SUPERVISORY CONTROL OF A 4TH GENERATION SMALL SCALE NUCLEAR REACTOR CORE MODELS-Core-2014

SUPERVISORY CONTROL OF A 4
TH
GENERATION
SMALL SCALE NUCLEAR REACTOR CORE MODEL

Group Members:
AIMEN BABUR (100404)
AITIZAZ YOUSAF (100500)
USMAN YOUSAF (100519)
M. ZUBAIR FAYYAZ (100600)

BE MECHATRONICS (2010-2014)

Project Supervisor
S Zahid Hussain Dr. Zafar ullah Koreshi
Assistant Professor Professor/Chair/Dean Engg

DEPARTMENT OF MECHATRONICS ENGINEERING
FACULTY OF ENGINEERING
AIR UNIVERSITY, ISLAMABAD
TH
GENERATION
SMALL SCALE NUCLEAR REACTOR MODEL

FINAL YEAR PROJECT REPORT

(2010-2014)

DEPARTMENT OF MECHATRONICS ENGINEERING
TH
GENERATION
SMALL SCALE NUCLEAR REACTOR MODEL
Submitted By:
AIMEN BABUR (100404)
AITIZAZ YOUSAF (100500)
USMAN YOUSAF (100519)
M. ZUBAIR FAYYAZ (100600)
Project Supervisor

_______________________ ________________________
Sir Zahid Hussain Dr. Zafarullah Koreshi
Assistant Professor Professor/ Chair/ Dean

Area In-charge (Robotics and Automation)

_____________________________________
Dr. Liaquat Ali Khan

Head of Department

______________________________________
Dr. Zafarullah Koreshi

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Acknowledgement
We express our humblest gratitude to Allah Almighty who has given us the direction
to accomplish our purpose and guided us through every thick and thin.
This project would not have been possible without the guidance and the help of
several individuals who have in one way or the other contributed and extended their
valuable assistance in the preparation and completion of this project.
We would like to acknowledge the assistance of our supervisors Mr. Zahid Hussain
and Senior Dean Dr. Zafar ullah Koreshi for guiding us throughout the designing
process, for the support for our study and research, for their patience, motivation and
immense knowledge. We thank them for their support and help because of which we
are able to complete our final year project in time. They assisted in performing a
comprehensive literature review. Moreover they have been regularly checking our
progress on the project.
Also, we would like to thank our parents and families for their financial, motivational
and never ending support in our study and in its success.

ii

Abstract
Energy is considered to be the life line of any economy and most vital requirement of
socio-economic development of a country. There has been an enormous increase in
the demand of energy all over the world including Pakistan due to industrial
development and population growth. Due to depleting reserves of oil, now the trend is
shifting towards electricity generation using nuclear power plants. Due to this reason,
we have picked our final year project related to nuclear energy. The goal of this
project is to design and fabricate small scale model of 4
th
generation nuclear reactor.
This report comprises of general introduction to nuclear reactor and SCADA,
modeling and simulation of DC motors used in the project and experimental setup.
The basic terminologies related to nuclear energy and generations of nuclear reactors
are discussed briefly whereas fourth generation of nuclear reactors is discussed with
detail along with its type. Advantages and design parameters of Toshiba 4S (super
safe, simple, small, secure) reactor are given as well. Modeling of DC motors includes
modeling of DC motor and calculations of torque. Experimental setup is elaborated
with solidworks models and fabricated parts diagrams. PLC programming and
softwares used are included in results. PLC programming is given in appendix A
whereas datasheets of HMI and motor is given in appendix B. We have succeeded in
controlling some parameters of the plant which include shutdown control, fuel
replacement control and k-effectiveness control.

iii

Table of Contents
Chapter 1: Introduction
1.1: Nuclear Physics ................. 1
1.1.1: Principle of Operation ................ 1
1.1.2: Types of Nuclear Reactor ............... 2
1.1.3: Components of Nuclear Reactor ................ 5
1.1.4: Generations of Nuclear Reactor ................. 7
1.2: SCADA (Supervisory Control and Data Acquisition) .............................. 8
1.2.1: Functions of SCADA ............. 9
1.2.2: Block Representation of SCADA ................ 10
1.2.3: SCADA Components ................... 10
Chapter 2: Theory
2.1: Nuclear Power in Pakistan .................. 12
2.1.1: Karachi Nuclear Power Complex ................. 13
2.1.2: Chashma Nuclear Power Complex .................. 13
2.1.3: Muzaffargarh Nuclear Power Complex ................... 14
2.2: Generation IV Nuclear Reactors ............. 14
2.2.1: Initiative Goals ................. 15
2.2.2: Six Concepts of Research and Development ............... 16
2.3: Toshiba 4S Reactor ............. 20
2.3.1: Why it is called 4S ................... 21
2.3.2: Advantages of 4S ................. 21
2.3.3: Plant Design Parameters ................... 22
2.3.4: Diagram of Complete Model of Nuclear Reactor .................... 23
Chapter 3: Electro-mechanical Modeling of DC motor
3.1: Modeling of DC Motor ............... 24
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3.2: Torque Calculations ................ 26
Chapter 4: Experimental Setup
4.1: Experimental Setup of Complete Model ..................... 29
4.1.1: Solidworks Model of Reactor .................. 30
4.2: Parts of Reactor ........................... 31
4.2.1: Fuel Subassemblies and Fuel Pins ............... 31
4.2.2: Reflector ................... 32
4.2.3: Shutdown Rods ................ 33
4.2.4: Upper and Lower Plate ................. 34
4.2.5: Shutdown Plate ............. 36
4.2.6: Fuel pin Upper and Lower Hexagons ...................... 37
4.2.7: Base of Assembly ................. 39
4.2.8: Motors ...................... 39
4.2.9: Proximity Sensor ...................... 40
Chapter 5: SCADA and Human Machine Interface (HMI)
5.1: Electronic Design .................... 42
5.2: Driver Circuit .................. 42
5.3: Programmable Logic Controller ...................... 44
5.4: HMI ............. 44
Chapter 6: Results
6.1: Results ................. 46
6.2: GX Developer ..................... 48
6.3: GT Developer .................. 48
Chapter 7: Future Recommendations
7.1: Limitations and Future Recommendations ................. 50
Appendix A ........ 51

v

Appendix B ......... 56
Bibliography ........... 59

vi

List of Figures
Figure 1.1: Nuclear Reaction Example......1
Figure 1.2: Nuclear Fission Reaction.2
Figure 1.3: Pressurized Water Reactor...3
Figure 1.4: Boiling Water Reactor.4
Figure 1.5: Uranium Pallets........5
Figure 1.6: Graphite Molten Salt Reactor..........5
Figure 1.7: Control Rods Assembly...6
Figure 1.8: Fuel Pin........................................................................................................6
Figure 1.9: Generations of Nuclear Reactors.........7
Figure 1.10: Example of a Plant Using SCADA............9
Figure 1.11: Block Diagram of SCADA..........10
Figure 2.1: Effect of Transmutation on Toxicity.........15
Figure 2.2: VHTR.........17
Figure 2.3: GFR........17
Figure 2.4: SFR........18
Figure 2.5: LFR........19
Figure 2.6: SCWR........19
Figure 2.7: MSR...........20
Figure 2.8: Cross Section of 4S Core.......22
Figure 2.9: Complete Model of 4S ......23
Figure 3.1: DC Motor.......24
Figure 3.2: DC Motor for Controlling Reflectors........................................................27
Figure 3.3: DC Motor for Controlling Shutdown Plate................................................28
Figure 4.1: Complete Model of 4S Reactor.........33
Figure 4.2: Front View of Solidworks Model ......34

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Figure 4.3: Side View of solidworks Model.........35
Figure 4.4: Solidworks Model of Reactor.35
Figure 4.5: Fuel Subassemblies and Pins.........36
Figure 4.6: Solidworks Model of Fuel Pin........37
Figure 4.7: Reflectors...........38
Figure 4.8: Solidworks Model of Reflectors.........38
Figure 4.9: Shutdown Rods..........39
Figure 4.10: Solidworks Model of Shutdown Rod...........40
Figure 4.11: Assembly of Upper and Lower Plates.........41
Figure 4.12: Solidworks Model of Upper Plate............41
Figure 4.13: Solidworks model of Upper and Lower Plate Assembly......42
Figure 4.14: Shutdown Plate............43
Figure 4.15: Solidworks Model of Shutdown Plate......43
Figure 4.16: Upper Hexagon of Fuel Pin.............44
Figure 4.17: Lower Hexagon of Fuel Pin.........44
Figure 4.18: Solidworks Model of Upper Hexagon..........45
Figure 4.19: Solidworks model ofLlower Hexagon..........45
Figure 4.20: Solidworks Model of Base of Assembly..........46
Figure 4.21: Motors for Reflectors and Shut Down Rod.............47
Figure 4.22: Inductive Proximity Sensor.........48
Figure 4.23: Inductive Proximity Sensor Used in Project........48
Figure 5.1: Electronic Design...........49
Figure 5.2: Driver Circuit 1..........50
Figure 5.3: Driver Circuit 2..........50
Figure 5.5: Mitsubishi FX 1N-24MR-ES.........51
Figure 5.6: Mitsubishi PLC Being used in Project...........51
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Figure 5.7: Mitsubishi HMI F940G0T-LWD.......52
Figure 6.1: Complete Project with HMI and Manual Control.........53
Figure 6.2: Side View of the Project............54
Figure 6.3: GX Developer............55
Figure 6.4: GT Developer............56

Chapter 1
Introduction
1.1 Nuclear Physics
In Nuclear physics, nuclear reaction is the process in which two nuclei collide with
each other and produce nuclei which are different than the nuclei colliding initially.
Nuclear reactors are the devices which are used for producing a steady flow of
neutrons and subsequent thermal energy from the exothermic fission reaction by the
collision of heavy nuclear particles. It is used for initiating and controlling a chain
reaction.

