EXPERIMENTAL FACILITIES FOR PERFORMANCE EVALUATION OF FAST REACTOR COMPONENTS

Transcription

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.Rajan Fast Reactor Technology Group INDIRA GANDHI CENTRE FOR ATOMIC RESEARCH KALPAKKAM INDIA TECHNICAL MEETING 11:28 ON EXISTING AND PROPOSED EXPERIMENTAL FACILITIES FOR FAST NEUTRON 1 SYSTEMS June 2013, IAEA, Vienna, Austria

2 Introduction Initial Years of Development Later years of Development Experimental Sodium Facilities Large Component Test Rig OUTLINE 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 :28 2

3 INTRODUCTION Lecturer for BHAVINI Engineers Design, construction and operation of Sodium cooled Fast breeder Reactors SFR) form the second stage of Indian Nuclear Power Programme. The40MWtFastBreederTestReactor(FBTR)isstillinoperation. 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. AlargerscalemodelisbeingsetupforhydraulicstudiesforfutureSFRs : :28

4 Initial Years of Development :28 4

5 Later Years of Development :28 5

6 500 kw sodium loop The oldest loop of FRTG with sodium hold up of 3 tons Commissioned in m 3 /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 :28 6 Gained experience on all aspects of sodium technology

7 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 m 3 /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 :28 7 Material of Construction : SS 316

8 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 :28 8

9 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. Transfer Arm (TA) TEST VESSEL-5 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 m :28 9 Test Vessel-2

10 IFTM Test Facility PTM REP Grid plate with SA positions PR Liner The Primary Ramp (PR) & Primary Tilting Mechanism (PTM) :28 10

11 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 :28 11 DC Conduction Pump

12 Experiments Planned Qualification and Testing of DSRDM, CSRDM for 40 years. Testing of Integrated Cold trap and Integrated Plugging Indicator for future SFR s :28 12

13 SOdium WAter Reaction Test Rig (SOWART) :28 13

14 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 m 3 /h Operated for nearly 25,000 h Maximum sodium temp. : 525 C High Pressure steam circuit to inject steam Material of Construction : SS :28 14

15 Wastage Experiments Impingement Wastage test section Self wastage Test Section :28 15

16 Experiments Completed & Planned SL.NO EXPERIMENT COMPLETED 1 Self wastage studies were carried out at different steam leak rates intherange of10-50mg/s 2 Testing of Model Cold Trap for secondary sodium circuits. EXPERIMENT PLANNED Impingement Wastage studies on 9 Cr. 1 Mo Specimens Collaboration with CEA. 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.9Cr1Mo]. 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 :28 16

17 Steam Generator Test Facility (SGTF) :28 17

18 Steam Generator Test Facility (SGTF) 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 m 3 /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 h. Maximum operating temperature : 530 C :28 18

19 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 :28 19

20 Decay Heat Removal system in PFBR Decay heat needs to be removedto limit the temperature and maintain integrity of components :28 20

21 SADHANA :28 21

22 Commissioned in 2009 SADHANA To demonstrate the passive decay heat removal system of PFBR Richardson no similitude 1:22 scaled model calledsafetydecayheatremoval loop innatrium(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 :28 22

23 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 Studying the behaviour of SGDHR during station black out s Test vessel Secondary sodium flow rate m 3 /h Natural convection flow during damper opening Opening of damper Time in seconds :28 23

24 Thermal Shock Test Facility :28 24

25 Thermal Shock Test Facility 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 :28 25

26 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 Electromagnet Thermal shock testing on hard faced alloys. Test vessel :28 26

27 In Sodium Test (INSOT) Facility-Fatigue loop :28 27

28 Commissioned in 2002 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 m 3 /h Cumulative operating hours : h Material of Construction : SS 316 L[N] :28 28

29 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 Experiments Planned Tribological studies on hard faced material specimens Thermal striping experiments Test vessel :28 29

30 In Sodium Test (INSOT) Facility-Creep loop :28 30

31 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 Sodiumholdupof500kg Air cooler, a heater vessel with 60 kw capacity immersion heaters. 5nos.ofTestsectionsinhotleg Maximum operating temp 600 C Electrochemical carbon meter Foil equilibration chambers Maximumsodiumflow:3m 3 /h Cum.operatinghours:25000h MaterialofConstruction:SS316L[N] :28 31

32 Experiments completed and planned Experiments Completed 27 nos of creep experiments Experiments Planned Creep experiments on different materials Test vessel :28 32

33 Bimetallic Loop (BIM loop) :28 33

34 Commissioned in 2003 Bimetallic Loop (BIM loop) 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 m 3 /h :28 34

35 Experiments Completed Bimetallic Loop (BIM loop) 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 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 h Self welding susceptibility studies on different combinations of material specimens Testing of in sodium pressure transducer. IMPACT AND TENSILE SPECIMENS INSIDE SAMPLE HOLDER SELF WELDING SPECIMENS WITH SODIUM :28 35

36 SILVERINA loop :28 36

37 SILVERINA loop 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 :28 37

38 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 :28 38

39 LEENA loop-leak Experiments in NAtrium TEST SECTION 1 TEST SECTION :28 39

40 LEENA loop-leak Experiments in NAtrium 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 TEST SECTION :28 40

41 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 Development and testing of fibre optic type leak detectors Testing of modified leak detector layout of future SFR s Test vessel :28 41

42 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 30 o 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 :28 42

43 Photograph of the test facility Photograph showing release and dispersion of sodium aerosols :28 Layout of aerosol sampling stations 43

44 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 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 m 3/ h capacity EM pump for heating and cooling circuit 170 m 3 /h capacity EM pump for testing which requires high flow. 220 kw heater capacity Designed for operation up to 600 C :28 44

45 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 :28 45

46 Experimental Water Facilities :28 46

47 SAMRAT Model IHX PUMP INNER VESSEL HOT POOL Drain line for excess water COLD POOL MAIN VESSEL ASA supply line BLKT FUEL STORAGE HEADER ROTAMETER Cold water Hot Water Tank :28 47 PUMP A

48 SAMRAT Model Details Commissioned in 2003 Thisis1/4 th scale,360 0,SSmodelofPFBRprimarycircuitbasedon2-loopdesign ofpfbr.bothhotandcoldplenumwasmodeled Threewaterstoragetanksoftotalcapacity50m 3 Twopumps 1200m 3 /h 10bar 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 Rodtypeheaterswerefixedinthecorefordecayheatremovalstudies :28 48

49 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 :28 49 DHX

50 Subassembly Test Facility :28 50

51 Details Subassembly Test Facility Sub assembly, orifices and labyrinth studies Water storage tanks of total capacity 10 m 3,Heatersinsidethetanks. Fourpumps m 3 /h 16bar 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 :28 51

52 1/24 Scale Model Details PFBRHotpoolmodel 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 :28 52

53 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 :28 53

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 :28 54

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 :28 55

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