and criteria
3.2 Equipment design
3.3 Choice of material-construction
4 Description of System and | PC217CCR002S04045GN B
Equipment
4.1 Description
4.2 Characteristics
43 Layout
5 Operating Parameters PC217CCRO02804045GN B
5.1 Normal operation |
5.2 Particular steady operation
53 Particular transient operation
5.4 Startup and normal shutdown
5.5 | Other operations
5.6 Control principles :
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PC2-03-12-03-02
CONTROL ROD CONTROL SYSTEM MANUAL Rev. B_E2-1
2 Function
2.1 General function
Core reactivity and neutron flux are controlled by combining the effects of a soluble
chemical poison (boric acid) dissolved in the reactor coolant with the action of control
rod cluster assemblies (RCCA) made of neutron absorbers.
The Control Rod Control System (CCR) is used to withdraw and insert the RCCAs.
Core axial power distribution varies with insertion of RCCAs. If this core axial power
is imbalance, it would be detrimental to optimum utilization of fuel. In order to
minimize core flux asymmetry, control rod shall be operated in a pre-programmed
sequence. The arrangement of control rod drive mechanisms have also been
determined and fixed for the same purpose.
A negative reactivity margin is provided by the shutdown banks which are fully
withdrawn position from the core during normal operation.
Manual control of the neutron flux distribution is provided by moving the shutdown
bank Al or A2.
Trip breakers are controlled by the reactor protection system. When receiving the trip
signals from the reactor protection system, trip breakers are opened. Then the power
supplies to CRDMs are lost, all the control rods drop into the core by gravity.
Control rod control system consists of:
a. Equipment for RCCA operation:
® control rod drive mechanisms (CRDM),
® electronic control equipment for CRDM,
® main control room equipment for manual operation of control rods and monitoring
of movement.
b. Equipment for rod position monitoring: (refer to “control rod position indication
system manual” )
© rod position detector,
@ rod position measuring and processing equipment.
@ = main control room monitoring equipment.
c. trip breaker cabinets.
2.2 Safety fimction
2.2.1 Reactor trip
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Bu
= CONTROL ROD CONTROL SYSTEM MANUAL
When a reactor trip is demanded by the reactor protection system (CRP), the power
supply to the CRDMs is interrupted through the trip breakers. Loss of power, all
RCCAs, whether initially in testing or in operating, shall drop into the core very
quickly by gravity, ie. within about 2 seconds.
The rod dropping into the core will absorb a large amount of neutron immediately to
choke off the nuclear reactions and making the core subcritical.
2.2.2 System safety requirements
The quantity of rod banks, the quantity of RCCAs per bank and the initial insertion of
the control rods are determined by following way as to ensure compliance with the
safety criteria, ie.:
The core is kept subcritical following a reactor trip by a predetermined amount known
as the negative reactivity margin. The value of this margin is determined by accident
analysis report.
An acceptable power distribution of neutron flux is maintained during power plant
operation.
The positive reactivity rate and positive reactivity due to a rod ejection accident are
limited.
2.2.3. Dropped RCCAs-stuck RCCA.
The control rod position indicating system particularly can display the individual
measured rod position in the main contro] room.
The operator is able to discern abnormal configurations of RCCs, Le.:
misaligned RCCAs,
stuck RCCAs,
dropped RCCAs.
2.2.4 Realignment
In normal operation all RCCAs in a bank are operated together. If misaligned RCCAs
or stuck RCCAs or dropped RCCAs occur, the local neutron flux variations would be
produced.
The operator can use realignment operating and return the cluster to correct position.
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CONTROL ROD CONTROL SYSTEM MANUAL
3 General Design
3.1 Design bases and criteria
3.1.1 Design bases
Tn the automatic mode the Control Rod Control System receives the “rod speed + rod
direction” signals from the reactor power control system (CRC), or by manual control
modes regulates the power so as to satisfy the necessary power of the turbine.