Figure 1.1: Nuclear Reaction Example
1.1.1 Principle of Operation
A nuclear reactor starts the chain reaction using the principle of nuclear fission. When a large
nucleus collides with a neutron, it splits into smaller nuclei. As a result of this reaction,
kinetic energy, free neutrons and gamma radiations are produced. These free neutrons can
start a new fission reaction on their own. A fission reaction produces approximately 200 MeV
as compared to a chemical reaction which produces only a few eV. This is called chain
reaction because once initiated, it does not stop by itself and results could be disastrous if
such a reaction is uncontrolled. [1]
Introduction

2

To control the chain reaction, neutron moderator or neutron poisons are used to change the
position of neutrons causing the reaction thereby controlling the release of energy and free
neutrons. Most commonly used moderators are heavy water, regular (or light) water and solid
graphite. Nuclear reactors usually have manual and automatic shut down systems to deal with
any emergency situations.

Figure 1.2: Nuclear Fission Reaction
1.1.2 Types of Nuclear Reactor
Depending upon their functionality, there are two broad categories of nuclear reactors:
1- Nuclear power reactors
2- Nuclear research reactors
Nuclear Power Reactors: They are usually found in nuclear power plants. They
produce thermal energy which can be used as it is or can be converted into
mechanical and electrical energy. [3]
Uses:
They are used for:
Electricity generation
Propulsion of ships
Supervisory Control of a 4
th
Generation Small Scale Nuclear Reactor Model
3

Heat production
Types of Nuclear Power Reactors: Following are different types of nuclear power
reactors:
1- Pressurized Water Reactor (PWR): This reactor uses enriched uranium as fuel
and light water is used as moderator and coolant. In this reactor, the pressure applied
to the coolant prevents it from boiling. The heat produced from the fuel is transferred
to the water of a secondary circuit. Steam is generated from water and this steam then
enters the turbine.

Figure 1.3: Pressurized Water Reactor
2- Boiling Water Reactor (BWR): The principle of operation is same as PWR
except that pressure applied to the coolant is lower so that it boils and the steam
generated is fed into the turbine.

Figure 1.4: Boiling Water Reactor
Introduction

4

3- Uranium Fuelled Reactor: They use uranium for nuclear fission reaction as one
kg of uranium can generate as much energy as 10 tones of oil.
4- Plutonium Fuelled Reactor: These reactors use plutonium as fuel for fission
reaction. Plutonium is hundred times more active than uranium as one g of plutonium
produces the same energy as one tone of oil.
Nuclear Research Reactors: Usually universities and research centers use nuclear
research reactors. They are also called non- power reactors. As compared to power
nuclear reactors, they operate at lower temperatures and are much simpler to use.
However, they require more highly enriched uranium as compared to power reactors
for neutron generation.
Uses:
They are used for:
Non- destructive testing
Analysis and testing of materials
Production of radioisotopes
Research purposes
Educational purposes
1.1.3 Components of Nuclear Reactor
The most common components are:
Nuclear Fuel: The material which is required for fission chain reaction is the
nuclear fuel. Uranium is the best fuel for a nuclear reactor

Figure 1.5: Uranium Pellets [9]
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5

Nuclear Reactor Core: The portion of nuclear reactor where the whole
reaction takes place is called nuclear reactor core.

Figure 1.6: Graphite Molten Salt Reactor [10]
Neutron Moderator: Neutron moderator is used for reducing the speed of
fast neutrons so as to control the fission chain reaction.
Control Rods: These are made using neutron-absorbing materials so that they
can be used to control the fission reaction.

Figure 1.7: Control Rods Assembly [11]
Introduction

6

Coolant: The fluid which is used to dissipate heat from the fluid in the nuclear
reactor is called coolant. It is also known as refrigerant.
Reactor Pressure Vessel: The pressure vessel which holds the nuclear reactor
core, stainless steel cylinder which surrounds the core and coolant.
Fuel Pin: The smallest unit of a reactor is a fuel pin. They are often
surrounded by a metal tube which is called cladding. Cladding stops the
fission products from escaping into the coolant.
1.1.4 Generations of Nuclear Reactors
There are four generations of nuclear reactors as mentioned in the following diagram:

Figure 1.9: Generations of Nuclear Reactors [12]

Generation 1:
This generation refers to the early prototype of power reactors from 1950s and 1960s.
Examples include
Shippingport in Pennsylvania
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7

Calder Hall-1 in United Kingdom
The only remaining plant of this generation is Wylfa Nuclear Power Station in
Wales.
Generation 2:
This generation points to the commercial reactors built till the end of 1990s. They
were built to be both reliable and reasonably priced. Examples include:
1- Boiling water reactors (BWR)
2-Pressurized water reactors (PWR)
3- Advanced Gas-Cooled Reactors (AGR)
Generation 3:
This generation is a development of generation 2 nuclear reactors by making
improvements in their designs. These improvements include:
Does not require any manual or electronic feedback for shutting down in
case of any emergency situation, this is known as passive safety
Has higher thermal efficiency
Reduces maintenance costs by adopting a standard design
Has improved fuel technology
Examples include:
1- Advanced Boiling Water Reactor (ABWR)
2- Advanced Pressurized Water Reactor (APWR)
Generation 4:
Currently all the research work is being done on generation 4 reactors. Initially many
reactors were taken into consideration but then this list was downsized to look into
most promising technologies. Rest of discussion is included on chapter 2.
1.2 SCADA (Supervisory Control and Data Acquisition)
SCADA stands for Supervisory Control and Data Acquisition. It is a computer
based system which provides communication with remote equipment in industries so
that their operation can be controlled. SCADA allows industries to monitor, gather
Introduction

8

and process data so that the process can be made more efficient. SCADA systems can
be used to provide information to the operator for rapid for action. SCADA systems
have also been given capability to store and download programs to controllers for
producing various products. They have also been given the capability to share their
information over internet which makes it really easy for a user to watch graphics and
have data from a process taking place anywhere in the world. [7]

Figure 1.10: Example of a Plant Using SCADA [7]
1.2.1 Functions of SCADA
Major functions of SCADA include:
Alarm Function: SCADA performs a preset or predefined function whenever
alarm rings in a process.
Analog Function: It displays and records analog quantities which are
measured using transducers.
Control Function: SCADA systems control all the manual and automatic
functions within a process.
Indication Function: It displays and records the status of all the devices
involved in a process.
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9

Accumulator Function: It accepts and totals digital pulses for displaying or
recording.
Sequence of Events Function: It recognizes preset events, associates a time
with the occurrence of each event and resets the data of event in order of
occurrence of events.
Logging/archeiving: SCADA has the capability of logging/archiving. Logging
is a medium storage of data on disk whereas archiving refers to long term
storage of data.
Report Generation: It can produce reports based on the results from the
transducers and the status of devices involved in the process.
1.2.2 Block Representation of SCADA
Following is a block diagram of SCADA system:

Figure 1.11: Block Diagram of SCADA
1.2.3 SCADA Components
SCADA consists of following basic components:
Introduction

10

Remote Terminal Unit (RTU): These units are connected to the sensors and
convert the signals received by the sensors to digital data. These are the
computer units present in field so as they can gather reports from the sensors
and deliver commands to control relays.
Programmable Logic Controllers: They have the same functions as RTUs
except that they have advanced control abilities as compared to RTUs and are
economical, adaptable and flexible.
SCADA Master Unit: These are large computers which act as central
processor for the SCADA system. It automatically regulates the managed
system according to the response from the sensors.
Communication Network: This network provides a connection between
RTUs or PLCs to the SCADA master unit.
Human Machine Interface (HMI): HMI is the apparatus which is used for
presenting the acquired data to a human operator. It helps operators to observe
and interact with the process.
Data Acquisition Server: It is a software service which connects field
devices like RTUs and PLCs through industrial protocols. The basic purpose is
to allow the operator to get data from sensors through field devices.
Supervisory System: system for collecting data and sending control
commands to the whole system is called supervisory system.
In this project, only HMI is being displayed and not the whole of SCADA.

Chapter 2
Theory
2.1 Nuclear Power in Pakistan
Amongst the most prominent Muslim countries of the world, one of the most
advanced countries is Islamic Republic of Pakistan. However, it is still not a
technologically developed country due to various problems which includes rapid
increase in population. Pakistan needs financially viable and secure sources of energy.
As Pakistan is still a developing country, it is looking forward to increase its potential
in the field of nuclear energy.
Pakistan is the first nuclear power of the Islamic world. In Pakistan, nuclear energy is
being provided by 3 licensed-commercial nuclear power plants. These power plants
include:
1- Chashma Nuclear Power plant
2- Karachi Nuclear Power plant
3- Muzaffargarh Nuclear Power plant
Although the nuclear power project of Pakistan is small having a capacity of 725
MWe but is trying to increase its capacity significantly. In 2010, 94.5 billion KWh of
electricity was produced by Pakistan out of which 33 TWh of electricity was
generated from oil, approximately same amount from hydroelectric power and about
26 TWh from natural gas. The contribution of nuclear power is really small i.e.
approximately 3.8 TWh which makes it only 3.8% of the total electricity. Nuclear
power plants have a total installed capacity of 20 GWe but only 12 GWe is being
used. Due to this reason, power shortages and load shedding is really common. In
order to increase nuclear power of the country, government adopted energy security
plan in 2005 and decided to increase the generation capacity to 160 GWe by 2030. In
July 2013, the ECNEC announced 3.5 GWe of new power projects comprising of
2200 MWe of nuclear power projects, 969 MWe of hydro power projects and 425
MWe of gas combined cycle. All these projects depend on Chinas support as only
China is interested in launching nuclear projects in Pakistan.
Theory

