presentation on frhtf

7/22/2019 Presentation on FRHTF

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Fluid Power & Tribology Section

Refuelling Technology Division

Bhabha Atomic Research Centre

Trombay, Mumbai - 85


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Hydraulic systems are being utilized for various applications in DAE for highforce applications like

sintering presses,

extrusion presses,

spent fuel choppers etc.

Fuelling machine

In AHWR, Fuelling machine snout assembly with special cooling arrangement ina high temperature(about 285 0C) zone.

Cooling Failure increase in the operating temp of hydraulic fluid loss of viscosity and hence lubrication

thermal degradation of the hydraulic fluid.

AHWR FM vertical assembly leakage of traditional hydraulic oil in areabelow the deck plate fire hazards.

To reduce the fire hazards, non-flammable hydraulic fluids are best suited.

RTD has planned to qualify an indigenous anhydrous fire resistant hydraulicfluid which can replace the traditional mineral oil based hydraulic fluid being

used in hydraulic systems of nuclear facilities. This will also ensure

the utilization of hydraulic systems up to higher operating fluid temperaturewithout any degradation of the properties of the operating fluid.

Mitigate the chances of fire accidents due to flashing or auto-ignition.

For this purpose, a FIRE RESISTANT HYDRAULIC FLUID TEST FACILTY (FRHTF) is

being developed by RTD at Engg. Hall3.


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Polyol Ester (POE) based FRHF can work in high temperature areas of nuclear facilities

and mitigate the chances of fire due to self burning in presence of hot surfaces.

But, very little experience of using it as compared to mineral oil.

Standard vane pump tests, fire resistant test with limited quantity of oils etc. are less

relevant because

we predominantly use axial piston pumps and motors;

Leaks occurring during operation of hydraulic system in high temperature area of

nuclear facility with radiation source present cannot be plugged or high temperature

sources cannot be eliminated as simulated during fire resistance testing as per IS:7895.

To fully evaluate POE based FRHF for nuclear industry; it is proposed to perform tests

like

Performance monitoring using Axial Piston Pump test;

Gamma radiation resistance testTribological evaluation at reasonably high temperatures of 90 0C and 120 0C.

(Tribology Lab) (out of scope of FRHTF)

Leak spray fire testing to simulate prolonged leakage on hot horizontal & vertical

surfaces; (out of scope of FRHTF)


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The facility is planned in the area outside Engg. Hall3 in FMTF Transformer area.

Areas between grid X20 x X28 to Z20 x Z28 will be utilized for FRHTF.

Within this space the power packs will be located between flowing grid locations

Power pack1 (PP-1): Y21 x Y22 to Z21 x Z22

Power pack2 (PP-2): Y23 x Y24 to Z23 x Z24 Power pack3 (PP-3): Y25 x Y26 to Z25 x Z26

20 21 22 23 24 25 26 27 28

Y

Z

Z


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Plan & Elevation of Fire Resistant Hydraulic Fluid Test facility (FRHTF)


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The hydraulic power pack/test setup) consists of

An axial piston pump of 3.5 cc/rev displacement

1 HP electrical motor,

A relief valve (operating range of 0-200 bar),

A pressure line bonnet valve,

Orifice,

Pressure gauge with a snubber,

a fan cooled radiator, and

a sampling point with MINIMESS VALVE coupling.

The tank is fitted with

a level switch and level indicator,

temperature sensor, temperature

switch and alarm,

Filler & air breather and

strainer with 100 micron rating .

10 Liters x 1HP x 2.5 LPM Oil Hydraulic Power Pack

Electrical Power:

3 f, 1 HP x 1450 RPM, 50+1%

Hz

24 V DC for solenoids

230 V AC Supply for the

various gadgets

Foundation Details of each power pack

590 mm X 460 mm X 12 mm, 4 bolts mounting


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Safety features and devices

Design pressure of the power pack pressure line components is 200 bar.

