EXPERIMENTAL FACILITIES FOR PERFORMANCE
EVALUATION OF FAST REACTOR COMPONENTS
*S. Chandramouli, V.A.Suresh Kumar, M.Shanmugavel,
G.Vijayakumar, V.Vinod, I.B. Noushad, B.Babu, G.Padma
Kumar, B.K.Nashine & K.K.Rajan
Fast Reactor Technology Group
INDIRA GANDHI CENTRE FOR ATOMIC RESEARCH
KALPAKKAM
INDIA
2013-06-17
11:28 ON EXISTING AND PROPOSED EXPERIMENTAL FACILITIES FOR FAST NEUTRON
1
TECHNICAL
MEETING
SYSTEMS
10-12 June 2013, IAEA, Vienna, Austria
OUTLINE
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Introduction
Initial Years of Development
Later years of Development
Experimental Sodium Facilities
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Large Component Test Rig
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Sodium Water Reaction Test Facility
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Steam Generator Test Facility
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SADHANA test facility
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Thermal Shock Test Facility
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In Sodium Test Facility [Fatigue Loop and Creep loop]
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Bi-Metallic loop
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SILVERINA sodium loop
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LEENA loop
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Test Facility for Sodium aerosol Dispersion Studies
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Sodium Facility for Component Testing [SFCT] & Sodium Technology
Complex
Experimental Water Facilities
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SAMRAT loop
Sub-Assembly Test Facility
1/24 scale model, 1/12 Scale Model
Summary
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Lecturer for BHAVINI Engineers
INTRODUCTION
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Design, construction and operation of Sodium cooled Fast breeder
Reactors SFR) form the second stage of Indian Nuclear Power Programme.
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The 40 MWt Fast Breeder Test Reactor (FBTR) is still in operation.
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500 MWe Prototype Fast Breeder Reactor (PFBR) is presently in the
advanced stage of construction.
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To test and qualify the reactor components, many experimental facilities in
sodium and water are in operation at IGCAR.
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For the research and developmental activities for future SFRs a
multipurpose sodium loop and a Sodium Technology Complex are also
envisaged.
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Experimental water test facilities are in operation for hydraulic studies.
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A larger scale model is being set up for hydraulic studies for future SFRs.
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Initial Years of Development
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Later Years of Development
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500 kW sodium loop
• The oldest loop of FRTG with sodium
hold up of 3 tons
• Commissioned in 1976
• 100 m3/h capacity Centrifugal pump for
sodium circulation
• Heater vessel with 500 kW power
• Sodium to air heat exchanger (NaX) of
500 kW Capacity
• Intermediate Heat Exchanger of 3 MW
capacity
• Operated for > 50,000 h
• Maximum operating temp of 550 °C
Completed Experiments
• Heat Transfer experiments of Heat Exchangers
• Performance testing of Electromagnetic Pumps
• Performance testing of Centrifugal pump & Electromagnetic pumps
• 2013-06-17
Calibration
11:28of Eddy current flow meter and PMFM
• Gained experience on all aspects of sodium technology
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Large Component Test Rig (LCTR)
• Commissioned in 1994
• Located in a 43 m tall building- Hall-III
• To carry out full scale testing of critical
components of PFBR in sodium, under
simulated reactor conditions
• Four test vessels in which independent
test conditions can be maintained
• Electro Magnetic Pump-20 m3/h for
sodium circulation and online purification
• Heater Vessel with 200 kW power
immersion heater
• 150 kW NaX for cooling sodium
• Sodium hold up in storage tanks: 100
tonnes
• Operated for more than 60,000 h
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• Max.Temperature of operation: 600 °C
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• Material of Construction : SS 316
Large Component Test Rig (LCTR)
TEST VESSEL-1
• Testing of Control Safety Rod Drive Mechanism
(CSRDM)
CSRDM was tested and qualified for 18 years of
reactor operation
• Testing of Diverse Safety Rod Drive Mechanism
(DSRDM)
DSRDM was tested and qualified for 10 years of
reactor operation
• Testing of UltraSonic Under Sodium Scanner
(USUSS)
USUSS was tested successfully in sodium
• Calibration of 58 numbers of Mutual Inductance type
Continuous Level Probes for PFBR
MI type continuous and discrete level probes with
active lengths more than 6000 mm were calibrated in
sodium
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Large Component Test Rig (LCTR)
TEST VESSEL-2 & TEST VESSEL-5
Dedicated facilities for testing of Fuel Handling machines
TEST VESSEL – 2
• Primary Ramp and Primary Tilting Mechanism
(PRPTM)
Sodium testing completed
• Inclined Fuel Transfer Machine
Testing of integrated IFTM is planned in air.