12

2.1.1 Karachi Nuclear Power Complex (KNPC)
KNPC, situated in Karachi, consists of Karachi Nuclear Power Plant (KANUPP). This
power plant is functional due to investments of international Atomic Energy Agency,
China National Nuclear Cooperation and China atomic energy authority. International
Atomic Energy Agency is responsible for its protection and inspection. The reactor
type present in this plant is Deuterium Uranium Pressurized Heavy Water Reactor
(PHWR) and the planned power generation is 8800MW. Following are the current
and future projects planned for this facility:
KANUPP-1: This project was inaugurated on 28 November 1972. The type of
reactor is CANDU-PHWR and the total power generated by this project is 137
MW. However, it is limited to 84 MW only.
KANUPP-2: It is a civilian nuclear power project of the government which is
still under construction. It was inaugurated on 26
th
November 2013. The
estimated cost is about $4.8 billion and power generation will be about 1100
MW. The type of nuclear reactor is CAP 1400 which is based on AP1000
Westinghouse Electric Company Pressurized water Reactor.
KANUPP-3: It is a project which is under construction just like KANUPP-2
and, once completed, will produce about 1100 MW of electricity. It is being
completed with the help of China.
KANUPP-4: This is a planned project whose construction has not yet started.
2.1.2 Chashma Nuclear Power Plant (CHASNUPP)
CHASNUPP, located near Chashma city Punjab, consists of Chashma Nuclear Power
Plant 1 and Chashma Nuclear power Plant 2. It is a commercial nuclear power plant
which is being constructed and financed by China and is being operated by Pakistan
Atomic Energy Commission. The reactor types used in this plant are Low Enriched
Uranium Very high temperature reactor (VHTR) and Pressurized Light Water Reactor
(PWR). The generation capacity is about 600 MW. The current and future projects are
as follows:
CHASNUPP-1: This project is located in Kundian, Punjab. It is a commercial
project which began operating in MAY 2000. The reactor type used is
pressurized water reactor and has generation capacity of 300 MW(e).
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13

CHASNUPP-2: This project is located in the south of Mianwali near Chashma
Barrage. It was inaugurated on 10 May 2012. The electricity generation
capacity is almost the same as CHASNUPP-1 i.e. 300 MW(e).
CHASNUPP-3 and CHASNUPP-4: The contract for the design of both these
projects was signed with Shanghai Nuclear Engineering Research and Design
Institute (SNERDI) ON 28
th
April 2009. Both projects have the capacity of
generating 340 MW(e) and design life is expected to be about 40 years. The
construction of CHASNUPP-3 is expected to be completed in 2016 while that
of CHASNUPP-4 in 2017.
CHASNUPP-5: This is a planned project between Pakistan and China which
has the capacity of 1000 MW(e).
2.1.3 Muzaffargarh Nuclear Power Complex
This complex is still under construction. When it is completed, it would have the
capacity of generating 1100 MW. According to Pakistan Atomic Energy Commission
(PAEC) plans, three Chinese nuclear reactors would be installed here.
2.2 Generation IV Nuclear Reactors
Power plants produce about 16% of the electricity around the world. Although the
second and third generation reactors, which are currently being used, provide
electricity cost-effectively and efficiently but still there is a room for improvement so
that opportunities are created for greater use of nuclear energy. The fourth generation
of reactors is expected to be ready by 2030. Following objectives are kept in mind
while designing these reactors:
Financial competitiveness
Superior safety
Minimum radioactive waste generation
Proliferation resistance
2.2.1 Initiative Goals
The goals of designing 4
th
generation reactors [13] are:
Theory

14

Sustainability: The major concern while designing these reactors was that the
environment is not affected adversely by these reactors. The environment was
to be kept clean through clean air limitations, preservation of resources and
waste management limitations. Due to the inadequate availability of repository
space all over the world, waste management is considered a major concern.
Performance of a reactor can be improved by making closed fuel cycles
allowing the fuel to be reused by the reactor so that less space is required for
the fuel in repository. Also, by transmutation, relative toxicity can be
controlled.

Figure 2.1: Effect of Transmutation on Toxicity
Reliability and Safety: An important goal of designing reactor is that it should
be reliable and safe. International rules and regulations for safe operation of
nuclear reactor and safe handling of fuel are to be strictly followed. Steps
should be taken so that the leakage of radioactive materials in the environment
is strictly controlled.
Financial Competitiveness: New reactors are designed such that they are
competitive for the ever changing energy demands of market. Nuclear reactors
can be privately owned or publicly owned. Plants are required to have a
standard size so that its parts can be replaced easily and ecomically. If each
reactor is designed uniquely then its parts cannot be replaced or duplicated
easily.
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15

Proliferation Resistance: Nuclear reactors are designed such that they have the
ability to deal with natural disasters such as earth quakes, tsunami etc. special
attention should be given to a reactors protection so that the theft of
radioactive materials or parts of plant by any individual or a group is not
possible.
2.2.2 Six Concepts for Research and Development
Keeping in mind the goals and objectives discussed above, following concepts were
considered for research and development: [4]
1- Very High Temperature Reactor (VHTR): Very high temperature reactor or
VHTR is a 4
th
generation gas cooled reactor designed to produce both electricity and
hydrogen. It is He cooled reactor with graphite moderator and once-through uranium
fuel cycle. Hydrogen acts as nuclear energy carrier. Applications of VHTR include:
Production of hydrogen
Heat of process for petrochemical industry
The reactor core is 600 MW core connected to a heat exchanger which is responsible
for providing process heat. For the production of hydrogen, a thermo chemical iodine-
sulfur process takes place due to heat supplied by reactor. A safety factor is that the
heat of the nuclear reactor is radiator away from graphite moderator so that it does not
damage the nuclear reactor. This reactor will be built underground so that the earth
absorbs all the excessive heat. VHTR provides high efficiency electricity production
and a variety of process heat applications without creating any safety hazards for
environment.

Figure 2.2: VHTR [14]
Theory

16

2- Gas Cooled Fast Reactor (GFR): GFR is a 4
th
generation reactor which uses a
fast neutron spectrum and He cooling system. It has a close fuel cycle. The fast
neutron spectrum is responsible for converting fertile uranium into fuel. This reactor
is responsible for producing electricity, hydrogen and process heat very efficiently.
This process heat can be used to produce hydrogen. As GFR recycles actinides, so
radio active waste is minimized and environment is not affected. The fast spectrum
has drawbacks that it has low thermal inertia and at low pressures of He coolant, there
is poor heat removal

Figure 2.3: GFR [15]
3- Sodium Cooled Fast Reactor (SFR): SFR is a 4
th
generation reactor which
features fast neutron spectrum, closed fuel cycle and NA cooling. The closed fuel
cycle is responsible for dealing with actinides which play a great role in environment
pollution. The full cycle has two major options:
One: 150 to 500 MWe generation of electricity, sodium cooled reactor and
Uranium-Plutonium-minor-actinide-zirconium metal fuel alloy supported by
fuel cycle
Two: 500 to 1500 MWe generation of electricity, sodium cooled reactor and
mixed Uranium-Plutonium oxide fuel supported by fuel cycle.SFR is designed
such that it can manage high level wastes including actinides.
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17

Figure 2.4: SFR [16]
4- Lead Cooled Fast Reactor (LFR): LFR is a 4
th
generation reactor which features
fast spectrum Pb, closed fuel cycle and Pb-Bi liquid metal- cooling. It can handle
management of actinides very efficiently. The fuel used in this reactor consists of
fertile uranium and transuranics. The process of natural convection is used for cooling
the reactor.
The small size LFR can be operated as nuclear battery. It requires refueling after an
interval of 15 to 20 years. It can be used for electricity production on small grids. This
system is best especially for developing countries which cannot spend too much
money on their nuclear energy systems.

Figure 2.5: LFR [17]
Theory

18

5- Supercritical Water Cooled Reactor (SCWR): SCWR is a 4
th
generation reactor
which operates at high temperature and high pressure. It features water cooling. It
ensures that the thermal efficiency provided is about one-third higher than light-water
reactors currently working. However, as the water is above the critical point, it
requires special material designs.
The main purpose of SCWR is production of electricity along with actinide
management efficiently.

Figure 2.6: SCWR [18]
6- MOLTEN SALT REACTOR (MSR): MSR is a 4
th
generation reactor which
causes fission reaction in a circulating molten salt fuel mixture. It has graphite core
channels with actinide recycle management. The fuel is circulating liquid mixture of
zirconium, sodium and uranium fluorides. The heat produced in the molten salt is
transferred to a power conversion system through intermediate and tertiary heat
exchangers. The power generated is approximately 1000 MWe. The liquid fuel used
in MSR can allow addition of actinides. These actinides form fluorinides in liquid
coolant which have excellent heat transfer characteristics.
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Figure 2.7: MSR [19]
2.3 Toshiba 4S Reactor
Toshiba 4S reactor is a small sodium cooled reactor which is made to meet the ever
increasing global market trends. This reactor has a unique design as compared to other
reactors. The goals are as follows:
Minimize the risks of security and environmental pollution
Can provide safe, clean and consistent electricity
Minimize the cost of infrastructure, operation and maintenance requirements
This reactor is designed to provide 10 MWe of power. Also, Toshiba has planned
about 50 MWe version as well. 4S is a fast neutron sodium reactor so it uses
neutron reflector panels. These panels are used to maintain the k effectiveness
parameter of the reactor to be 1. If k is greater than 1, reflectors move downwards
to cover the control rods and if k is less than 1, then the reflectors move upwards.
Thus this reactor has the ability to handle any emergency situation without
complete shut down. [6]
Theory