Pressure relief valve

Max. Operating pressure200 bar Max. Flow capacity120 lpm

Temperature HighLamp Alarm, wired provision for alarm to control roomduring remote control mode

Tank level LowTrip and lamp alarm, wired provision for alarm to control

room during remote control mode local as well as remote stop provisions.

Incoming phase indications

Overload Relays for Pump Motor (3.2 amps) and cooling motor (2 amp) to prevent heavy inrush current to the motors.

System with MCBsto prevent system damage Inventory of Oillimited to 10 litres per tank

Material of construction of Tubes and isolation valvesSS 304

Sample withdrawal through Minimess coupling, resulting in minimalpenetration of the pressure boundary.


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Details of the hydraulic components

Sr. No. Categ. of item Item description1. Mech. Hydraulic Pump

Type Positive displacement axial piston pump

Pressure Rating 315 Bar

Displacement 2.5 cc per revolution

Permissible speed 1500 rpm

Make Shanghai Xiaoli Hydraulics Co.,Ltd

Model No. 2.5-MCY-14-1B

2. Mech. Pressure relief valvePressure Rating 200 bar

Max Flow capacity 100 lpm

Make Rexroth

Model No: DBDH-10-200

3. Mech. Pressure gaugePressure Range 0160 bar

Dial Size 0-4

Make WIKA

Connections BSP

4. Mech. Union Bonnet ValveType Stem type needle valve(Regulating)

Pressure Rating 200 bar

Connections 3/8NPT (F) x 3/8NPT (F)

Operating temperature Ambient to 1200

CMaterial SS316


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Details of the hydraulic components

5. Mech. Tank

Material SS - 304

Make Shop fabricated

6. Mech. Suction strainerMesh size 100 micron

7. Mech. Level GaugeMake - Hydroline

Model No LG6-03

8. Mech. Air breatherMake - Hydroline

Model No FSB- 05

9. Elect. Electrical motorPower rating 1 hp

Phase and voltage rating 3 Phase, 415 V Electric Supply

Speed 1450 RPM

Frequency 50+1% Hz

Make Siemens

10. Mech. &

elect.

Air cooled radiatorMake Falls

Heat removal capacity 1 HP

Type Radiator

Electric motor 3 Phase, 415 V, 56 W x 2800 RPM, 50+1% Hz

11. Elect. Temperature sensor and indicator

Make-

Selec controlsType PT 100

Power consum tion - 5VA 230V AC


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Details of the hydraulic components12. Mech. &

elect.

Float SwitchType Top mounted magnetic level switch

Model No - VMT-04-F65-PG9

Material of construction Wetted part : SS304

Float : SS316LMax working temp 120 deg C

Max switching current 3 amp

Switch rating 0.5 amps at 230 V or 100 VA

13. Mech. Tubes

Material SS- 304

Pressure rating Pressure line - Minimum 200 bar, Return line - 20 bar

Sizes

Suction line

Pressure line

Gauge line

1x 1.6 mm thick

x 1.5 mm thick

x 1 mm thick

14. Mech. Gauge Isolator

Operating Pressure 350 bar

Mounting Panel installation

Connections 1/4BSP

15. Mech. Sampling Valve

Type Minimess coupling

Material SS-304

Connection BSP

Working pressure 630 bar


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The FRHTF consists of 3 numbers of test setup. Each setup is

having 3 Phase Electric Supply, 415 V, 1 HP x 1415 RPM, 50+1% Hzelectric

motor for hydraulic pump

3 Phase Electric Supply, 415 V, 56 W x 2800 RPM, 50+1% Hzelectric

motor for radiator

24 V DC Supply for the solenoids 230 V AC Supply for the various gadgets

Independent 3 phase power supplies are required for all three

units.

Power supplies shall be sufficient enough to power up all thegadgets of each test set-up.


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Install the power pack mounting bolts.

Fill hydraulic oil FRHF or Mineral oil into the reservoir of respectivepower packs up to HIGH level of the sight glass.

