distinguished scientist & director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70...

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SCIENCE AND TECHNOLOGY OF FAST BREEDER REACTOR PROGRAMME IN INDIA: CHALLENGES AND ACHIEVEMENTS SCIENCE AND TECHNOLOGY OF FAST BREEDER REACTOR PROGRAMME IN INDIA: CHALLENGES AND ACHIEVEMENTS Indira Gandhi Centre for Atomic Research Indira Gandhi Centre for Atomic Research Kalpakkam Kalpakkam Baldev Raj Baldev Raj Distinguished Scientist & Director Prof. Jai Krishna Memorial Award 2008, Annual Convention of INAE, December 5-6, 2008, Goa

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Page 1: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

SCIENCE AND TECHNOLOGY OF FAST BREEDER REACTOR

PROGRAMME IN INDIA: CHALLENGES AND ACHIEVEMENTS

SCIENCE AND TECHNOLOGY OF FAST BREEDER REACTOR

PROGRAMME IN INDIA: CHALLENGES AND ACHIEVEMENTS

Indira Gandhi Centre for Atomic ResearchIndira Gandhi Centre for Atomic ResearchKalpakkamKalpakkam

Baldev RajBaldev RajDistinguished Scientist & Director

Prof. Jai Krishna Memorial Award 2008, Annual Convention of INAE,December 5-6, 2008, Goa

Page 2: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

22

Energy Challenges

Increase in Demand

Public and Political acceptance

Cost effectiveness

Reduced Emissions

Motivation for More & Clean Energy -> Better quality of life

Energy defines the index of quality of life. But has to meet many challenges

Page 3: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability
Page 4: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability
Page 5: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

8582

8075

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90868484

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1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03

Ava

ilabi

lity/C

apac

ity F

acto

r (%

) ----

->

THREE STAGE NUCLEAR POWER PROGRAM

Stage Stage –– I PHWRsI PHWRs

•• 1515-- OperatingOperating•• 3 3 -- Under constructionUnder construction•• Several others plannedSeveral others planned•• Construction planned Construction planned

for 700 for 700 MWeMWe unitsunits•• Gestation period Gestation period

being being reducedreduced•• POWER POTENTIAL POWER POTENTIAL ≅≅

10,000 MWe10,000 MWeLWRsLWRs

•• 2 BWRs Operating2 BWRs Operating•• 2 VVERs under 2 VVERs under

constructionconstruction

Stage Stage –– III and BeyondIII and BeyondThorium Based ReactorsThorium Based Reactors

•• 30 kWth KAMINI30 kWth KAMINI-- OperatingOperating•• 300 MWe AHWR300 MWe AHWR-- Under Under

Regulatory ExaminationRegulatory Examination

•• POWER POTENTIAL = POWER POTENTIAL = 155,000 155,000 GWeGWe--yy

•• Availability of ADS Availability of ADS can enable early can enable early introduction of Thoriumintroduction of Thorium

•• Participation in ITER Participation in ITER towards development of towards development of fusion technologyfusion technology

Kalpakkam Kalpakkam –– Unique Nuclear Site in the World housing all Three Stages & CloUnique Nuclear Site in the World housing all Three Stages & Closed Fuel Cycle Facilitiessed Fuel Cycle Facilities

IGCAR IGCAR –– Mission Oriented Centre for Development of Science Based TechnoMission Oriented Centre for Development of Science Based Technology for FBRlogy for FBR

Stage Stage -- IIIIFast Breeder ReactorsFast Breeder Reactors

•• 40 MWth FBTR 40 MWth FBTR -- OperatingOperatingTechnology Objectives Technology Objectives realisedrealised

•• 500 MWe PFBR500 MWe PFBR--under construction under construction

•• POWER POTENTIAL: Minimum POWER POTENTIAL: Minimum 530 530 GWeGWe

Page 6: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Indian energy resources and Nuclear Contribution

Page 7: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Energy Potential1 kg of coal 3 kWh1 kg of oil 4 kWh1 kg U (natural) 50,000 kWh

(if reprocessed) 3,500,000 kWh

ADVANTAGES OF FAST BREEDER REACTORSADVANTAGES OF FAST BREEDER REACTORS

Ø Effectively utilizes the natural uranium (nearly 80 %)Ø Consumes the depleted fuel discharged from thermal reactorsØ Breeds more fissile material (plutonium) than consumed

With a large number of thermal reactors operating and planned worldwide, the limited available natural uranium would be consumed very fast. On the other hand, with FBRs, energy supply can be ensured over a few centuries.

