FSTS Leak Rate Qualification Procedure

J. Botelho DireitoEN/CV/PJ

29/11/2012 FSTS - Leak Rate Qualification Procedure

Leak Rate Qualification ProcessLeak Rate Qualification START

Leak search after Mechanical AssemblyLow pressure test (1/3 x service pressure)

Search for leaks lower than 10-2 mbar.l/s (Bubble Test)

Definition of the circuit maximum leak rateEDMS 1250033

Helium Leak Search

Leak rate< 10-2 ?

YES

NO

Validation Pressure Test (VTP)0.8 x Service Pressure (>24 hrs)

HSE Pressure Test1.43 x Service Pressure

Leak Rate lower than defined ?

YES

NO

VPT Accepted?

END of Leak QualificationPlant Qualified

HSE Acceptence?

NO

Installation of Safety valves and Pressure Transmitters

YES

Helium Leak SearchNO

YES

29/11/2012 FSTS - Leak Rate Qualification Procedure

Maximum Leak Rate for the FSTS

He Leak Rate [mbar.l/s](inlet pressure of 0.1 mbar)

Number of connections (or locations to be tested)

Maximum leak rate per connection

Condenser 3.47x10-3 30 1.16x10-4

Vapour line 5.62x10-3 30 1.87x10-4

Liquid line 3.22x10-4 200 1.61x10-6

Brine Circuit 1.53x10-4 100 1.53x10-6

29/11/2012 FSTS - Leak Rate Qualification Procedure

Validation Pressure Test

29/11/2012 FSTS - Leak Rate Qualification Procedure

Pressure TestPressure test fluid NitrogenReturn piping total volume [m3] 1.6P internal initial [bar] 40.000P external initial [bar] 1T initial [°C] 22Nitrogen viscosity [Pa.s] 1.83E-05Pressure test duration [hr] 24P internal final [bar] 39.435P external final [bar] 1T final [°C] 22Pressure test leak rate [mbar.lt/s] 9.67E+00Mass of Nitrogen lost during the test [kg] 1.038

Working pressure translationWorking pressure [bar] 0.31Working pressure leak rate [mbar.lt/s] -5.47E-03Working fluid translationWorking fluid air.mixWorking fluid temperature 22Working fluid state #Superheated vaporair.mix #Superheated vapor Viscosity [Pa.s] 1.83E-05air.mix #Superheated vapor leak rate [mbar.lt/s] -5.46E-03air.mix #Superheated vapor intake per year [kg/year] 0.202Moisture intake (Service cavern conditions: 22 °C; 60% RH) [kg/year] 0.002

Pressure TestPressure test fluid NitrogenCondenser total volume [m3] 2.5P internal initial [bar] 25.000P external initial [bar] 1T initial [°C] 22Nitrogen viscosity [Pa.s] 1.80E-05Pressure test duration [hr] 24P internal final [bar] 24.915P external final [bar] 1T final [°C] 22Pressure test leak rate [mbar.lt/s] 2.27E+00Mass of Nitrogen lost during the test [kg] 0.244

Working pressure translationWorking pressure [bar] 0.31Working pressure leak rate [mbar.lt/s] -3.29E-03Working fluid translationWorking fluid air.mixWorking fluid temperature (winter average min low) 5.5Working fluid state #Superheated vaporair.mix #Superheated vapor Viscosity [Pa.s] 1.75E-05air.mix #Superheated vapor leak rate [mbar.lt/s] -3.39E-03air.mix #Superheated vapor intake per year [kg/year] 0.133Moisture intake (Yearly average max high: 14.5 °C; 73.3% RH) [kg/year] 0.001

Thermosyphon Circuit – Return Line Thermosyphon Circuit – Condenser

Validation Pressure Test

29/11/2012 FSTS - Leak Rate Qualification Procedure

Pressure TestPressure test fluid NitrogenVolume total [m3] 0.22P internal initial [bar] 40.000P external initial [bar] 1T initial [°C] 22Nitrogen viscosity [Pa.s] 1.83E-05Pressure test duration [hr] 24P internal final [bar] 39.770P external final [bar] 1T final [°C] 22Pressure test leak rate [mbar.lt/s] 5.51E-01Mass of Nitrogen lost during the test [kg] 0.059

Working pressure translationWorking pressure [bar] 16Working pressure leak rate [mbar.lt/s] 8.79E-02Working fluid translationWorking fluid R218Working fluid temperature 20Working fluid state #Subcooled liquidR218 #Subcooled liquid Viscosity [Pa.s] 1.87E-04R218 #Subcooled liquid leak rate [mbar.lt/s] 8.60E-03R218 #Subcooled liquid loss per year [kg/year] 1.863

Pressure TestPressure test fluid NitrogenVolume total [m3] 1.670P internal initial [bar] 20.000P external initial [bar] 1T initial [°C] 20Nitrogen viscosity [Pa.s] 1.79E-05Pressure test duration [hr] 24P internal final [bar] 18.901P external final [bar] 1T final [°C] 20Pressure test leak rate [mbar.lt/s] 1.98E+01Mass of Nitrogen lost during the test [kg] 2.125

Working pressure translationWorking pressure [bar] 10Working pressure leak rate [mbar.lt/s] 4.91E+00Working fluid translationWorking fluid C6F14Working fluid temperature -70Working fluid state #Subcooled liquidC6F14 #Subcooled liquid Viscosity [Pa.s] 5.79E-03C6F14 #Subcooled liquid leak rate [mbar.lt/s] 1.51E-02C6F14 #Subcooled liquid loss per year [kg/year] 9.000

Thermosyphon Circuit – Liquid Line Brine Circuit