The rods are divided into two functional categories. These categories are contro! rods
and shutdown rods. The reactor power is controlled by combining the effects of
chemical compensate with rod control. Both the shutdown rods and the control rods
are used to shutdown reactor.
The Control Red Control System has the function that the shutdown rods can be
operated manually. During the reactor is started-up, first the shutdown rods are
withdrawn manually and they are always in the fully withdrawn position during the
normal operation. Then the control rods are withdrawn in predetermined programmed
sequence.
The Control Rod Control System allows that the control rods can be operated in
manual mode or automatic mode. With the two modes, the control rods are operated
in predetermined programmed sequence. That sequence is stipulated that movement
order is reversible, i.e. the order of the insertion is opposite to the withdrawal. In the
manual operation, the rod stepping rate for withdrawal or insertion can be preset, but
it is fixed in movement. In the automatic mode, rod stepping rate which is varied and
direction are determined by output of the reactor power control system.
Trip breakers must be complied with single failure criteria. They have enough
redundancy to ensure that trip function can’t be lost because of failure of singie trip
breaker.
Trip breakers can be tested by the operator manually in the main control room during
the normal operation of the reactor. Note that every time only one trip breaker can be
test. After the first trip breaker is reset, the another can be test.
3.1.2 Design criteria
3.1.2.1 Control rod control system
© Safety criteria
HAF102-91
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CONTROL ROD CONTROL SYSTEM MANUAL, Rew.
PC2~03-12-03-02
BE2-6
6.3 Zoning Yes
6.4 Protection against sabotage Yes
3.2 Equipment Design
3.2.1 CRDMs
37RCCAs are provided 21 for the control rods and 16 for shutdown rods.
Each RCCA is attached to a grooved drive shaft, distance between the grooved pitches
is 10 mm, which therefore represents the smallest possible RCCA movement.
CRDM consists of 3 electromagnetic coils located on the outside of the pressure
housing, each energizing one movable pole located inside the pressure housing. These
mechanisms are therefore perfectly leak tight. (Figure 3.2.1)
The first pole operates a stationary gripper latch, which grips a groove on the drive shaft.
The second pole operates a movable gripper latch, which grips another groove on the
drive shaft.
The third pole actuates the entire movable gripper latch assembly and transfers it one
step. Energization of the third coil lifts the RCCA one step, while the third coil lost
power, the movable gripper Jatch will drop one step by gravity and spring,
Appropriate sequential energization of these three coil moves the RCCAs via the
drive shaft (withdrawal or insertion).
3.2.2. CRDM operation
3.2.2.1 Arrangement of RCCA in banks and groups
In order to preclude flux imbalance, two or three or four clusters are moved
simultancously.
They are positioned symmetrically in the core in a form of a bank or a group.
The RCCA in core center is assigned into control rod bank T4.
a, Shutdown banks
The 16 shutdown RCCAs are divided into 2 banks:
Al: 2 groups of 4 RCCAs, AIGI1 and A1G2.
A2: 2 groups of 4 RCCAs, A2G1 and A2G2. -
b. Control banks
The 21 control RCCAs are divided into 4 banks:
T1: 2 groups of 4 RCCAs,T1G1 and T1G2.
T2: 2 groups of 2 RCCAs, T2G1 and T2G2.
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PC2-03- 12-03-02
CONTROL ROD CONTROL SYSTEM MANUAL Rev. B E2-7
T3: 2 groups of 2 RCCAs, T3G1 and T3G2.
T4: 1 group of 3 RCCA for T4G1 and 1 group of 2 RCCAs for T4G2.
3.2.2.2 CRDM selection and operating principles
Rod banks may be operated in two modes:
a: individual,
b: overlapping.
During normal reactor operation the shutdown banks are operated in individual mode.
Control banks are operated in overlapping mode.
Shutdown banks are manually operated in individual mode at a preset speed. The
direction of travel is set by the operator.
Control banks are operated in overlapping automatically or manually.
Manual operation is controlled from the main control room. The operator chooses the
direction but the speed is preset.
In automatic operation the speed and the direction are determined by the reactor
power control system.