TEST VESSEL- 5
Transfer Arm (TA)
• The vessel is 13 m long and 1.7 m dia
• This Vessel can accommodate a grid plate with
the number of sub assemblies (SA), Transfer Pot
and Transfer Arm on it
• Sodium hold up in TV-5 is 24.2 m3
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Test Vessel-2
IFTM Test Facility
PTM
REP
Grid
plate
with SA
positions
PR
Liner
The Primary Ramp (PR) & Primary Tilting
Mechanism (PTM)
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Large Component Test Rig (LCTR)
TEST VESSEL-3
Heat transfer and temperature distribution
studies
• Heat transfer and temperature distribution
studies in roof slab model and control plug
model of PFBR
• Studies on effectiveness of cooling circuit
of top shield
Testing of FFLM
• FFLM testing was carried out at various
sodium temperatures up to 550 °C
• Sodium vapour condenser testing
Other experiments in LCTR
• Performance testing of Annular Linear induction
Pump (ALIP)
• Performance testing of DC Conduction Pump
(DCCP)
• Subassembly wetting experiments
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DC Conduction Pump
Experiments Planned
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Qualification and Testing of DSRDM, CSRDM for 40
years.
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Testing of Integrated Cold trap and Integrated
Plugging Indicator for future SFR’s.
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SOdium WAter Reaction Test Rig (SOWART)
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SOdium WAter Reaction Test Rig (SOWART)
• Commissioned in 2001
• To study the behavior of self wastage and impingement wastage during Nawater reaction and Development of water/steam leak detection methods in
sodium
• Sodium hold up in tank: 10 tonnes
• On line purification with air cooled cold trap, 150 kW immersion heater power in
hot leg and cold leg.
• Sodium to Air Heat Exchanger-150 kW, Main heat exchanger-380 kW
• Flat Linear Induction Pump for sodium circulation- Rated sodium flow : 10 m3/h
• Operated for nearly 25,000 h
• Maximum sodium temp. : 525°C
• High Pressure steam circuit to inject steam
• Material of Construction : SS 316
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Wastage Experiments
Impingement
Wastage test
section
Self wastage
Test Section
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Experiments Completed & Planned
EXPERIMENT
COMPLETED
SL.NO
EXPERIMENT PLANNED
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Self wastage studies were carried Impingement Wastage studies on 9 Cr.
out at different steam leak rates 1 Mo Specimens Collaboration with
in the range of 10-50 mg/s
CEA.
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Testing of Model Cold Trap for Development
and
Testing
secondary sodium circuits.
indigenously developed cover
hydrogen meters
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Adjacent tube wastage studies
were carried out for steam leak
rates from 100 mg/s to 1 g/s as
R&D for Indian SG tube materials
[Mod. 9 Cr 1 Mo].
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Development
of
acoustic
methods to detect sodium water
reaction in steam generator
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Testing of In sodium and cover
gas hydrogen meters of various
range.
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of
gas
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Steam Generator Test Facility (SGTF)
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Steam Generator Test Facility (SGTF)
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A Stem Generator (SG) of 5.5 MWt with 19 tubes,23 m length without weld joints.
A furnace oil fired heater (5.7 MW) to heat the sodium from 355 °C to 525 °C
A 170 m3/h ALIP for circulation of sodium
SG outlet steam conditions are 170 bar, 493 °C
Hydrogen Leak Detection system to detect tube failure
Air cooled Cold trap, Plugging Indicator.
Cover gas system, Sodium water reaction products discharge circuit
Conventional steam water system.
Commissioned in 2003
Cumulative operating hours 40000 h.
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11:28
Maximum
temperature : 530 °C
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Steam Generator Test Facility (SGTF)
SGTF SG
Power: 5.5 MWt
No.of tubes: 19
Tube length: 23 m
Material: Mod 9Cr-1Mo
PFBR SG
Power : 158 MWt
No.of tubes: 547
Tube length: 23 m
Material: Mod9Cr-1Mo
Experiments completed
• Endurance testing of SG
• Estimation of SG Heat transfer area margin
• Assessment of flow instability
• Testing of SG under transient conditions and assessing
the performance of thermal baffles
• SG stability map for PFBR operation
• SG leak detection by acoustic leak detection system
• Performance testing of 2 MW Air Heat Exchanger.
• Flow Induced Vibration of SG tubes
• Temperature profile of SG with plugged tubes
• SG depressurization studies
Experiments Planned
• Assessing the thinning of SG tubes
• Assessing the fretting wear SG tubes at tube support
location
• Measurement of axial temperature distribution along the
SG tube length.