2.752.352.20< 1Fast

2.062.262.041.34Thermal

Pu-239U-233U-235Nat.UReactor

No. of neutrons generated from fission per neutron absorbed in the fissile material

(BTCE)

Page 8: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Advantages of FBR Advantages of FBR –– contdcontd……FBR is important from waste management and environmental considerations. Burns actinides and long lived radioactive fission products. Generation of precious metals such as Cs, Pd etc which have many important societal applications and can be extracted from its waste (wealth from waste).

Current trends in oil prices and available uranium resources bring FBR with closed fuel cycle to focus

Page 9: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

• China, France, India, Japan, Korea, Russia, and USA have interest in FRs

• France, Japan, and USA have signed an MOU to cooperate under the Global Nuclear Energy (GNEP) Partnership to demonstrate the feasibility of the sodium-cooled fast reactor technology to accomplish sustainability requirements

• International collaborative programmes on innovative reactors such as Generation-IV & INPRO are focusing on FRs

• 390 reactor years operating experience including test reactors

WORLD FAST REACTOR SCENARIOWORLD FAST REACTOR SCENARIOThe interest in FBR has been renewed internationally

FBR provides ever growing challenges & opportunities in FBR provides ever growing challenges & opportunities in science and technologyscience and technology

Page 10: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

FBR PROGRAMME IN INDIAFBR PROGRAMME IN INDIA

Ø India started FBR programme with the construction of FBTR Ø FBTR is a 40 MWt (13.5 MWe) loop type reactor. The design is

same as that of Rapsodie-Fortissimo except for incorporation of SG and TG (agreement signed with CEA, France in 1969).

Ø FBTR is in operation since 1985.Ø 500 MWe Fast Breeder Reactor Project (PFBR) through

Indigenous design and construction Ø Govt. granted financial sanction for construction in Sep 2003. Ø Construction of PFBR has been undertaken by BHAVINI. Ø PFBR will be commissioned by 2010. Ø Beyond PFBR: 4 units of 500 MWe FBR (twin unit concept) similar

to PFBR with improved economy and enhanced safety by 2020. Ø Subsequent reactors would be 1000 MWe units with metallic fuel

Page 11: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

20 years ofsuccessfuloperation

Credible confidence in

fuel cycle

Cradle forhuman

resources

Backbone of regulatory perception

in INDIA

Fast Breeder Test ReactorFast Breeder Test Reactor

Page 12: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

40 MWt, 13.5 MWe, Loop type, PuC - UC

1250 MWt, 500 MWe, Pool Type, UO2-PuO2

APPROACH TO BIG LEAP IN FBR PROGRAMMEAPPROACH TO BIG LEAP IN FBR PROGRAMME

•380 r-y worldwide FBR operational

•experience

•Rich experience with MOX fuel

•30 y of focused R&D programme

•involving extensive

•testing and validation

•Science based technology

•Peer Reviews

•Synergism among DAE, R&D

Institutions

and Industries

Page 13: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

PFBRPFBR REACTOR ASSEMBLYREACTOR ASSEMBLY

01 MAIN VESSEL

02 CORE SUPPORT STRUCTURE

03 CORE CATCHER

04 GRID PLATE

05 CORE

06 INNER VESSEL

07 ROOF SLAB

08 LARGE ROTATABLE PLUG

09 SMALL ROTATABLE PLUG

10 CONTROL PLUG

11 CSRDM / DSRDM

12 TRANSFER ARM

13 IHX

14 PRIMARY SODIUM PUMP

15 SAFETY VESSEL

16 REACTOR VAULT

Page 14: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

PFBRPFBR SECONDARY SODIUM MAIN SYSTEMSECONDARY SODIUM MAIN SYSTEM

Number of sodium loops : 2Primary Pumps : 2 Nos.Secondary Pumps : 2 Nos.IHX : 4 Nos.SG Modules : 8 Nos.Turbo-Generator : 1 No.