The travel speed of shutdown banks and control banks varies between from 6 steps to
60 steps per minute. The maximum speed and minimum speed are determined
respectively according to the requirements of the nuclear power plant transient state
safety analysis and operating.
Bank movement sequences
The upward bank movement sequence is as follows:
Upward movement of shutdown banks: Al, A2.
Upward movement of contro] banks: T1, T2, T3, T4.
The downward bank movement sequence is as follows:
downward movement of control banks: T4, T3, T2, T1.
downward movement of shutdown banks: A2, Al.
Rod operation rules:
RCCAs in the same group are operated simultaneously,
Jn any bank, operation of groups is offset by half a cycle, i.e. group 1 and group 2
operate alternately (except in realignment mode).
The cycle is the time interval between two steps of the rod movement, i.c. the time
interval from the beginning of one moving step to the beginning of the next step, it
docsity.com
PC2-03-12-03-02
CONTROL ROD CONTROL SYSTEM MANUAL Rev. B E2-§
depends on the rod speed.
Ability to stop RCCAs movement at any time implies that the two groups may be
misaligned, but there is only a difference of one step between them at best.
Reversal of direction is programmed such that the last ceased motion group will be
now the first to move in the new direction.
Two control banks are operated simultaneously in overlap region.
The control bank withdrawals are programmed such that when T1 bank reaches a
preset position, T2 bank begins to move out simultaneously with T1 bank. When T1
bank reaches the top of the core, it stops, T2 bank continues to move. When T2 bank
reaches a preset position, T3 begins to move out, and so on. This withdrawal sequence
continues until the unit reaches the desired power level.
The control bank insertion sequence is the opposite with the withdrawal sequence.
(Figure 3.2.2)
Overlap occurs in the upper or the lower section of the core. There is no overlap in the
middle section of the core, only one bank is moving.
Overlap between successive control banks is adjustable from 0 to 140 steps, with an
accuracy of +1 step.
Overlap setpoints can be preset.
The overlap setpoints:
$1-210 S3-190 Ss-190
S2-70 82-90 S6-90
The advantage of overlapping operation is that it moves simultaneously 2 rod groups
in the bottom half of the core and in the top half. This provides mote ideal differential
reactivity equivalent of control rods wherever they are situated in the core,
There is a special equipment (the rod position realignment device) in the main control
room, it allows one or more RCCAs in a bank to be separated and operated alone.
In order to prevent sticking, the RCCAs are never fully inserted. As soon as the
reactor trip breakers are closed, the RCCAs will be lifted to the baseline elevation.
3.2.2.3. CRDM coil
a. CRDM coil operation
The same type of coil in the group is energized simultaneously.
Any RCCA can be controlled individually by opening the lift coil circuits of the other
docsity.com
c2-08-
CONTROL ROD CONTROL SYSTEM MANUAL Rev.
12-03-02
B E2~i1
ambient conditions.
The coil power supply is direct current with a ripple of 150Hz. The 260V three-phase
busbar is rectified through a three-phase haif-wave thyristor circuit to each coil.
The current is regulated by adjusting the firing time of each thyristor.
Three independent current regulation systems are provided since there are three
separate coils in each CRDM.
3.2.5 Trip breaker
There are four pairs of trip breakers (two of each pair) which are divided into four
channels of Al, A2, B1, B2. The four channels are corresponding to Al, A2, B1, B2
channel of the reactor protection system separately and controlled by the reactor
protection system. Eight trip breakers are installed in four cabinets separately, which
are configured to 2/4 general voting logic. They are connected with M-G set. When
two or more than two pairs of trip breakers are actuated by the signal from the reactor
protection system, latches are released due to loss of power supplies to the coils, all
the shutdown rods and control rods drop into the core by gravity. (Fig. 3.2.5)
Each trip breaker has two coils: shunt coil and undervoltage coil, which are controlled
by the reactor protection system. The undervoltage coils and the shunt coils are
simultaneously actuated by the same relay actuation module in case of protection
system actuation, and each relay actuation module actuates two relays. One relay for
the undervoltage coil and another one for the shunt coil.