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Decay Heat Removal system in PFBR
Decay heat needs to be
removed to limit the
temperature and maintain
integrity of components
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SADHANA
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SADHANA
• Commissioned in 2009
• To demonstrate the passive decay heat removal system of PFBR –Richardson no similitude
• 1:22 scaled model called SAfety Decay Heat removAl loop in NAtrium (SADHANA)
• Test Vessel -4 with immersion heaters of 450 kW capacity for simulating the Main vessel of
PFBR with decay heat from reactor core.
• Decay Heat Exchanger inside Test Vessel
• Air heat exchanger at 19 m elevation.
• Chimney for inducing natural draft
• Cumulative operating hour 4000 h.
• Maximum Operating Temperature : 550 °C
• Material of construction : SS 316 L
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Experiments completed and planned
Experiments Completed
Steady State experiment for evaluating the heat transfer capacity.
Heat removal capacity of DHX and AHX
Transient experiments to evaluate the heat transfer capacity
Measurement of air flow distribution in AHX shell side.
Experiments Planned
Studying the behaviour of SGDHR during SCRAM
Test vessel
Studying the behaviour of SGDHR during station black out
7.0
500 s
6.5
Secondary sodium flow rate m3/h
6.0
5.5
5.0
4.5
Natural convection flow during damper opening
4.0
3.5
3.0
Opening of damper
0
250
500
750
1000
1250
1500
1750
2000
Time in seconds
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Thermal Shock Test Facility
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Thermal Shock Test Facility
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Commissioned in 2011
For the thermal shock testing of DSRDM electromagnet & TSMS
Thermal shock 5-8 °C/sec
Static sodium test facility with two test vessels
Sodium inventory: 1.5 tonnes
Static test facility
Sodium heater capacity 35 kW
Maximum operating temperature: 635 °C
Cumulative operating hours : 5000 h
Material of construction : SS 316 L
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Experiments completed and planned
Experiments Completed
1000 thermal shock cycles were conducted on the DSRDM
Electromagnet and the magnet has been qualified for 10 years
of reactor operations.
Experiments Planned
Response time measurement of Temperature Sensitive Test vessel
Electromagnet
Thermal shock testing on hard faced alloys.
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In Sodium Test (INSOT) Facility-Fatigue loop
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In Sodium Test (INSOT) Facility-Fatigue loop
• Commissioned in 2002
• To study the mechanical properties of PFBR component materials under the influence of
flowing sodium
• Low cycle fatigue and creep-fatigue interaction studies
• Sodium hold up : 500 kg
• Tribometer section, friction wear chamber, thermal striping chamber
• Air cooler, a heater vessel with 60 kW capacity immersion heaters
• Test sections in hot leg with maximum operating temperature of 600 °C
• Electrochemical carbon meters
• Foil equilibration chambers
• Maximum sodium flow: 3 m3/h
• Cumulative operating hours : 15000 h
• Material of Construction : SS 316 L[N]
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Experiments completed and planned
Experiments Completed
36 numbers of low cycle fatigue experiments and 13 numbers
of creep fatigue interaction experiments.
4 nos of tribometer experiments with various material
specimens
Test vessel
Experiments Planned
Tribological studies on hard faced material specimens
Thermal striping experiments
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In Sodium Test (INSOT) Facility-Creep loop
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In Sodium Test (INSOT) Facility-Creep loop
Commissioned in 2003
To study the creep properties of PFBR component materials under the influence of
flowing sodium
Sodium hold up of 500 kg
Air cooler, a heater vessel with 60 kW capacity immersion heaters.
5 nos. of Test sections in hot leg
Maximum operating temp 600 °C
Electrochemical carbon meter
Foil equilibration chambers
Maximum sodium flow : 3 m3/h
Cum. operating hours : 25000 h
Material of Construction : SS 316 L[N]
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Experiments completed and planned
Experiments Completed
27 nos of creep experiments
Experiments Planned
Creep experiments on different materials
Test vessel
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Bimetallic Loop (BIM loop)
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Bimetallic Loop (BIM loop)
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Commissioned in 2003
Loop is constructed with SS 316LN and 9Cr-1Mo materials
Simulates the secondary sodium circuit of PFBR
Specimens of Mod 9 Cr 1 Mo and SS 316 L[N] materials in sample holders
Surface area ratio, sodium velocity and sodium purity are maintained
Electro Chemical Carbon Meter
Self welding studies on material specimens
On line purification with air cooled Cold trap
Heater vessel with 250 kW capacity immersion heaters
Maximum temperature : 530°C
Maximum sodium flow : 5 m3/h
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Bimetallic Loop (BIM loop)
Experiments Completed
• Carbon transfer behavior and its influence on the mechanical properties of PFBR
secondary circuit materials (Mod. 9Cr-1Mo & SS 316 LN)
• 40,000 h of operation completed
• Specimens withdrawn after 15,000 h, 30,000 h and 40000 h of operation for analysis
• Self welding experiments on material specimens
Experiments Planned
• Carbon transfer behaviour studies on Mod 9 Cr 1 Mo/SS 316 L[N] for 50000 h
• Self welding susceptibility studies on different combinations of material specimens
• Testing of in sodium pressure transducer.