Page 15: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

CHALLENGES IN SCIENCE AND TECHNOLOGY OF FBRCHALLENGES IN SCIENCE AND TECHNOLOGY OF FBR

Science

• Metals and their performance under high temperature, sodium, irradiation environments over the long reactor life

• Development of non-metallic materials operating at high temperatures and radiation environments (special high density concrete, elastomers, ceramics, cables, etc)

• Sodium chemistry, aerosol behaviour, sodium fire and sodium water reactions

• Special sensors for sodium applications (detection of water leaks in steam generator, sodium leaks, purity measurements, level detectors)

• Thermal hydraulics and Structural mechanics (turbulences, instabilities, gas entrainments, thermal striping, stratifications, ratcheting, etc)

Engineering

• Design for components at high temp & long life

• Design of mechanisms operating in sodium and argon cover gas space

• Design to accommodate Na leak & Na water reactions

• Seismic design of interconnected buildings, components and thin shells with fluid-structure interaction

• ISI &repair of reactor internals • High temp. fission chamber

• Manufacture of large dimensioned welded thin shell structures made of austenitic stainless steel petals with close tolerances (~thickness) eg. Main & safety vessels, inner vessel, thermal baffles, etc

• Machining of large dimensioned and tall slender components with stringent tolerances (grid plate, absorber rod drive and component handling systems)

• Fabrication of large size box structures with controlled distortions

• Hard facing technology

• Development of Inflatable seals and large size bearings

Technology

Page 16: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Design Parameters for High Burnup

• Increasing fission gas plenum• Increasing the pellet density• Decreasing the smeared density• Annular pellet concept• High performance materials (High void

swelling resistance, low Irradiation creep and improved high temperature properties

DESIGN OF CORE FOR HIGH BURNUPDESIGN OF CORE FOR HIGH BURNUP

Page 17: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

• Large temperature difference (150 K) existing in hot pool leads to risk of thermal stratification.

• Stratification causes sharp axial gradient in the adjoining metal wall.

• Stratified layers oscillate causing high cycle fatigue

• Mitigation of stratification calls for novel thermal hydraulic design of hot pool component

POOL THERMAL HYDRAULICS POOL THERMAL HYDRAULICS

CP

Core

IHX

CP

Core

IHX

• Due to large pool surface area and free surface velocity, there is risk of argon gas entrainment within hot & cold pools.

• Gas entrainment can cause reactivity oscillations in case of bulk of argon bubble entering in to the core

• General design guidelines is to Minimize the Free Surface Velocity to Mitigate Gas Entrainment in Hot Pool

Page 18: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

THERMAL STRIPING DESIGN THERMAL STRIPING DESIGN

Thermal striping limits on structural wall

Thermal striping values (CFD)

Page 19: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Experiment Theory Experiment TheoryTheory

SEISMIC DESIGN SEISMIC DESIGN

Shake table tests on RA model

NICB model for seismic analysis FEM model of RA Buckling modes of thin vessels Drop time of absorber rods

• Development of seismic design criteria• Analysis of nuclear island connected buildings

(NICB) and also extract floor response spectra at various component support locations

• Seismic analysis of reactor assembly to derive seismic forces

• Investigation of buckling of thin shells

• Ensuring the reactor scramability• Investigation of pump seizure• Shake table testing for validation of analysis and

qualification• Long term R&D: behaviour of bearing, non-linear sloshing,

parametric instability of thin shells, study of cliff-edge effects, fluid-structure interaction of perforated structures

Page 20: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

ANALYSIS OF SHOCKANALYSIS OF SHOCK--STRUCTURE INTERACTION: HIGHLIGHTSSTRUCTURE INTERACTION: HIGHLIGHTS

Mechanical consequences of Core Disruptive Accident (CDA)

Validation of computer code FUSTIN Demonstration of structural integrity by tests

• Complicated loading scenarios on the vessel & top shield have been realistically simulated

• A series of ~65 tests have been conceived in a novel way and successfully completed at Terminal Ballistic Research Laboratory, Chandigarh over the period of 4 years

• Sophisticated instrumentations were deployed to derive extensive data for investigations.