20

2.3.1 Why it is called 4S
This reactor is called 4S reactor because these S stand for:
Super Safe: 4S is super safe because it uses reflectors to control the radioactivity of
plant which may lead to any emergency situation. The reactor will be underground
and it uses passive cooling system for removal of process heat.
Simple: all the parts of plant are easily available or can be built at factories
and assembled on the spot. It is really easy to ship the parts as well. Low
maintenance cost and long life-cycle makes 4S reactor really simple and easy
to operate.
Small: the total area of the reactor will be really small i.e. 26m * 16m. Its
height is only 0.68m. Thus this reactor can be easily handled as it is small and
safe.
Secure: Due to its ability to cope up with natural disasters like earthquakes, it
is completely secure and safe. As it is built underground so access to the core
and fuel is restricted. Also, refueling is required after 20 to 30 years so it
comes as an advantage as well.[6]
2.3.2 Advantages of 4S
Following are the advantages of 4S reactor:
No onsite refueling is required for about 10 - 30 years. This long refueling
period makes it very efficient and simple to use.
As the plant is located underground, so the access to the reactor and fuel is
restricted which makes it very safe and reliable.
The heat produces during the operation is safely removes so that any
emergency situation is avoided.
The reactor has the ability to cope up with natural disasters.
There is no heavy lifting equipment present on site which reduces the security
risks.
It is ensured that the maintenance and inspection cost is kept to the minimum.
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21

There is a primary shutdown system which consists of reflectors and back up
system consisting of shutdown rod which makes it completely safe and secure.
2.3.3 Plant Design Parameters
Core Design Parameters:
The core is shaped as a cylinder whose height is about 2.5 m while the equivalent core
diameter is 0.95 m. There are 18 fuel subassemblies. Each fuel subassembly contains
fuel pins. Each fuel pin consists of bonding sodium, U-Zr alloy, shell tubes and plugs
at both ends. The fuel pins are arranged in the subassemblies along a predetermined
grid and a top shield is present so as to give protection to the reactor. There is 1
shutdown rod in each fuel subassembly. These shutdown rods act as back up of the
shut down mechanism. The absorber material used in the shutdown rods is B4C.

Figure 2.8: Cross Section of 4S Core [20]
Reflector Design Parameters:
The reflectors are the only moveable parts in the reactor. There are total 6 reflectors in
the assembly. The material used for the reflectors is Mod9Cr1Mo. The thickness of
the material is 38 cm while height is 2.7 m. Reflectors are a part of primary shut down
system while shutdown rods are a part of back-up shutdown system.
Theory

22

2.3.4 Diagram of Complete Model of 4S Reactor
Following is the complete model of 4S reactor.

Figure 2.9: Complete Model of 4S [21]

Chapter 3
Electro-Mechanical Modeling of DC Motor
3.1 Modeling of a DC Motor
This chapter focuses on the mathematical modeling and the torques calculated of DC
motors used in the project. DC motor is an electromagnetic system designed by a
coupled second order ODE.
The modeling of a DC motor is as follows:

Figure 3.1: DC Motor
Applying KVL, we have:
3.1
Where:
V
a =
total voltage
V
ra =
voltage across the resistor
V
la
= voltage across the inductor
According to Ohms law, we have:
3.2
Modeling

24

Next, we have:

3.3
For motor, we have:
3.4
Putting the values in equation (3.1):

For current, we have equations:

3.5
Taking derivative, we have:

For torque, we have:

3.6
Putting all the values in equation:

After simplifications:

Taking Laplace inverse:

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25

The transfer function is:

3.7
3.2 Torque Calculation
Torque refers to the ability of the force to rotate an object around its axis. Before
selection of motors for the project, torque for each motor was calculated so that the
selection was made based on the requirements of the project. Following equations are
used for finding the torque of all the motors:
We have:
3.8
Where:
P = pitch of ball screw
Putting d
o
= 1.5 cm and P = 1 cm, we have:
d
p
= 1.4350 cm
For torque calculation of three motors, we have following expression:

3.9
Where:
M = mass of body
P = pitch of ball screw
One motor is being used to control the motion of reflectors. The torque for this motor
is as follows:
M = mass of reflector = 20 kg
dp = 1.4350 cm
dr = 1.14cm
= 0.2463
Modeling

26

Lead angle == 1.2706
Putting all the values, the torque for first motor comes out to be:
T
1
= 0.654 N-m
Following is the figure of the motor used for controlling the motion of reflectors.

Figure 3.2: DC Motor for Controlling Reflectors
The other two motors are being used with shutdown plate. One is being used to
control the motion of plate in the vertical direction while one is being used to control
the motion in the horizontal direction for fuel cell replacement. The torque
calculations for both motors are as follows:
M of upper plate = 8 kg
dp = 1.4350 cm
dr = 1.14cm
= 0.2463
Lead angle = = 1.2706
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27

So, we have:
T
2
= T
3
= 0.2618 N-m
Following is the figure of these two motors discussed above

Figure 3.3: DC Motor for Controlling Shutdown Plate

Chapter 4
Experimental Setup
4.1 Experimental Setup of Complete Model
The complete body of reactor is made up of aluminium because it is very light weight
and economical. In the assembly, there are 19 fuel subassemblies and each
subassembly contains 6 fuel pins. The reflectors are used also made of aluminium.
There is an upper and lower lid. Shutdown rods are connected to the upper lid. Both
the reflectors and shutdown rods are operated by using motors for providing safety
system for reactor. Programmable Logic Controller (PLC) is used for controlling the
motors whereas SCADA is used for data acquisition.

Figure 4.1: Complete Model of 4S Reactor
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29

4.1.1 Solidworks Model of Reactor

Figure 4.2: Front View of Solidworks Model

Figure 4.3: Side View of Solidworks Model
Experimental Setup

30

Figure 4.4: Solidworks Model of Reactor
4.2 Parts of Reactor
4.2.1 Fuel Subassemblies and Fuel Pin
There are total 18 subassemblies in 4S reactor and each subassembly has 6 hexagons
or fuel pins. The length of each fuel pin is 45 cm and diameter is 1 cm. These fuel
subassemblies are responsible for fission reaction in the reactor.

Figure 4.5: Fuel Subassemblies and Pins
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31

Solidworks Model

Figure 4.6: Solidworks Model of Fuel Pin
4.2.2 Reflector
Reflectors are responsible for controlling the fission reaction and shutdown of reactor
in case of any emergency situation. There are 3 reflectors in reactor assembly. In the
4S the reflector is made of beryllium but we have used aluminum in this model. The
reactors are controlled using a motor which is responsible for its up and down
motion. The thickness of reflector is 5.6 cm whereas length of reflector is 45 cm.
Following is the diagram for reflectors:

Figure 4.7: Reflector
Experimental Setup

32

Solidworks Model

Figure 4.8: Solidworks Model of Reflectors
4.2.3 Shutdown Rods
Shutdown rods provide a backup for emergency shutdown of reactor. Shutdown rods,
usually of a neutron absorber such as boron or hafnium, provide control and a backup
for emergency shutdown of the reactor. There is a shutdown rod in each subassembly
so there are total 19 shutdown rods in this reactor assembly. The length of each
shutdown rod is 45 cm while diameter is about 1 cm. These shutdown rods are
connected to upper lid of fuel cell which is controlled by a motor.

Figure 4.9: Shutdown Rods
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33

Solidworks Model

Figure 4.10: Solidworks Model of Shutdown Rod
4.2.4 Upper and Lower Plate
The upper and lower plates of assembly are circular in shape. Both plates hold the 19
fuel subassemblies together with each other. The radius of the plates is 47 cm whereas
the distance between two subassemblies is 1 cm.

Figure 4.11: Assembly of Upper and Lower Plates
Experimental Setup

34

Solidworks Model

Figure 4.12: Solidworks Model of Upper Plate
Figure 4.13: Solidworks Model of Upper and Lower Plate Assembly
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35

4.2.5 Shutdown Plate
There is one shutdown plate at the top of assembly responsible for moving the
shutdown rods. All the shut down rods are connected to this plate and this plate moves
up and down using the feedback of a DC motor. The distance between two rods is
3.27 cm whereas the radius of one rod is 1 cm.

Figure 4.14: Shutdown Plate
Solidworks Model

Figure 4.15: Solidworks Model of Shutdown Plate
Experimental Setup

36

4.2.6 Fuel Pin Upper and Lower Hexagons
There are two hexagons at both the ends of fuel pins. They hold the fuel rods within a
fuel pin. The diameter of each hole is 1 cm whereas each side of hexagon is 4 cm. The
upper hexagon has one hole for shutdown rod as well.

Figure 4.16: Upper Hexagon of Fuel Pin

Figure 4.17: Lower Hexagon of Fuel Pin
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37

Solidworks Model
Figure 4.18: Solidworks Model of Upper Hexagon

Figure 4.19: Solidworks Model of Lower Hexagon
Experimental Setup

38

4.2.7 Base of Assembly
The height of base is about 93.30 cm whereas width is about 50.50 cm. This base is
used to support whole of the structure.
Solidworks Model
Figure 4.20: Solidworks Model of Base of Assembly

4.2.8 Motors
Four D.C motors are attached. One motor is for moving reflectors. One is for the
shutdown plate and last one is for replacing the fuel subassembly or fuel cell. The
specifications for all the three motors are as follows:
RPM: 90
Voltage: 12 V DC
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39

Figure 4.21: Motors for Reflectors and Shutdown Rod
4.2.9 Proximity Sensor
The proximity sensors used is PRL 18-5 DN. Sensor input is inductive. The range of
sensor is approximately 8mm. Two proximity sensors are used in this project. One is
for shutdown plate and the other is used for reflectors. The purpose is to control the
upper limit for the shutdown plate and lower limit for reflectors.