The control circuits of trip breakers are supplied by 220V DC sytem (EDH).
To avoid the common mode failure, the specification of two breakers of each channel
must be the same, but they must be different type or be produced by different
manufactories.
Different channel of trip breaker cabinets must be physically separated and electric
isolated. Layout of the external cables must be separated.
3.2.6 Interlock of control red control system
3.2.6.1 Interlock of rod stopping
Important interlock signals as follows:
C-1: 1/2 neutron flux (intermediate range) above setpoint. Block automatic and
manual control rod withdrawal. (from CRP)
C-2: 2/4 neutron flux (power range) above setpoint. Block automatic and manual
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Pr PC2-03-12-03-02
CONTROL ROD CONTROL SYSTEM MANUAL Rev. B 2-12
control red withdrawal. (from CRP)
C-3: 2/4 overtemperature AT above setpoint. Block automatic and manual control rod
withdrawal. (from CRP)
C-4: 2/4 overpower AT above setpoint. Block automatic and manual control rod
withdrawal. (from CRP)
C-5: 1/1 main steam pressure after control valve below setpoint. Block automatic
control rod withdrawal, (from CRP)
C-11: 1/1 bank T4 control rod position above setpoint. Block automatic control rod
withdrawal]. (from CRD
C-12: 2/4 negative change rate of nuclear power above setpoint. Block automatic
control rod withdrawal. (from CRP)
C-15: 1/1 bank T4 control rod position lower then “low-low" setpoint. Block
automatic control rod insertion. (from CRD
(Figure 3.2.6)
3.2.6.2 Rod position interlock
Before shutdown rods are withdrawn to the top of the core, withdrawal of control reds
in overlap mode is forbidden.
Control rods are stopped when they reach the position of 5 steps from the bottom of
the core in overlap mode.
Before control rod bank T1 reach the position of 5 steps (low insertion limit),
insertion of shutdown rods manually is forbidden.
3.3. Choice of material - construction
Following componets are used for control equipment:
Programmable Logic Controller (PLC);
CMOS (Complementary Metal Oxide Semiconductor) integrated circuit.
Silicon controlled rectified componet.
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CONTROL ROD CONTROL SYSTEM MANUAL
PC2-03-12-03-001
Rev. A E2-13
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CONTROL ROD CONTROL SYSTEM MANUAL Rev.
4 Description of system and Equipment
4.1 Description
4.1.1 General
The control rod control system comprises two main parts:
a. Rod control part.
b. Rod position indication part. (refer to “contro! rod position indication system
manual” )
4.1.1.1 Control red control system cabinet
a. Control logic cabinet
Its function is to generate the necessary signals to step the rods during startup,
continuous operation, and shutdown of the nuclear power plant. It receives command
signals from the main control room and the reactor power contro] system (CRC). In
response to these signals, it selects the CRDMs to be driven and send command
signals to the assigned power cabinet to drive control rods.
The cycler which determines rod stepping frequency should be designed so that after
receiving a motion demand signal, it should cause the rods to step within the time
Tespouse requirements.
The control logic cabinet is capable of supervising the operation of a maximum
configuration of four contro! banks and two shutdown banks.
In addition to supervising the operation, the control logic cabinet has fault monitoring
circuit to monitor the internal fault within it, and receive monitoring signals from each
of its associated power cabinet. When a fault condition is detected, necessary action is
taken to prevent unsafe operation going on or dropping of control rod into the core.
b. Power cabinet
A power cabinet comprises two separate power equipment units. Each power
equipment unit is associated with a CRDM.
Each power equipment unit consists of:
@ = Three three-phase, half-wave, phase-controlled thyristor bridges
They are used to control and regulate current to the connected CRDM coils, the first
bridge is used to supply the stationary gripper coil, the second bridge used to supply
the movable gripper coil, and the third bridge used to supply the lift coil.