IMPACT AND
TENSILE SPECIMENS
INSIDE SAMPLE
HOLDER
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SELF WELDING
SPECIMENS WITH
SODIUM
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SILVERINA loop
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SILVERINA loop
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Commissioned in 1998
Three numbers of test pots
Possible to do independent tests in the test pots
AC conduction pump for sodium circulation
Sodium inventory of 1.3 tonnes
Cold trap & PI for purification
Maximum sodium temp: 550 °C
Operated for more than 40,000 h
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Experiments Completed and Planned
Experiments Completed
Qualification of Diverse Safety Rod Drive Mechanism [DSRDM] electromagnet
Performance testing of Transfer arm bearing in sodium.
Performance testing Sodium Ionization Detector [SID]
Testing of Eddy Current type position sensor for DSRDM of PFBR.
Flowmeter magnet compatibility to sodium aerosols.
Sodium aerosol compatibility on inflatable seal rubber material.
Calibration of Mutual Inductance type level probes.
Friction and Wear studies on materials in sodium using reciprocating
type tribometer.
Performance testing of 3–in-1 thermocouple in sodium.
Experiments Planned
Testing of RADAR type level probe for sodium level measurement
Sodium vapour concentration measurement in cover gas
Studies on high temperature Ultrasonic transducers
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LEENA loop- LEak Experiments in NAtrium
TEST SECTION 1
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TEST SECTION 2
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LEENA loop- LEak Experiments in NAtrium
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Commissioned in 2007
To qualify the sodium leak detector layout of PFBR
A sodium dump tank, test vessel, test sections with leak simulators.
A leak simulator consists of a hole of size one mm drilled in the test section,
closed with a tapered pin and experiments were conducted.
Static sodium facility
Cum. operating hours is 1000 h
Maximum sodium temperature : 550 °C
Material of construction : SS 316/304
TEST SECTION 1
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TEST SECTION 2
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Experiments completed and planned
Experiments Completed
19 numbers of experiments at sodium leak rates from 200 g/h
to 5000 g/h were completed.
Experiments Planned
Experiments on Sandwich & foild type leak detectors
Test vessel
Development and testing of fibre optic type leak detectors
Testing of modified leak detector layout of future SFR’s
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TEST FACILITY FOR ATMOSPHERIC DISPERSION STUDIES OF SODIUM AEROSOLS
DURING A SODIUM FIRE
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Sodium aerosols will be released in to
the atmosphere in case of Sodium leak
from pipes of PFBR
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Quantity of sodium aerosols and
information on chemical species in the
aerosols are important for safety
studies.
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A test facility was constructed to study
the atmospheric dispersion
characteristics of sodium aerosols in
open atmosphere
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Commissioning of the facility was carried
out by burning 5kg sodium.
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Aerosols samplers were deployed in a
30o conical sector up to 400m distance
from the release point based on the wind
profile.
Aerosols resulting from sodium burning
were released at 10 m height using a
chimney.
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50 kg of sodium fire was conducted and
the aerosols sampling was done up to a
distance of 750 m.
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Various sampling techniques used for
characterization of the dispersed sodium
aerosols
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More experiments for chemical
speciation studies and to confirm that the
experimental values are within allowable
threshold limits
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Wind flow analysis was carried out and
experiment was carried out during
favorable wind direction
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Photograph of the test
facility
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Photograph showing release and
dispersion of sodium aerosols
Layout of aerosol sampling stations
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SODIUM FACILITY FOR COMPONENT TESTING (SFCT)
A new sodium loop called SFCT is planned to be constructed
The commissioning of the facility will be completed by Dec 2015.
Objectives
• Erosion, Corrosion and thermal shock testing of Cr-Mo steel secondary circuit
piping and pipe fittings in sodium.
• Testing and calibration of medium length MI type continuous/discrete level probes
and RADAR level probes.
• In-sodium testing of small and medium size reactor components which are part of
reactor.