Figure 4.22: Inductive Proximity Sensor
Experimental Setup

40

Figure 4.22: Inductive proximity sensor (Autonics) used in the Project

Chapter 5
SCADA and Human Machine Interface (HMI)
5.1 Electronic Design
The electronic circuit of the reactor consists of 24VDC relays, Programmable logic
controller (PLC) and the communication circuit. Following is a circuit diagram which
is showing all the connections.

Figure 5.1: Electronic Design
5.2 Driver Circuits
The driver circuit controls the motors which are responsible for the motion of reflectors,
upper plate and rotation motor. In our project, 2 number of 8 pin round Finder Relay is being
used for each motor rotation either clockwise or anticlockwise. This circuit permits altering
the course of an engine by utilizing a switch or controller chip. Thus relay acts like H- Bridge.
Following is a diagram:

Figure 5.2: Driver Circuit 1
SCADA and Human Machine Interface (HMI)
42

Figure 5.3: Driver Circuit 2
5.3 Programmable Logic Controller
The microcontroller that is being used is Mitsubishi FX 1N-24MR-ES. It has 14 digital inputs
and 10 digital outputs. It is a compact PLC available as both AC and DC powered. Although
the PLC provides both relay and transistor outputs but for this project, relay output is being
used. LEDs are used for indicating the status of all the inputs and outputs. The programming
system is user friendly

Figure 5.5: Mitsubishi FX 1N-24MR-ES
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43

Figure 5.6: Mitsubishi PLC Being Used in Project
5.4 HMI
HMI being used is Mitsubishi HMI F940G0T-LWD. It is a 5.7 inch human machine interface.
Installation is very simple and operation is user friendly. HMI provides clear display for text
and graphic processes. The messages displayed are precise and informative. Also, in case of
any error situation, instructions are displayed. In this project, both manual control and HMI
control is provided.

Figure 5.7: Mitsubishi HMI F940G0T-LWD

Chapter 6
Results
Following are some images of the project after complete coding of PLC and HMI:
Figure 6.1: Complete Project with HMI and Manual Control
For coding of PLC, GX developer is used whereas for designing HMI, the software of
GT designer has been used. By using these softwares, the following parameters have
been achieved in this project:
Shut down control
Fuel replacement control
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45

K- effectiveness control
Figure 6.2: Side View of the Project
6.2 GX Developer
GX Developer is software used for PLC programming. The advantage of using this
software is that the interface is quite simple and instinctive. Another advantage is that
this software supports sequential function chart, instruction list and ladder diagram
languages. Users can switch between different languages while programming. Many
advanced options are available for configuring special function modules or any
function blocks required. [8]
Results

46

Figure 6.3: GX developer
6.3 GT Designer
GT Designer is software used to design HMI screens for Mitsubishi. It is user friendly
software which helps and facilitates fast learning due to its simple interface.
The features include: [8]
A range of indicators and touch switches
Communication setting utility
Preview utility
Checking function for consistency

Figure 6.4: GT developer

Chapter 7
Future Recommendations
7.1 Limitations and Future Recommendations
As it is always said that There is always a room for improvement and one should
strive more and more till he/she achieves the best, same is the case with this project.
It is complete in some aspects while there is some space for the improvement of
design of this nuclear reactor.
Some of the improvements are as follows:
HMI of the project can be improved by including pop up messages and more
control parameters.
This prototype design has the potential for mass production.
More control parameters can be added in future to make it more effective.
This project can help invoke innovative ideas in future.
This project is useful as an educational supplement to an undergraduate or graduate
course in Industrial Automation in a Mechatronics Engineering program and in Power
Plants or Nuclear Power Plants in a Mechanical/Nuclear Engineering program in
universities. It illustrates essential components of a 4
th
generation safe, small and
modular nuclear reactor which is likely to be commercially available in the next 2-
3years. This model also incorporates essential features of industrial automation such
as the use of an industrial PLC. Electromechanical components such as DC motors,
proximity sensors and integrates all control in Human Machine Interface (HMI)
which is a very important area in Engineering.
Although this model illustrates essential features of the 4S core, it is limited to fuel,
control mechanism and reflector movement and thus does not include fluid flow
inside the core. Its limitations are core mechanisms and it does not give information
on the thermal hydraulics of the complete power plant. That will be a bigger project
and is expected to require a longer period for completion.
Future Recommendations
48

Some of the suggested recommendations include an improvement of the HMI to
incorporate pop-up messages and some additional controls such as fuel assembly
replacement.
The project is recommended to be included in the curriculum of universities
conducting engineering programs; it is of most value in educational institutions and
will require a production strategy to enable any commercial orders to be efficiently
processed.

Appendix A
PLC Coding: The PLC programming is based on ladder logic. Contacts are on
the left side of ladder logic whereas coils are on the right side. Timer is used to
control the reflectors.

Appendix A

50

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51

Appendix A

52

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53

Appendix B
Data Sheet for MITSUBISHI FX 1N-24MR-ES
Model
Number FX1S FX1N FX3G FX3U/FX3UC

Programmi
ng

I/O Points 30(+4 optional) 128(+4 optional)
256 total (combined local and CC-Link 384 total (combined local and

remote I/O) CC-Link remote I/O)

Address
Range Max. 30 direct addressing Max. 128 direct addressing
Max. 128 direct addressing and Max. 256 direct addressing and
Max. 128 remote I/O Max. 256 remote I/O

Program
Memory
32,000 steps EEPROM (internal), 64,000 steps RAM (internal),

2,000 steps EEPROM 8,000 steps EEPROM exchangeable EEPROM memory exchangeable FLROM memory

cassette cassette

Instruction
Time 0.55 s or 0.7 s / contact instruction 0.21 s or 0.42 s / contact instruction 0.065 s / contact instruction

Number of
Instruction
s
27 sequence instructions, 27 sequence instructions, 29 sequence instructions, 29 sequence instructions,

2 step ladder instructions, 2 step ladder instructions, 2 step ladder instructions, 2 step ladder instructions,

85 applied instructions 89 applied instructions 123 applied instructions 210 applied instructions

Programmi
ng
Language
Step ladder, instruction list, SFC Step ladder

Program
Execution
Cyclical execution, refresh mode processing

Program
Protection

2 different keywords, maximum
8 or 16-character keyword

8 character keyword with 3 protection levels each (*1) protection with 3 protection

password length 16 characters

levels each (*1)

Devices

512 total, with 384 general 1,536 total, with 384 general
7,680 total, with 384 general (M0 - 7,680 total, with 500 general

Auxiliary
Relays
M384), 1152 EEPROM latched (M384 - (M0 - M499), 524 optional latched

(M0 M383) and 128 latched (M0 -M383) and 1,152 latched

M1535), and 6,144 general/optional (M500 - M1023), and 6,656

(M384 M511) (M384 - M1535)

latched (M1536 - M7679) latched (M1024 - M7679)

Special
Auxiliary
Relays
256 (M8000 - M8255) 512 (M8000 - M8511)

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55

4,096 total, with 1,000 EEPROM
4,096 total, with 1,000 optional

State
Relays

latched (S0 - S999) and 3,096

128 all latched (S0 - S127) 1,000 all latched (S0 - S999) latched (S0 - S999) and 3,096

general/optional latched

latched (S1000 - S4095)

(S1000 - S4095)

256 total, with 206 100ms 320 total, with 206 100ms
512 total, with 206 100ms

64 total, with 31 points partially (T0 - T191, T192 - T199 and

Timers
(T0 - T199 and T250 - T255), (T0 - T199 and T250 - T255),

switchable between 100ms and T250 - T255), 46 10ms

46 10ms (T200 - T245), and 4 46 10ms (T200 - T245), and 68 1ms

10ms (T32 - T62) (T200 - T245), and 260 1ms

1ms (T246-T249) (T246 - T249 and T256 - T319)

(T246 - T249 and T256 - T511)

External
Setpoint
Entry Via
Potentiomete
r
2 0

235 total (16-bit and 32-bit), with 235 total (16-bit and 32-bit), with
235 total (16-bit and 32-bit),

32 total (16-bit only), with 16 with 120 general (C0 - C99 and

Counters
36 general (C0 - C15 and C200 - 36 general (C0 - C16 and C200 -

general (C0-C15) and 16 latched C200 - C219) and 115 latched

C219) and 199 latched (C16 - C219) and 199 EEPROM latched

(C16-C31) (C100 - C199 and C220 -

C199 and C220 - C234) (C16 - C199 and C220 - C234)

C234)

1 phase, 6 points max: 60 kHz / 2 1 phase, 6 points max: 60 kHz /

High-Speed
Counters
points, 10 kHz / 4 points ; 2 2 points, 10 KHz /4 points;
21 total, with 16 1-phase (C235 - C250) and 5 2-phase (C251 - C255)

phase, 2 points max: 2 phase, 2 points max: 30 kHz /

30 kHz / 1 point, 5 kHz / 1 point 1 point, 5 kHz /1 point

1 phase, 6 points max: 60 kHz / 1 phase, 8 points max: 100 kHz /

High-Speed
Counter
Speed
4 points, 10 kHz / 2 points 6 points; 10 kHz / 2 points

2 phase, 3 points max: 30 kHz / 2 phase, 2 points max: 50 kHz /

2 points, 5kHz/1 point 2 points

Real-Time
Clock Year, month, day, hour, minute, second, day of the week

8,000 total, with 128 general
8,000 total, with 200 general

256 total, with 128 general 8,000 total, with 128 general (D0 - D127), 972 EEPROM latched

Data
(D0 - D199), 312 optional latched

Appendix B

56

Registers
(D0 - D127) and 128 latched (D0 - D127) and 7,872 latched (D128 - D1099), and 6,900

(D200 - D511), and 7,488 latched

(D128 - D255) (D128 - D7999) general/optional latched

(D512 - D7999)