Structural integrity analysis of PFBR RA under CDA

Page 21: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

CHALLENGING R&D: COMPONENT TESTING CHALLENGING R&D: COMPONENT TESTING

Seismic testing of reactor assemblySimulation of complex thermal hydraulics phenomenonPrototype testing of components under actual environment (sodium & temperature)

Components for sodium testing

Transfer arm

Control & safety rod drive mechanism

Diverse safety rod drive mechanism

Page 22: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Performance Testing of LCT

SODIUM FIRE AND SODIUM LEAK COLLECTION TRAYSSODIUM FIRE AND SODIUM LEAK COLLECTION TRAYS

Draining of Leaked Na into LCT

CFD simulation of Na draining

• Sodium leak in the sodium pipelines can cause sodium fire which is the critical issue in the sodium cooled FBR design

• Efficient leak detection systems

• Optimisation of sodium leak collection tray design towards minimising the effects of sodium fire

• Full Scale demonstration in SGTF (under operation) and Sodium Fire Test Facility (under construction)

Steam Generator Test Facility

Page 23: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

ISI of bimetallic (SS & CS) weld SPIDER ROBOT On Mockup Steam Generator Tube

Sheet

NDE: CHALLENGESNDE: CHALLENGES

Inspection of fuel pin end plugEddy Current Imaging Technique for Detection of Voids in Sodium Bonded Metallic Fuel Pins

Inservice Inspection of Main Vessel In-Service Inspection of stem generator

Page 24: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Risk Oxygen Meter

Cover gas hydrogen meter

Polymer electrolyte based hydrogen sensor

Semiconductor oxide based Compact hydrogen sensor

Electrochemical in-sodium hydrogen meter

Electrochemical in-sodiumcarbon meter

SENSORS FOR SODIUM APPLICATION SENSORS FOR SODIUM APPLICATION (DEVELOPED AT IGCAR)(DEVELOPED AT IGCAR)

Eddy CurrentFlow Meter

Sodium IonisationDetector

Special Features

Temp. range – up tp 450ºC

Resolution – from 13 ppb

Sensitivity –ppb to percentage

Response time – from 30 s

Page 25: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

ELECTROCHEMICAL HYDROGEN METER (ECHM) FOR SODIUM CIRCUITSELECTROCHEMICAL HYDROGEN METER (ECHM) FOR SODIUM CIRCUITS

E = RT/2F ln (p (sample)/ p (ref))H H2 2

pH2 (sodium) related [H]Na by Sievert’s Law (pH2)1/2 = CH / k

0.04

0.05

0.06

0.07

0.08

0.09 0.1

0.2

0.3

0.4

-15-808

1523303845

emf /

mV

CH / ppm

Meter testing pot

Sodium loop

Pre-amplifier

Display unit

ECHM housing

Performance of ECHM inFBTR east sodium circuit

Cal

ibra

tion

setu

p

Laboratory Calibration

Response of ECHM in SteamGenerator Test Facility

Page 26: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

INTELLIGENT WELDING INTELLIGENT WELDING ––ONON--LINE MONITORING & PROCESS CONTROLLINE MONITORING & PROCESS CONTROL

Base MetalWeld Metal

Welding TorchIR Camera

Thermal Images of Weld Image Processing & Neuro-fuzzy based Control

System

Digital Welding Power Source

Base MetalWeld Metal

Welding TorchIR Camera

Thermal Images of Weld Image Processing & Neuro-fuzzy based Control

System

Digital Welding Power Source

• Views weld pool from arc side using infrared camera

– Provides adaptive control for weld bead penetration

– Acts as seam-tracking device

• Thermal image of weld pool & surrounding area• Used to control welding parameters & maintain correct weld beadpenetration

Page 27: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

APPLICATION OF RESULTS FROM BASIC RESEARCH APPLIED TO APPLICATION OF RESULTS FROM BASIC RESEARCH APPLIED TO HARDFACING OF PFBR COMPONENTSHARDFACING OF PFBR COMPONENTS

200

300

400

500

600

700

800

0 5 10 15 20 25 30 35 40

Time of exposure (ageing) at 823 K (years)

Estim

ated

Vic

kers

har

dnes

s (H

V, 1

0 kg

f)

Colmonoy 5 at 300 KColmonoy 5 at 673 KColmonoy 5 at 823 KStellite 6 at 300 KStellite 6 at 673 KStellite 6 at 823 K

0 450 900 1350 1800

0

0.004

0.008

0.012

0.016

Near Interface (0.15-0.2 mm)Single layerDouble layer

Wei

ght L

oss

(g) →

Sliding distance (m) →

Normal Load : 120 NSliding Velocity : 0.25 m/s • Ageing studies on Ni base hardfacing alloys

confirmed no significant deterioration in hardness with high temperature exposure.