@ = Thyristor bridge control circuit
12-03-02
BL OE2-17
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CONTROL ROD CONTROL SYSTEM MANUAL Rev. B E2-18
It is the interface between the logic part and the power part. It converts logic signals
into analog setpoints so that the bridge can supply the required current to the coil (Fig
4.1.1).
A group comprises of 2~4 cluster of rods, their CRDMs are controlled by 1~2 power
cabinets. Because the whole group shall move together, there is a time sequence
assignment module in the power cabinet for one group.
The function of the time sequence assignment module is to provide current time
sequence signals to three coils of CRDMs of group.
After the time sequence assignment module has received the start pulse in terms of
group from logic cabinet, cycle begins according to the predetermined program, and
signals are sent to all the thyristor control circuit of this group.
The cycle of the time sequence assignment module is 780ms.
Based on the direction signal of withdrawal or insertion from logic cabinet, there are
two kinds of program produced in the time sequence assignment module: withdrawal
time sequence and insertion time sequence.
ce. DC. hold cabinet
A failure in the power cabinet may require replacement of a card, fuse, or other
component. To avoid the possibility of dropping rods during maintenance, there is a
switch in the power cabinet used to energize stationary gripper coil from a separate
125VDC and 7OVDC power supply. The 125VDC power supply is used to assure
latching of the stationary gripper and the 70VDC power supply is used to hold the
gripper without overheating the coil.
The 125VDC and 70VDC power supplies are generated by the DC. hold cabinet.
Power of the DC. hold cabinet is taken from the reactor trip breakers.
Each power supply consists of a three-phase transformer (Y/A) and a full wave, three-
phase rectifier unit.
d. Control supply distribution cabinet
It provides the redundant control source supplies to the control logic and power
cabinets. The 220V is supplied by the AC. instrumentation power supply system
(channel C). The 150V is from M-G set.
e. 260V AC. power distribution cabinet
This three-phase power is supplied by the M-G set and distributed to each of 19 power
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CONTROL ROD CONTROL SYSTEM MANUAL Rev. BE2-21
cabinet and power cabinet.
ERP: CRDM Power Supply System. Provide 260V AC three phases power supply to
the power cabinet and DC. hold cabinet through the reactor trip breakers.
CPC: Plant Computer system. Control rod contro! system transmits following signals
to the plant computer system;
Rod speed, direction and alarm signals.
CRP: Reactor Protection System. Provide interlock signals used to inhibit rod
movement (C1,C2,C3,C4,C5,C12). Emergency reactor trip signal is sent to the trip
breakers.
CRI: Control Rod Position Indicating System. Receive demanded rod position signal.
Provide interlock signals used to inhibit rod movement (C11,C15).
CRC: Reactor Power Control System. Signals are transmitted to the control system to
be used for rod travel speed control and direction selection. (Figure 4.1.2)
CMC: Main control room. All kinds of control switches and status indicators and test
switches of trip breakers are instalied on the control board in the main control room.
4.2 Characteristics
4.2.1 Drive shaft
The travel step, i.e. the distance between two grooves, is 10 mm.
Total travel is 280 steps.
4.2.2. CRDM
The maximum design speed is 60 steps per minute.
The maximum design load is 1471.5 N. (excluding the weight of the drive shaft)
Cycle for up or down one step requires at least 780 ms.
During a cycle, the sequence of current values in the movable gripper coil is low
current, high current, zero current, high current, low current.
The sequence of current values in the stationary gripper coil is zero current, high
current, zero current.
The sequence of current values in the lift coil is zero current, high current, low current,
zero current.
when not transferring the drive-shaft, only the movable gripper coil is energized, with
low current.
In the hot state, the average voltage at energized coil terminal is approximately
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CONTROL ROD CONTROL SYSTEM MANUAL Rev. B
PC2-03-12-
100VDC to 120VDC.
4.2.3 Position detector and rod position indication equipment
Refer to control rod position indication system manual.
4.2.4 Control red control system cabinets
Travel speed of RCCA varies between 6 steps per minute and 60 steps per minute
with a tolerance of +2 steps.
