An integrated approach for Safer, Productive and Reliable PHWR fuel manufacturing at NFC

Abstract

India has been pursuing three-stage nuclear power programme and has developed comprehensive capabilities in all aspects of nuclear power and fuel cycle and is also recognized as a country with advanced nuclear technologies in the comity of nations. The first stage of Pressurized Heavy Water Reactors (PHWRs) based on natural uranium has reached a state of maturity. In view of civilian nuclear safeguards agreement with NSG and IAEA, Nuclear Power Reactors and associated fuel manufacturing facilities at Nuclear Fuel Complex (NFC) are grouped into safeguarded and out-of-safeguarded facilities for complaining with all IAEA material identification requirements. The civilian nuclear energy generation has to be accelerated for achieving energy security for the country. NFC has mastered both fuel and structural manufacturing technologies of 220, 540 and 700 MWe PHWRs. NFC is increasing the production capacities to meet the fuel and structural requirements of the forthcoming 700 MWe nuclear power reactors. Nearly 20GWe of nuclear energy generation is being planned through PHWR route. Accordingly, several improvements were carried out, aiming at improving productivity, safety and radiological aspects during production augmentation of fuel fabrication facilities. The UO₂ powder production process from is standardized by optimizing process parameters for different types of raw materials. Process automation in the production process has resulted in higher productivity, safety and product reliability. The new process modifications have resulted in reduction of effluents generation and improvement in uranium recovery from tail end products. Flexible manufacturing systems consisting of automatic workstations and robots were introduced in the 19 and 37 element PHWR fuel assembly lines. Various safety measures were introduced right from design stage for improving radiological safety of workmen. State-of-art equipment were designed, developed and commissioned for reduction/ elimination of fatigue-oriented operations, which has resulted in substantial increase of productivity. Similarly numerous process modifications were carried out in the zircoloy fabrication line for achieving higher recovery, productivity and quality. The paper covers various process modifications that are carried out in PHWR fuel and structural production processes. These improvements have resulted in increasing safety, productivity and reliable nuclear fuel production.