EXPERIMENTAL FACILITIES FOR PERFORMANCE EVALUATION …

2013-06-17 11:28 1

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.RajanFast Reactor Technology Group

INDIRA GANDHI CENTRE FOR ATOMIC RESEARCHKALPAKKAM

INDIA

TECHNICAL MEETING ON EXISTING AND PROPOSED EXPERIMENTAL FACILITIES FOR FAST NEUTRON

SYSTEMS

10-12 June 2013, IAEA, Vienna, Austria

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OUTLINE• Introduction

• Initial Years of Development

• Later years of Development

• Experimental Sodium Facilities

– Large Component Test Rig

– Sodium Water Reaction Test Facility

– Steam Generator Test Facility

– SADHANA test facility

– Thermal Shock Test Facility

– In Sodium Test Facility [Fatigue Loop and Creep loop]

– Bi-Metallic loop

– SILVERINA sodium loop

– LEENA loop

– Test Facility for Sodium aerosol Dispersion Studies

– Sodium Facility for Component Testing [SFCT] & Sodium Technology

Complex

• Experimental Water Facilities

– SAMRAT loop

– Sub-Assembly Test Facility

– 1/24 scale model, 1/12 Scale Model

• Summary

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3

Lectu

rer f

or B

HA

VIN

I E

ng

ineers

• Design, construction and operation of Sodium cooled Fast breeder

Reactors SFR) form the second stage of Indian Nuclear Power Programme.

• The 40 MWt Fast Breeder Test Reactor (FBTR) is still in operation.

• 500 MWe Prototype Fast Breeder Reactor (PFBR) is presently in the

advanced stage of construction.

• To test and qualify the reactor components, many experimental facilities in

sodium and water are in operation at IGCAR.

• For the research and developmental activities for future SFRs a

multipurpose sodium loop and a Sodium Technology Complex are also

envisaged.

• Experimental water test facilities are in operation for hydraulic studies.

• A larger scale model is being set up for hydraulic studies for future SFRs.

INTRODUCTION

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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

• Calibration of Eddy current flow meter and PMFM

• Gained experience on all aspects of sodium technology

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Large Component Test Rig (LCTR)


• 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

• Max.Temperature of operation: 600 °C

• Material of Construction : SS 316

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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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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-2

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

TEST VESSEL-2 & TEST VESSEL-5

Dedicated facilities for testing of Fuel Handling machines

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IFTM Test Facility

PR

Liner

REP

PTM

Grid

plate

with SA

positions

The Primary Ramp (PR) & Primary Tilting

Mechanism (PTM)

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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

DC Conduction Pump

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Experiments Planned

• Qualification and Testing of DSRDM, CSRDM for 40

years.

• 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)


• To study the behavior of self wastage and impingement wastage during Na-

water 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

Self wastage Test Section

Impingement Wastage test

section

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SL.NO

EXPERIMENT

COMPLETED

EXPERIMENT PLANNED

1 Self wastage studies were carried

out at different steam leak rates

in the range of 10-50 mg/s

Impingement Wastage studies on 9 Cr.

1 Mo Specimens Collaboration with

CEA.

2 Testing of Model Cold Trap for

secondary sodium circuits.

Development and Testing of

indigenously developed cover gas

hydrogen meters

3 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].

4 Development of acoustic

methods to detect sodium water

reaction in steam generator

5 Testing of In sodium and cover

gas hydrogen meters of various

range.

Experiments Completed & Planned

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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.


• Cumulative operating hours 40000 h.

• Maximum operating temperature : 530 °C

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SGTF SGPower: 5.5 MWtNo.of tubes: 19

Tube length: 23 mMaterial: Mod 9Cr-1Mo

PFBR SGPower : 158 MWtNo.of tubes: 547

Tube length: 23 mMaterial: 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


• 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

Test vessel

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

� Studying the behaviour of SGDHR during station black out

0 250 500 750 1000 1250 1500 1750 2000

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

500 s

Opening of damper

Seco

nd

ary

sodiu

m flo

w r

ate

m3/h

Time in seconds

Natural convection flow during damper opening

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Thermal Shock Test Facility

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Thermal Shock Test Facility


• 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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Test vessel


� 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

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


• 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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Test vessel


� 36 numbers of low cycle fatigue experiments and 13 numbers

of creep fatigue interaction experiments.

� 4 nos of tribometer experiments with various material

specimens

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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Test vessel


� 27 nos of creep experiments

Experiments Planned

� Creep experiments on different materials

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Bimetallic Loop (BIM loop)

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• 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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SELF WELDING

SPECIMENS WITH

SODIUM

IMPACT AND

TENSILE SPECIMENS

INSIDE SAMPLE

HOLDER


• 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.

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SILVERINA loop

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SILVERINA loop


• 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


� 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 TEST SECTION 2

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LEENA loop- LEak Experiments in NAtrium

TEST SECTION 1 TEST SECTION 2

• 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

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Test vessel


� 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

� 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

• Sodium aerosols will be released in to the atmosphere in case of Sodium leak from pipes of PFBR

• Quantity of sodium aerosols and information on chemical species in the aerosols are important for safety studies.

• A test facility was constructed to study the atmospheric dispersion characteristics of sodium aerosols in open atmosphere

• Aerosols resulting from sodium burning were released at 10 m height using a chimney.

• Various sampling techniques used for characterization of the dispersed sodium aerosols

• Wind flow analysis was carried out and experiment was carried out during favorable wind direction

• Commissioning of the facility was carried

out by burning 5kg sodium.

• Aerosols samplers were deployed in a

30o conical sector up to 400m distance

from the release point based on the wind

profile.

• 50 kg of sodium fire was conducted and the aerosols sampling was done up to a distance of 750 m.

• More experiments for chemical speciation studies and to confirm that the experimental values are within allowable threshold limits

2013-06-17 11:28 43Layout of aerosol sampling stations

Photograph of the test

facility

Photograph showing release and

dispersion of sodium aerosols

2013-06-17 11:28 44

� 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.

SODIUM FACILITY FOR COMPONENT TESTING (SFCT)

�

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

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.

� 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

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Experimental Water Facilities

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SAMRAT Model

HEADER

FU

EL

BL

KT

ST

OR

AG

E

PUMP A

PUMP

INNER VESSEL

HOT POOL

COLD POOL

MAIN VESSEL

IHX

Cold

water

Tank

ROTAMETER

Drain line

for excess

water

ASA supply line

Hot Water

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SAMRAT Model

Details


• 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

Test vessel

DHX


Hydraulic Studies

• Velocity measurements at IHX inlet window.

• Free level fluctuation study

• Control plug flow distribution study

• IHX flow distribution study

• Gas entrainment study


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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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


• 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

• PFBR Hot pool model

• Perspex model- Geometrical -1/24

• Only fuel zone simulated

• Pool thermal hydraulic studies


• 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


• Understanding gas entrainment phenomena

• Development of devices to mitigate gas entrainment

2013-06-17 11:28 54

Large Scale Model [5/8]

Details

• A large scale 5/8 model of primary

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.

2013-06-17 11:28 55

Summary

• Brief details about various experimental facilities catering to the testing and performance evaluation requirements of fast reactor components have been brought out.

• 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.

• 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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EXPERIMENTAL FACILITIES FOR PERFORMANCE EVALUATION …