(D1100 - D7999)

Extension
Registers 24,000(R0~R23999) 32,768(R0~R32767)

Extension
File
Registers
24,000(ER0~R23999) 32,768(ER0~R32767)

internal/optional memory optional memory

Index
Registers
16

Special
Data
Registers 256 (D8000 - D8255) 256 (D8000 - D8255) 512 (D8000 - D8511)

Pointers 64 128 2,048 4,096

Nestings
8

Interrupt
Inputs
6

Constants 16-bit: K: -32,768 to +32,767; H: 0 to FFFF; 32-bit: K: -2,147,483,648 to +2,147,483,647; H: 0 to FFFF FFFF

Data Sheet for Motors

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Turnitin Originality Report
4S Reactore: a demonstration unit by Aimen Babur
From 4S Reactor (BEMTS)
Processed on 12-Jul-2014 17:35 PKT
ID: 439066849
Word Count: 4777
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< 1% match (publications)
Vincent Schultz. "Nuclear fuel cycle, ionizing radiation, and effects on biota of the natural
environment", Critical Reviews in Environmental Science and Technology, 10/1980

paper text:
1.1: NUCLEAR REACTORS: In Nuclear physics, nuclear reaction is the process in which two
particles collide with each other and produce particles which are different than the particles
colliding initially. Nuclear reactors are the devices which are used for producing a steady flow of
neutrons by the collision of heavy nuclear particles. It is used for initiating and controlling a chain
reaction. Figure 1.1: nuclear reaction example 1.1.1: PRINCIPLE OF OPERATION: A nuclear
reactor starts the chain reaction using the principle of nuclear fission. When a large nucleus
collides with a neutron, it splits into smaller nuclei. As a result of this reaction, kinetic energy, free
neutrons and gamma radiations are produced. These free neutrons can start a new fission reaction
on their own. A fission reaction produces approximately 200 MeV as compared to a chemical
reaction which produces only a few eV. This is called chain reaction because once initiated, it
does not stop by itself and results could be disastrous if such a reaction is uncontrolled. To control
the chain reaction, neutron moderator or neutron poisons are used to change the position of
neutrons causing the reaction thereby controlling the release of energy and free neutrons. Most
commonly used moderators are heavy water, regular (or light) water and solid graphite. Nuclear
reactors usually have manual and automatic shut down systems to deal with any emergency
situations. Figure 1.2: nuclear fission reaction 1.1.2: TYPES OF NUCLEAR REACTOR:
Depending upon their functionality, 3there are two types of nuclear reactors: ? Nuclear
research reactors ? Nuclear power reactors NUCLEAR RESEARCH
REACTORS: Usually universities and research centers use nuclear research reactors.
They are also called non- power reactors. As compared to power nuclear reactors, they operate at
lower temperatures and are much simpler to use. However, they require more highly enriched
uranium as compared to power reactors for neutron generation. USES: They are used for: Non-
destructive testing Analysis and testing of materials Neutron scattering Production of
radioisotopes Research purposes Educational purposes NUCLEAR POWER REACTORS: They
are usually found in nuclear power plants. They produce thermal energy which can be used as it is
or can be converted into mechanical and electrical energy. 8TYPES OF NUCLEAR
POWER REACTORS: Following are different types of nuclear power reactors: ?
URANIUM-FUELLED REACTOR: They use uranium for nuclear fission reaction as one kg of
uranium can generate as much energy as 10 tones of oil. ? PLUTONIUM FUELLED REACTOR:
These reactors use plutonium as fuel for fission reaction. Plutonium is hundred times more active
than uranium as one g of plutonium produces the same energy as one tone of oil. ?
PRESSURIZED WATER REACTOR (PWR): For this reactor, enriched uranium is used as fuel

61

and light water is used as moderator. In this reactor, the pressure applied to the coolant prevents it
from boiling. The heat produced from the fuel is transferred to the water of a secondary circuit.
Steam is generated from water and this steam then enters the turbine. Figure 1.3: pressurized water
reactor BOILING WATER REACTOR (BWR): The principle of operation is same as PWR
except that pressure applied to the coolant is lower so that it boils and the steam generated is fed
into the turbine. Figure 1.4: boiling water reactor 1.1.3: COMPONENTS OF NUCLEAR
REACTOR: The most common components are: ? NUCLEAR FUEL: The material which is
required for fission chain reaction is the nuclear fuel. Uranium is the best fuel for a nuclear reactor
Figure 1.5: uranium pallets ? NUCLEAR REACTOR CORE: The portion of nuclear reactor where
the whole reaction takes place is called nuclear reactor core. Figure 1.6: Graphite molten salt
reactor ? NEUTRON MODERATOR: Neutron moderator is used for reducing the speed of fast
neutrons so as to control the fission chain reaction. ? CONTROL RODS: These are made using
neutron-absorbing materials so that they can be used to control the fission reaction. Figure 1.7:
control rods assembly ? COOLANT: The fluid which is used to dissipate heat from the fluid in the
nuclear reactor is called coolant. It is also known as refrigerant. ? REACTOR PRESSURE
VESSEL: The pressure vessel which holds the nuclear reactor core, stainless steel cylinder which
surrounds the core and coolant. 1.1.4: GENERATIONS OF NUCLEAR REACTORS: There are
four generations of nuclear reactors: ? GENERATION 1: This generation refers to the early
prototype of power reactors from 1950s and 1960s. Examples include Shippingport in
Pennsylvania Calder Hall-1 in United Kingdom The only remaining plant of this generation is
Wylfa Nuclear Power Station in Wales. ? GENERATION 2: This generation points to the
commercial reactors built till the end of 1990s. They were built to be both reliable and reasonably
priced. Example include: 6Boiling water reactors (BWR) Pressurized water
reactors (PWR) Advanced Gas-Cooled Reactors (AGR) ? GENERATION 3: This
generation is a development of generation 2 nuclear reactors by making improvements in their
designs. These improvements include: Does not require any manual or electronic feedback for
shutting down in case of any emergency situation, this is known as passive safety Has higher
thermal efficiency Reduces maintenance costs by adopting a standard design Has improved fuel
technology Examples include: 5Advanced Boiling Water Reactor (ABWR)
Advanced Pressurized Water Reactor (APWR) ? GENERATION IV: Currently all
the research work is being done on generation 4 reactors. Initially many reactors were taken into
consideration but then this list was downsized to look into most promising technologies. Rest of
discussion is included on chapter 2. Figure 1.8: generations of nuclear reactors 1.2: SCADA:
SCADA is the abbreviation for supervisory control and data acquisition. It is a system which

provides communication with remote equipment in industries through computers so that their
operation can be controlled. SCADA allows industries to monitor, gather and process data so that
the process can be made more efficient. SCADA systems can be used to provide information to
the operator for rapid for action. SCADA systems have also been given capability to store and
download programs to controllers for producing various products. They have also been given the
capability to share their information over internet which makes it really easy for a user to watch
graphics and have data from a process taking place anywhere in the world. Figure 1.9: example of
a plant using SCADA 1.2.1: FUNCTIONS OF SCADA: Major functions of SCADA include:
ALARM FUNCTION: SCADA performs a preset or predefined function whenever alarm rings in
a process. ANALOG FUNCTION: It displays and records analog quantities which are measured
using transducers. CONTROL FUNCTION: SCADA systems control all the manual and
automatic functions within a process. INDICATION FUNCTION: It displays and records the
status of all the devices involved in a process. ACCUMULATOR FUNCTION: It accepts and
totals digital pulses for displaying or recording. SEQUENCE OF EVENTS FUNCTION: It
recognizes preset events, associates a time with the occurrence of each event and resets the data of
event in order of occurrence of events. LOGGING/ARCHIVING: SCADA has the capability of
logging/archiving. REPORT GENERATION: It can produce reports based on the results from
the transducers and the status of devices involved in the process. 1.2.2: BLOCK
REPRESENTATION OF SCADA: Following is a block diagram of SCADA system: Figure 1.10:
block diagram of SCADA 1.2.3: SCADA COMPONENTS: SCADA consists of following basic
components: REMOTE TERMINAL UNIT (RTU): these units are connected to the sensors and
convert the signals received by the sensors to digital data. These are the units present in the
computer field to enable them to gather information from sensors and delivering commands to
control relays. PROGRAMMABLE LOGIC CONTROLLERS: They have the same functions as
RTUs except that they have advanced control abilities as compared to RTUs and are economical,
adaptable and flexible. SCADA MASTER UNIT: These are large computers which act as
central processor for the SCADA system. It automatically regulates the managed system
according to the response from the sensors. COMMUNICATION NETWORK: This network
provides a connection between RTUs or PLCs to the SCADA master unit. HUMAN MACHINE
INTERFACE (HMI): HMI is the apparatus which is used for presenting the acquired data to a
human operator. It helps operators to observe and interact with the process. DATA
ACQUISITION SERVER: It is a software service which connects field devices like RTUs and
PLCs through industrial protocols. The basic purpose is to allow the operator to get data from
sensors through field devices. SUPERVISORY SYSTEM: system for collecting data and
sending control commands to the whole system is called supervisory system. In this project, only
HMI is being displayed and not the whole of SCADA. 2.1: NUCLEAR POWER IN PAKISTAN:
Amongst the most prominent Muslim countries of the world, one of the most advanced countries
is Islamic Republic of Pakistan. However, it is still not a technologically developed country due to