•Hardness measurement, microstructural examination and wear tests confirmed significant reduction in properties by dilution from base metal. Hence, a minimum deposit thickness of 2 mm and Plasma Transferred Arc process were recommended.

•Hardfacing of 6 m diameter grid plate has been carried out without cracking by Mechanized Plasma Transferred Arc Process

Predicted reduction in hardness with time

Effect of dilution on wear loss of the deposit

Hardfacing of PFBR Grid Plate

Hardfacing: A Technological Challenge in Reactor Component Fabrication

Page 28: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

POST POST –– IRRADIATION EXAMINATION FACILITY (PIE)IRRADIATION EXAMINATION FACILITY (PIE)Establishment of Leak Tight Concrete

Hot Cells, Lead Cells, Glove boxes

Installation of Remote Handling and Viewing Devices

MSM, Power Manipulators, In-cell CranesPeriscopes, Shielding Windows, CCD

Alpha Tight Fuel Transfer Systems

Inert Gas Ventilation System

In-cell Equipments & Gadgets

Laser Based Dismantling Machine, Metrology, Non-Destructive Techniques,

Neutron Radiography, Metallography, Fission Gas extraction, Mechanical Testing, Electron Microscopy

Hot cell Facility

Metrological Equipment& Laser Dismantling

Tensile TestingMachine

Fission Gas ExtractionRemote Metallography

Comprehensive Facilities Established for assessing the Irradiation Performance

of FBTR Fuel

Remote Examination Facilities

Page 29: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

25GWd/t 50GWd/t

100GWd/t 155 GWd/t

Complete closure of Fuel-Clad gap with increasing burn-up

Low Fission gas release ( ~15 %) and Plenum pressure (~2 MPa) in Carbide fuel pins

Progressive increase in the Dimensionsof Wrapper & Cladding

Sufficient Strength & Ductility of Cladding &Wrapper (at 80 dpa)

No Fuel pin/ Wrapper Failure in the Reactor

FBTR fuel burnup enhanced through PIE and Thermo-

Mechanical analysis from 25 GWd/t to 155

GWd/t

(485 C)

(430 C)

11.5%

3.5%∆V /

V %

Void Swelling of SS316 Clad & Wrapper

Strength Changes of SS316 Cladding with dpa

LIFE EXTENSION OF FBTR FUEL THROUGH PIELIFE EXTENSION OF FBTR FUEL THROUGH PIE(U0.3,Pu0.7)C fuel + SS316 Cladding & Wrapper

Page 30: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Digital Instrumentation & ControlDigital Instrumentation & Control

• About 15000 process signals are processed by distributed digital control system, developed in-house with about 50 000 lines of code

• Digital design and development has been verified & tested w.r.t software & hardware

• Pulse Coded Safety Logic System has been developed to ensure fail safe operation of the plant

Reactor Simulator for PFBRReactor Simulator for PFBR

• Design basis events are modeled to provide comprehensive training to plant operators

• Integrated modeling of I&C systems for effective simulation of plant operation

• Dedicated simulator for Fuel Handling Systems and operation

• 3 D animated human-machine interface system has been developed

• Real time simulator for the fast transient events- under development

Page 31: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Components manufactured under technology development

Page 32: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Main vessel SG

CONSTRUCTION OF PFBR: STATUS CONSTRUCTION OF PFBR: STATUS

PFBR will be commissioned by Sept 2010

Ø Technology with strong R&D backupØ Manufacturing technology

development completed prior to start of project

Ø Capability of Indian industries to manufacture high technology nuclear components demonstrated (main vessel, safety vessel, steam generator, grid plate)