Input voltage: 220VAC_ 1%.
Input voltage: 260VAC : no.
Coil current values are allowed to be set.
Tolerance of coil current is 5%.
The time response of the control rods before it begins to drop following the arrival of
a trip signal at the trip breakers is 0.3 second.
The time iag between actual rod move and demanded rod move is one second during
the rods are in automatic control.
No single failure in equipment shall cause the banks to move in other than the
prescribed sequence.
The equipment design shall be such that with a single failure, stmultaneous
withdrawal of more than two banks of control or shutdown rods is not possible.
43 Layout
4.3.1 Layout of electrical equipment
4.3.1.1 Main control room
Controls:
a. Bank selector,
b. In - Hold - Out Level,
c. Test Bank Selector,
d. Lift Coil Disconnect Switches,
e. Startup Pushbutton,
f. Alarm Reset Pushbutton,
g. +1 Pushbuttons,
h. -1 Pushbuttons,
i. Realignment Mode Selector,
j. Trip Breaker switches.
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CONTROL ROD CONTROL SYSTEM MANUAL Rey.
12-03-02
B E2-23
Status lights:
a. Out Light,
b. in Light,
c. Manual Light,
d. Automatic Light
e. Test Light
f. Interlock signal status Lights. (C1, C2, C3, C4, C5, C11, C12, C16)
Indicators:
a, Rod Speed Indicator,
b. Demand Position displayer,
c. Realignment Step Counter.
Annunciators:
a. Rod Control Urgent Failure,
b. Rod Control Non-Urgent Failure.
4.3.1.2 Rod control room
The control rod contro! system equipment is installed in the rod contro! room, which
includes:
a. Two control logic cabinets,
b. one control power supply distribution cabinet,
c. Nineteen power cabinets,
d. Two 260V AC. power supply distribution cabinets,
e, one DC. bold cabinet,
£. 1" Generator distribution cabinet,
g. 2* Generator distribution cabinet,
h. MG Set control cabinet,
1. Ay trip breaker cabinet,
j. A> trip breaker cabinet,
k. By trip breaker cabinet,
1. Bo trip breaker cabinet,
mi. Test cabinet.
The equipment is exposed to the following ambient conditions:
Ambient temperature <30°C in normal operation.
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CONTROL ROD CONTROL SYSTEM MANUAL
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CONTROL ROD CONTROL SYSTEM MANUAL Rev. B E2-27
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CONTROL ROD CONTROL SYSTEM MANUAL Rev.
12-03-0
02
B B2-28
5 Operating Parameters
5.1 Normal operation
Control rod banks are operated automatically from 15% to 100% reactor rated power.
5.2 Particular steady operation
When turbine load is less then 15% rated power, select switch of control rod banks
will be changed from auto into manual by operator, control rod banks will be operated
manually.
5.3 Particular transient operation
5.3.1 System internal failure
5.3.1.1 Acontrol bank cannot be moved
If the failed bank responds to manual control only, manual control mode is used until
the fault has been removed. After fault climination, automatic operation can again be
used.
5.3.1.2 Acontrol bank inserts continuously
Controls are switched to manual mode:
a. First case: if the RCCAs respond to manual controls, equilibrium condition can be
reestablished after inserting several steps. Allow failure examination while
maintaining equilibrium condition. If the RCCAs do not respond to manual controls,
The plant operation procedures shall be followed.
b. Second case: If RCCAs insertion continues, the reactor is tripped.
5.3.1.3 A control bank withdraws continuously
If the interlock is not actuated, the reactor will be tripped because of over nuclear
power.
5.3.1.4 Acluster or several clusters drop
a. If several clusters have dropped: a reactor trip may be triggered by high nuclear
flux change rate depending on the power level and the location of the dropped
clusters,
b. If only one cluster has dropped: manual controls are used and power is reduced,
then dropping cluster is aligned to correct position.
5.3.1.5 RCCA misalignment
Controls are switched to manual mode and the correct operation of rod position
displayer is checked.
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