63

various problems which includes rapid increase in population. Pakistan needs financially viable
and secure sources of energy. As Pakistan is still a developing country, it is looking forward to
increase its potential in the field of nuclear energy. Pakistan is the first nuclear power of the
Islamic world. In Pakistan, nuclear energy is being provided by 3 licensed-commercial nuclear
power plants. These power plants include: ? 2Chashma Nuclear Power plant ? Karachi
Nuclear Power plant ? Muzaffargarh Nuclear Power plant Although the nuclear power
project of Pakistan is small having a capacity of 725 MWe but is trying to increase its capacity
significantly. In 2010, 94.5 billion KWh of electricity was produced by Pakistan out of which 33
TWh of electricity was generated from oil, approximately same amount from hydroelectric power
and about 26 TWh from natural gas. The contribution of nuclear power is really small i.e.
approximately 3.8 TWh which makes it only 3.8% of the total electricity. Nuclear power plants
have a total installed capacity of 20 GWe but only 12 GWe is being used. Due to this reason,
power shortages and load shedding is really common. In order to increase nuclear power of the
country, government adopted energy security plan in 2005 and decided to increase the generation
capacity to 160 GWe by 2030. In July 2013, the ECNEC announced 3.5 GWe of new power
projects comprising of 2200 MWe of nuclear power projects, 969 MWe of hydro power projects
and 425 MWe of gas Theory combined cycle. All these projects depend on Chinas support as only
China is interested in launching nuclear projects in Pakistan. 2.1.1: KARACHI NUCLEAR
POWER COMPLEX (KNPC): KNPC, situated in Karachi, consists of Karachi Nuclear Power
Plant (KANUPP). It is functional due to investments of 7international Atomic Energy
Agency. International Atomic Energy Agency is responsible for its protection and
inspection. The reactor type present in this plant is Deutrium Uranium PHWR-4 and the planned
power generation is 8800MW. Following are the current and future projects planned for this
facility: ? KANUPP-1: This project was inaugurated by then president Zulfiqar Ali Bhutto on 28
November 1972. The type of reactor is CANDU-PHWR and the total power generated by this
project is 137 MW. However, it is limited to 84 MW only. ? KANUPP-2: It is a civilian nuclear
power project of the government which is still under construction. It was inaugurated by Prime
Minister Nawaz Shareef on 26th November 2013. The estimated cost is about $4.8 billion and
power generation will be about 1100 MW. The type of nuclear reactor is CAP 1400 which is
2based on AP1000 Westinghouse Electric Company Pressurized water Reactor.
? KANUPP- 3: It is a project which is under construction just like KANUPP-2 and, once

completed, will produce about 1100 MW of electricity. It is being completed with the help of
China. ? KANUPP-4: this is a planned project whose construction has not yet started. 2.1.2:
CHASHMA NUCLEAR POWER COMPLEX (CHASNUPP): It is a commercial nuclear power
plant which is being constructed and financed by China and is being operated by Pakistan Atomic
Energy Commission. The reactor types used in this plant are Low Enriched Uranium Very high
temperature reactor (VHTR) and Pressurized Light Water Reactor (PWR). The generation
capacity is about 600 MW. The current and future projects are as follows: ? CHASNUPP-1: this
project is located in Kundian , Punjab. It is a commercial project which began operating in MAY
2000. the reactor type used is pressurized water reactor and has generation capacity of 300 MW. ?
CHASNUPP-2: this project is located in the south of Mianwali near Chashma Barrage. It was
inaugurated by former Prime Minister Syed Yousaf Raza Gillani on 10 May 2012. The electricity
generation capacity is almost the same as CHASNUPP-1 i.e. 300 MW. ? CHASNUPP-3 and
CHASNUPP-4: Both projects have the capacity of generating 340 MW and design life is expected
to be about 40 years. The construction of CHASNUPP-3 is expected to be completed in 2016
while that of CHASNUPP-4 in 2017. ? CHASNUPP-5: this is a planned project between Pakistan
and China which has the capacity of 1000 MW. 2.1.3: MUZAFFARGARH NUCLEAR POWER
COMPLEX: This complex is still under construction. When it is completed, it would have the
capacity of generating 1100 MW. According to Pakistan Atomic Energy Commission (PAEC)
plans, three Chinese nuclear reactors would be installed here. 2.2: GENERATION IV NUCLEAR
REACTORS: Power plants produce about 16% of the electricity around the world. Although the
second and third generation reactors, which are currently being used, provide electricity cost-
effectively and efficiently but still there is a room for improvement so that opportunities are
created for greater use of nuclear energy. It is expected that the fourth generation of reactors to be
ready by 2030. Following objectives are kept in mind while designing these reactors: ? Financial
competitiveness ? Superior safety ? Minimum radioactive waste generation ? Proliferation
resistance ? SUSTAINABAILITY: the major concern while designing these reactors was that the
environment is not affected adversely by these reactors. The environment was to be kept clean
through clean air limitations, preservation of resources and waste management limitations. Due to
the inadequate availability of repository space all over the world, waste management is considered
a major concern. Performance of a reactor can be improved by making closed fuel cycles allowing
the fuel to be reused 2.2.1: INITIATIVE GOALS: The goals of designing 4th generation reactors
are: by the reactor so that less space is required for the fuel in repository. Also, by transmutation,
relative toxicity can be controlled. Figure 2.1: effect of transmutation on toxicity ? RELIABILITY
AND SAFETY: an important goal of designing reactor is that it should be reliable and safe.
International rules and regulations for safe operation of nuclear reactor and safe handling of fuel
are to be strictly followed. Steps should be taken so that the leakage of radioactive materials in the
environment is strictly controlled. ? FINANCIAL COMPETITIVENESS: New reactors are
designed such that they are competitive for the ever changing energy demands of market. Nuclear

65

reactors can be privately owned or publicly owned. Plants are required to have a standard size so
that its parts can be replaced easily and ecomically. If each reactor is designed uniquely then its
parts cannot be replaced or duplicated easily. ? PROLIFERATION RESISTANCE: Nuclear
reactors are designed such that they have the ability to deal with natural disasters such as earth
quakes, tsunami etc. special attention should be given to a reactors protection so that the theft of
radioactive materials or parts of plant by any individual or a group is not possible. 2.3: TOSHIBA
4S REACTOR: Toshiba 4S reactor is a small sodium cooled reactor which is made to meet the
ever increasing global market trends. This reactor has a unique design as compared to other
reactors. The goals are as follows: ? Minimize the risks of security and environmental pollution ?
Can provide safe, clean and consistent electricity ? Minimize the cost of infrastructure, operation
and maintenance requirements This reactor is designed to provide 10 MWe of power. Also,
Toshiba has planned about 50 MWe version as well. 44S is a fast neutron sodium
reactor so it uses neutron reflector panels. These panels are used to maintain the k
effectiveness parameter of the reactor to be 1. If k is greater than 1, reflectors move downwards to
cover the control rods and if k is less than 1, then the reflectors move upwards. Thus this reactor
has the ability to handle any emergency situation without complete shut down. 2.3.1: WHY
CALLED 4S: This reactor is called 4S reactor because these S stand for: ? SUPER SAFE: 4S is
super safe because it uses reflectors to control the radioactivity of plant which may lead to any
emergency situation. The reactor will be underground and it uses passive cooling system for
removal of process heat. ? SIMPLE: all the parts of plant are easily available or can be built at
factories and assembled on the spot. It is really easy to ship the parts as well. Low maintenance
cost and long life-cycle makes 4S reactor really simple and easy to operate. ? SMALL: the total
area of the reactor will be really small i.e. 26m * 16m. Its height is only 0.68m. Thus this reactor
can be easily handled as it is small and safe. ? SECURE: Due to its ability to cope up with natural
disasters like earthquakes, it is completely secure and safe. As it is built underground so access to
the core and fuel is restricted. Also, refueling is required after 20 to 30 years so it comes as an
advantage as well. 2.3.2: ADVANTAGES OF 4S: Following are the advantages of 4S reactor: ?
No onsite refueling is required for about 10 - 30 years. This long refueling period makes it very
efficient and simple to use. ? As the plant is located underground, so the access to the reactor and
fuel is restricted which makes it very safe and reliable. ? The heat produces during the operation is
safely removes so that any emergency situation is avoided. ? The reactor has the ability to cope up
with natural disasters. ? There is no heavy lifting equipment present on site which reduces the
security risks. ? It is ensured that the maintenance and inspection cost is kept to the minimum. ?
There is a primary shutdown system which consists of reflectors and back up system consisting of
shutdown rod which makes it completely safe and secure. 2.3.3: PLANT DESIGN
PARAMETERS: CORE DESIGN PARAMETERS: The core is shaped as a cylinder whose height