Form tolerance specified for vessels : < thkAchieved : < ½ thkInsignificant weld repair

Page 33: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

REPROCESSING OF FAST BREEDER RECTOR HIGH BURN UP FUELSREPROCESSING OF FAST BREEDER RECTOR HIGH BURN UP FUELS

16 Stage Bank

CORAL facility demonstrated the successful reprocessing of mixed carbide fuels with high Pu with a burn up of 100,000 MWd/t for the first time in the world

Centrifugal Extractor

Single Pin Chopper

Modelling and Simulation

Online Monitoring

CORAL Facility

Design of Process Flow Sheet

Page 34: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

ReprocessingSafetyI & CMaterial Reactor PhysicsDesign

Repeatability

Scale up

Modeling

Pilot plant

Equipment

Process

Chemistry

Implementation

Review

Experiment

Analysis

Criteria

Philosophy

Performance evaluation

Integration

Simulation

Software

Hardware

Sensor

Production

Technology development

Simulation & Modeling

Synthesis

Data generation

Integration

Experiment

Simulation

Data

Design criteria

Principles

Manufacture

Design

Analysis

Code

Model

Continuum

Micro mechanics

Domains

Scie

nce

& T

echn

olog

yMATURITY MAPPING

• Judicious Mixing of step by step and concurrent• Inter-woven • Multi & Interdisciplinary • Matrix management

Page 35: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Marching from Science to Technology A Case Study : PFBR Fuel Subassembly

Totality of Fuel Design & Interfaces to Make the System Robust

Structural Mechanics• Fuel pin Integrity• Core Mechanics• Core Seismic• Flow Induced Vibration• End Plug Weld • Impact Analysis

Design Interfacing with Reactor Physics,

Material Technology, Fuel cycle technology and manufacturing technology

Evolution

Potential : 108 kWhWith int. breeding : 1.5.108 kWh Extracted : 107 kWhPower density : 416 W/ ccLimited by structural materials

Technology• Clad 2.6 m & 0.4 mm thk• Tight tolerances Fine

Surface Finish• Wrapper- 3.6 m long • Verticality- 3 mm• Annular pellet

Safety• Novel design features and design

provisions ( Radial Coolant entry & multiple holes, Blockage Adaptor, Helical spacer Wire) to prevent flow blockages

• Simulation of flow blockage & propagation and their effects

• Benchmark experiments Thermal Hydraulics• Optimum flow zoning• Maximise foolant mixing • Flow distribution• Flow characterization• Temperature Mapping• Hot spot analysis

Science• Reactor Physics• Material Characterization

(Physical & Chemical) • Fuel Chemistry

(Thermodynamics & Kinetics)• Radiation damage• Modeling & Experimental

Verification • Post Irradiation Examination

Page 36: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Design and Technological Challenges of Typical PFBR Components and Structures

Grid Plate Steam Generator NICB

Box type structure made of top and bottom plates connected by intermediate shell and 1758 sleeves all with SS 316 LNHard facing with colmonoydeposits which is its largest industrial utilizationTight machining and assembly

tolerances (<0.2 mm horizontality and 0.5 mm verticality) Assembly of a large number of parts (~14900) Top and bottom plates are perforated by removal of about 80 % of the material and called for innovative handling techniques.

Tall component of about 25 m height and has more than 500 tubes, made of modified 9 Cr 1 Mo steel. By adopting in-bore welding, tube-to-tube sheet joint are carried out with stringent acceptance standards on dimensions and weld quality The maximum concavity achieved is practically zero and maximum weld thinning is less than the permissible < 0.2 mm Welding technology has been matured based on elaborate technology development exercises and many trials.