• Sodium freezing studies simulating the secondary circuit of future FBRs.
• Performance testing of different types of EM pumps and flowmeters.
FEATURES OF SFCT
Material of construction is SS 316LN.
Sodium inventory is 6 tonnes.
35 m3/h capacity EM pump for heating and cooling circuit
170 m3/h capacity EM pump for testing which requires high flow.
220 kW heater capacity
Designed for operation up to 600 °C.
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SODIUM TECHNOLOGY COMPLEX
New Building, Large sodium inventory – 100 tonnes
Three large test vessels & Sodium Purification Circuit
Heating & Cooling systems
Interconnecting pipe lines of varying sizes.
Air test facility
Sodium disposal and cleaning facility
Nuclear clean room
Studies
Qualification and Testing of CSRDM/CSR and DSRDM/DSR with improved safety features
Qualification of third shut down system for reactor operations.
Testing of any other lengthy components of CFBR.
Under Sodium Ultrasonic Scanning System & Sweep Arm Scanner.
Developmental studies on In Vessel Under Sodium Examination techniques for in
service inspection.
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Experimental Water Facilities
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SAMRAT Model
PUMP
IHX
INNER VESSEL
HOT POOL
COLD POOL
Drain line
for excess
water
MAIN VESSEL
STORAGE
FUEL
BLKT
ASA supply line
ROTAMETER
HEADER
Hot Water
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PUMP A
Cold
water
Tank
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SAMRAT Model
Details
• Commissioned in 2003
• This is 1/4th scale, 3600 , SS model of PFBR primary circuit based on 2-loop design
of PFBR. Both hot and cold plenum was modeled
• Three water storage tanks of total capacity 50 m3
• Two pumps – 1200 m3/h – 10 bar
• Plate type heat exchangers to control water temperatures.
• Perspex windows provided for visualization in cold pool
• Core includes blanket and storage zone along with Fuel zone
• Individual core SA is modeled
• Velocity measurement by HFA (Hot Film Anemometer), propeller anemometer and
temperature measurement by K-type thermocouples (1, 0.5 & 0.25 mineral
insulated)
• Free level oscillation measured by conductivity probes
• Rod type heaters were fixed in the core for decay heat removal studies.
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Experiments completed
Experiments Completed
Hydraulic Studies
• Velocity measurements at IHX inlet window.
• Free level fluctuation study
• Control plug flow distribution study
• IHX flow distribution study
• Gas entrainment study
Test vessel
Experiments Completed
Thermal Studies
• Secondary pump trip studies
• Optimum location for thermocouple probes
• Thermal stratification studies
• Thermal striping studies
• Safety Grade Decay Heat Removal studies
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DHX
Subassembly Test Facility
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Subassembly Test Facility
Details
• Sub assembly, orifices and labyrinth
studies
• Water storage tanks of total capacity 10
m3 , Heaters inside the tanks.
• Four pumps – 25-250 m3/h – 16 bar
• Plate type heat exchangers to control
water temperatures.
• Pneumatic valves with control systems
Experiments Completed
• Development of pressure drop devices for
PFBR
• Hydraulic characteristics of PFBR SA.
• Pressure drop & Cavitation studies of FBTR
subassemblies.
• Hydraulic studies of ECFM/CFMM
• FIV and lift force studies of PFBR SA.
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1/24 Scale Model
Details
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PFBR Hot pool model
Perspex model- Geometrical -1/24
Only fuel zone simulated
Pool thermal hydraulic studies
Experiments Completed
• Flow pattern in the hot pool
• Free level fluctuation
• Gas Entrainment
• Thermal stratification in the hot pool, DHR
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1/12 Scale Model
Details
• Surge tank model of PFBR secondary
sodium circuit
• Perspex model – Geometrical-1/12
• Ultrasound Velocity Profiler used for flow
field mapping in the model
• Flow visualization with dye injection
Experiments Completed
• Understanding gas entrainment phenomena
• Development of devices to mitigate gas entrainment
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Large Scale Model [5/8]
Details
• A large scale 5/8 model of primary
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vessel of FBR is envisaged to be
constructed during the coming years for
pool hydraulic studies.
Designed
to
simulate
the
gas
entrainment in a pool with both Froude
number and Weber number simulation.
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Summary
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Brief details about various experimental facilities
catering to the testing and performance evaluation
requirements of fast reactor components have been
brought out.
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These facilities have been found to be immensely
useful to continue research and development
activities in the areas of component development
and testing, sodium technology, thermal hydraulics
and sodium instrumentation for the SFR’s.
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In addition new facilities which have been planned
will be of great importance for the developmental
activities related to future SFR’s.
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