is about 2.5 m while the equivalent core diameter is 0.95 m. There are 18 1fuel
subassemblies. Each fuel subassembly contains fuel pins. Each fuel pin consists of
bonding sodium, U-Zr alloy, shell tubes and plugs at both ends. The fuel pins are arranged in the
subassemblies along a predetermined grid and a top shield is present so as to give protection to the
reactor. There is 1 shutdown rod in each fuel subassembly. These shutdown rods act as back up of
the shut down mechanism. The absorber material used in the shutdown rods is B4C. Figure 2.8:
cross section of 4S core REFLECTOR DESIGN PARAMETERS: The reflectors are the only
moveable parts in the reactor. There are total 6 reflectors in the assembly. The material used for
the reflectors is Mod9Cr1Mo. The thickness of the material is 38 cm while height is 2.7 m.
Reflectors are a part of primary shut down system while shutdown rods are a part of back-up
shutdown system. 2.3.4: DIAGRAM OF COMPLETE MODEL OF 4S REACTOR: Following is
the complete model of 4S reactor: Figure 2.9: complete model of 4S Supervisory control of 4th
generation small scale nuclear reactor 3.1: MODELING OF A DC MOTOR: This chapter focuses
on the mathematical modeling and the torques calculated of DC motors used in the project. DC
motor is an electromagnetic system designed by a coupled second order ODE. The modeling of a
DC motor is as follows: Figure 3.1: DC Motor Applying KVL, we have:
................................................................................... (3.1) Where: Va = total voltage Vra = voltage
across the resistor Vla = voltage across the inductor According to Ohms law, we have:
................................................................................................ (3.2) Next, we have: Modeling And
Simulation ............................................................................................. (3.3) For motor, we have:
.................................................................................................. (3.4) Putting the values in equation
(3.1): For current, we have equations:
............................................................................................................ (3.5) Taking derivative, we
have: For torque, we have: ..................................................................................................... (3.6)
Putting all the values in equation: After simplifications: Taking Laplace inverse: The transfer
function is: ..................................... (2.7) 3.2: TORQUE CALCULATION Following equations are
used for finding the torque of all the motors: We have: ........................... (9) Where: P = pitch of
ball screw Putting do = 1.5 cm and P = 1 cm, we have: dp = 1.4350 cm For torque calculation of
three motors, we have following expression: Where: M = mass of body P = pitch of ball screw
One motor is being used to control the motion of reflectors. The torque for this motor is as
follows: M = mass of reflector = 20 kg dp = 1.4350 cm 25 Modeling And Simulation dr = 1.14cm
= 0.2463 Lead angle == 1.2706 Putting all the values, the torque for first motor comes out to
be: T1 = 0.654 N-m The other two motors are being used with shutdown plate. One is being used
to control the motion of plate in the vertical direction while one is being used to control the motion
in the horizontal direction for fuel cell replacement. The torque calculations for both motors are as
follows: M of upper plate = 8 kg dp = 1.4350 cm dr = 1.14cm = 0.2463 Lead angle = = 1.2706

67

So, we have: T2 = T3 = 0.2618 N-m 4.1: EXPERIMENTAL SETUP OF COMPLETE MODEL:
The complete body of reactor is made up of aluminium coz it is very light weight and economical
as well. In the assembly, there are 18 1fuel subassemblies and each subassembly
contains 9 fuel pins. The reflectors are used also made of aluminium. There is an upper
and lower lid. Shutdown rods are connected to the upper lid. Both the reflectors and shutdown
rods are operated by using motors for providing safety system for reactor. PLC is used for
controlling the motors whereas SCADA is used for data acquisition. Figure 4.1: complete model
of 4S reactor Experimental Setup 4.1.1: SOLID WORKS MODEL OF REACTOR: Figure 4.2:
front view of solid works model Figure 4.3: side view of solid works model Figure 4.4: solid
works model of reactor 4.2: DIFFERENT PARTS OF REACTOR: 4.2.1: FUEL
SUBASSEMBLIES AND FUEL PIN: There are total 18 subassemblies in 4S reactor and each
subassembly has 6 hexagons or fuel pins. The length of each fuel pin is 45 cm and diameter is 1
cm. These fuel subassemblies are responsible for fission reaction in the reactor. Figure 4.5: fuel
subassemblies and pins SOLID WORKS MODEL: Figure 4.6: solid works model of fuel pin
4.2.2: REFLECTORS: Reflectors are responsible for controlling the fission reaction and shutdown
of reactor in case of any emergency situation. There are 3 reflectors in reactor assembly. All are
made of aluminium. The reactors are controlled using a motor which is responsible for its up and
down motion. The thickness of reflector is 5.6 cm whereas length of reflector is 45 cm. Following
is the diagram for reflectors: Figure 4.7: reflectors SOLID WORKS MODEL: Figure 4.8: solid
works model of reflectors 4.2.3: SHUTDOWN RODS: Shutdown rods provide a backup for
emergency shutdown of reactor. There is a shutdown rod in each subassembly so there are total 18
shutdown rods in this reactor assembly. The length of each shutdown rod is 45 cm while diameter
is about 1 cm. These shutdown rods are connected to upper lid of fuel cell which is controlled by a
motor. Figure 4.9: shutdown rods SOLID WORKS MODEL: Figure 4.10: solid works model of
shutdown rod 4.2.4: UPPER AND LOWER PLATE: The upper and lower plates of assembly are
circular in shape. Both plates hold the 19 fuel subassemblies together with each other. The radius
of the plates is 47 cm whereas the distance between two subassemblies is 1 cm. Figure 4.11:
assembly of upper and lower plates SOLID WORKS MODEL: Figure 4.12: solid works model of
upper plate Figure 4.13: solid works model of upper and lower plate assembly 4.2.5:
SHUTDOWN PLATE: There is one shutdown plate at the top of assembly responsible for moving
the shutdown rods. All the shut down rods are connected to this plate and this plate moves up and
down using the feedback of a DC motor. The distance between two rods is 3.27 cm whereas the
radius of one rod is 1 cm. Figure 4.14: shutdown plate SOLID WORKS MODEL: Figure 4.15:
solid works model of shutdown plate 4.2.6: FUEL PIN UPPER AND LOWER HEXAGONS:
There are two hexagons at both the ends of fuel pins. They hold the fuel rods within a fuel pin.
The diameter of each hole is 1 cm whereas each side of hexagon is 4 cm. The upper hexagon has

one hole for shutdown rod as well. Figure 4.16: upper hexagon of fuel pin Figure 4.17: lower
hexagon of fuel pin SOLID WORKS MODEL: Figure 4.18: solid works model of upper hexagon
Figure 4.19: solid works model of lower hexagon 4.2.7: BASE OF ASSEMBLY: The height of
base is about 93.30 cm whereas width is about 50.50 cm. This base is used to support whole of the
structure. SOLID WORKS MODEL: Figure 4.20: solid works model of base of assembly 4.2.8:
MOTORS: Three D.C motors are attached. One motor is for moving reflectors. One is for the
shutdown plate and last one is for replacing the fuel subassembly or fuel cell. The specifications
for all the three motors are as follows: ? RPM: 90 ? Voltage: 24 V DC ? Current: 2.5 4 Ampere
Figure 4.21: motors for reflectors and shut down rod 4.2.9: PROXIMITY SENSOR: The
proximity sensors used is PRL 18-5 DN. Sensor input is inductive. The range of sensor is
approximately 8mm. Two proximity sensors are used in this project. One is for shutdown plate
and the other is used for reflectors. The purpose is to control the upper limit for the shutdown plate
and lower limit for reflectors. Figure 4.22: inductive proximity sensor Figure 4.22: inductive
proximity sensor used in project 5.1: Electronic Design The electronic circuit of the reactor
consists of 24VDC relays, Programmable logic controller and the communication circuit.
Following is a circuit diagram which is showing all the connections. Figure 5.1: Electronic Design
5.2: Driver Circuits The driver circuit controls the motors which are responsible for the motion of
reflectors, upper plate and rotation motor. In our project, 2 number of 8 pin round Finder Relay is
being used for each motor rotation either clockwise or anticlockwise. This circuit permits altering
the course of an engine by utilizing a switch or controller chip. Thus relay acts like H- Bridge.
Following is a diagram: SCADA and HMI Figure 5.2: Driver Circuit 1 Figure 5.3: Driver Circuit
2 5.3: Programmable Logic Controller The microcontroller that is being used is Mitsubishi FX
1N-24MR-ES. It has 14 digital inputs and 10 digital outputs. It is a compact PLC available as both
AC and DC powered. Although the PLC provides both relay and transistor outputs but for this
project, relay output is being used. LEDs are used for indicating the status of all the inputs and
outputs. The programming system is user friendly Figure 5.5: Mitsubishi FX 1N-24MR-ES Figure
5.6: Mitsubishi PLC Being Used in Project 5.4: HMI HMI being used is Mitsubishi HMI
F940G0T-LWD. It is a 5.7 inch human machine interface. Installation is very simple and
operation is user friendly. HMI provides clear display for text and graphic processes. The
messages displayed are precise and informative. Also, in case of any error situation, instructions
are displayed. In this project, both manual control and HMI control is provided. Figure 5.7:
Mitsubishi HMI F940G0T-LWD 6.1: Results Following are some images of the project after
complete coding of PLC and HMI: Figure 6.1: Complete Project With HMI and Manual Control
Figure 6.2: Side View of the Project For coding of PLC, GX developer is used whereas for
designing HMI, the software of GT designer has been used. By using these softwares, the
following parameters have been achieved in this project: ? Shut down control ? Fuel replacement
control ? K- effectiveness control 7.1: LIMITATIONS AND FUTURE RECOMMENDATIONS:
As it is always said that There is always a room for improvement and one should strive more and

69

more till he/she achieves the best, same is the case with this project. It is complete in some
aspects while there is some space for the improvement of design of this nuclear reactor. Some of
the improvements are as follows: ? HMI of the project can be improves by including text
messages and more control parameters. ? This prototype design has the potential for mass
production. ? More control parameters can be added in future to make it more effective. ? This
project can help invoke innovative ideas in future. APPENDIX A: Plc coding: Theory Theory
Theory Theory Supervisory control of 4th generation small scale nuclear reactor Supervisory
control of 4th generation small scale nuclear reactor Supervisory control of 4th generation small
scale nuclear reactor Experimental Setup Supervisory control of 4th generation small scale nuclear
reactor Experimental Setup Supervisory control of 4th generation small scale nuclear reactor
Experimental Setup Supervisory control of 4th generation small scale nuclear reactor
Experimental Setup Supervisory control of 4th generation small scale nuclear reactor Supervisory
control of 4th generation small scale nuclear reactor SCADA and HMI Supervisory control of 4th
generation small scale nuclear reactor SCADA and HMI Supervisory control of 4th generation
small scale nuclear reactor SCADA and HMI Supervisory control of 4th generation small scale
nuclear reactor SCADA and HMI Supervisory control of 4th generation small scale nuclear
reactor SCADA and HMI Supervisory control of 4th generation small scale nuclear reactor 1 2 3 4
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 27 28 29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

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