Nuclear island consisting of eight inter-connected buildings resting on 6 m thick common base raft, is novel innovative civil design concept introduced first time in an FBRDesigned to achieve compact layout giving due considerations for maintenance, safety.Adoption of many innovative construction methodologies to proceed civil construction and mechanical component erection concurrentlySeismic design of nuclear island calls most challenging and advanced analysis techniquesConcrete mass - 3.8 lakhs tonnes

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Fast Breeder Reactor Project

State-of-art concepts Incorporation of

World wide FBR experiences

Platform for demonstration of

international aspirations

ConvergenceConsolidation &

Validation

Synergism with Academic, R&D institutions and

Industries

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CAPITAL COST REDUCTION MEANS FOR CAPITAL COST REDUCTION MEANS FOR FUTURE FBRS FUTURE FBRS

4x500 MWe FBR

Twin Unit Concept with common fuel building and spent fuel storage

Reduction in main vessel diameter

In-Vessel purification system

Reduction in height of each components supported on top shield and entire reactor assembly by improved design of top shield

Use of cost optimised materials of construction

Enhanced burn-up to reduce fuel cycle cost

Reduced construction time (7 y to 5 y)

Enhanced design life 40 y to 60 y

Enhanced capacity factor (75 to 85 %)

UEC is comparable to that of fossil power plants

1000 MWe FBRs

Metallic fuel Metallic fuel

Ferritic steels for core Ferritic steels for core

UEC competitive to that UEC competitive to that of fossil power plantsof fossil power plants

Cost comparison of Fast Reactors

Cost Reduction due to Investment in R&D

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Vision Statement: IGCAR & BHAVINI

To be a global leader in design, construction and operation of sodium cooled fast breeder reactors and associated fuel cycle facilities

0.5 GWe (2010)

2.5 GWe (2020)

250 GWe (2052)

Page 40: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Refre

sher

cour

ses

Wor

ksho

ps

Summer

Projects for 400-500

students every year

Spon

sore

d Re

sear

ch

MoU with Colleges and

Research institutes

IGCAR -

ACADEMIA -

RESEARCH

INSTITUTE -

LINKAGES

Research support for PG and PhD -faculty and students

Exte

rnal

Re

gist

ratio

n –

join

t gui

danc

e sc

hem

e

UGC-DAECSR

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• Gas Entrainment in Liquids• Improved Safety with Liquid Metal • Material Modeling with Micromechanics Based Approach• Complex Thermal Hydraulics and Two Phase Flow• CFD and Power Plant Dynamics • Seismic Integrity Assessment • Advanced Civil Design with Interconnected Structures• Prediction of Ageing and Damage Mechanisms for Long

and Reliable Plant Life with NDE Techniques

Generic Challenges to Attract Bright Minds to Nuclear Engineering

Bulk separation processes at extremely low concentrationsSingle molecule spectroscopyMicrostructure tailoring to achieve near zero corrosion rateDesign with Enhanced Conceptualisation and ModellingModelling to enable long life systems

Fuel Cycle

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IGCAR TODAY

INDUSTRYUNIVERSITY

RESEARCH INSTITUTE

Development of FBR and associated Fuel Cycle Technologies

Mission Centre with University Status

•Construction and commissioning of FBR plant

•Construction and operation of fast reactor fuel reprocessing plant

•Development of enriched boron production facility

•Widespread interactions with industry with co-responsibility with BHAVINI

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Consumption Per Capita -2007 : Tonnes Oil Equivalent

Scarce Soil Fertility

Global ImbalancesGlobal Imbalances

World needs to agree and World needs to agree and implement (with time frame) implement (with time frame) adequate and robust processes for adequate and robust processes for equity before it becomes root equity before it becomes root cause of destruction of this cause of destruction of this beautiful and unique planet.beautiful and unique planet.

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Page 45: Distinguished Scientist & Director85 82 80 75 71 67 60 90 84 84 86 79 75 69 72 89 50 55 60 65 70 75 80 85 90 95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Availability

Global leadership in mega technology of high relevance to

India and World

Enhanced Synergy with

Academia,

Research and

Industry

Mega collaboration

with leading national

& international institutes

Basic science,

scientific breakthroughs

for challenging technology

Human resources (attracting, nurturing, mentoring and motivating)

FBTR life extension for next 20 yearsRobust PFBR

Realising Fast Reactor Fuel Cycle FacilityDesign and development for 500 MWe FBRs with improved economy (UEC Rs.2.00) and enhanced safety

High performance fuel cycle technologiesSignificant Progress towards realisation of Metal fueled reactor & associated fuel cycle

CHALLENGES, APPROACHES AND TARGETSCHALLENGES, APPROACHES AND TARGETS

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A developed civilization scenario