Fill the case drain of the pump.

Give 3 phase supply to the starter box. Ensure that the direction of the

motor is clockwise as viewed from the shaft end of the Pump.

Check that the pressure relief valve is fully open.

Start the electric motor.

Ensure that the pump is primed.

Fully close bonnet valve.

Increase the pressure by screwing in relief valve item No. 12 to the

required pressure as indicated in the pressure gauge item No.13.

The power pack is now ready for the end use.


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General operating conditions

Operating pressure 080 bar

Operating temperature range 30 0C to 120 0C Ambient temperature 10 0C 45 0C

PP - 1 PP - 2 PP - 3

Operating Fluid Polyol ester based FRHF

(flash point296 0C)

Hydraulic Mineral Oil

(flash point206 0C )

Polyol ester based

FRHF(flash point296 0C)

Operating pressure 80 bar 80 bar 80 bar

Operating Temp 65 0C 65 0C 90 0C

To compare the performance of Polyol Ester and Mineral Oil

at the limit of mineral oil operating temperature.

Further high temperature will assist in accelerated testing of

these oils.


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Radiato

r

Control

panelTank

Level gauge

Pressure

gauge

Elect. MotorTemperatur

e

transmitter

Relief Valve

The relief valve is set at 80 bar in all 3 set-ups. Combined action of bonnet valve opening and relief valve setting with

cooling provision will generate different set of required operating temperatures which will be monitored using temperature

indicator and transmitter put into the hydraulic setup tank. Initially the operator will adjust bonnet valve opening to achieve

required test temperature. The setup will be made to run continuously to demonstrate accelerated testing. No preheating will

be done. The pumps will start with cold condition.


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During testing various samples will be drawn and following

evaluations will be carried out of the test facility Volumetric efficiency of pump

Total Acid number (TAN)

Kinematic viscosity

Condition monitoring by Particle counting

Moisture content

Thermal stability due to oxidation

Electrical motor current measurement

Vibration monitoring using accelerometer

Change in weight of the pump


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Fire extinguishers (Foam type and DCP type) are planned for

the facility Fire Section has been intimated to provideadequate fire-fighting equipment.

The facility is placed outside Hall-3 in open space, so thorough

ventilation is available.

To prevent the facility from flooding and rain, the power packsare proposed to be

installed 350 mm above the ground and

covered with sufficiently sized canopies.

Equipment kept at 1.5 m distance apart.


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Safety Precautions

Periodically oil level check the in the reservoir. Do not ignore

the alarm light on the panel.

Periodically temperature check. Do not ignore the alarm on

the panel.

Ensure that all the connecting electric wires are properly

sealed and not exposed.

Keep a constant watch on the joint and interface leakages.


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Troubleshooting

Sr.

no.

Trouble Cause Remedy

1. Rise in

Temperature

Slippage in the pump Replace the pump.

Pressure setting high. Check and adjust.

Oil level low Top up oil.

Oil contamination level high Check. Filter.

Replace.

Cooler motor not running Check and take

action

1. Rise in noise level Starvation of the Pump Check the oil level.

Aeration of pump Check pumps oil

seal.

Check suction joints.

Pressure setting high. Check and adjust.Cavitation due to strainer choke. Replace strainer.

Vibration of the pipes Locate and clamp.

1. Loss of Pressure Pressure Relief Valve sticky. Open and clean.

Pump worn out. Replace the pump.

Relief valve poppet does not seat Service the valve by


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Design Basis Accidents (DBA) and immediate actions needed.

Sr.

no..

Accidents Ultimate result

that may

happen

Safety feature in facility/

equipment

Action needs to

be action at the

instant

Any improvement planned

1. Coupling breaks Generation of

projectile

Enclosed in bell housing, so no

projectile.

Switch off the

unit and replace

the coupling.

-

2. Union Bonnet

Isolation valve

blocked

Rupture of

tubes

Temp high due

to RV throttling

Pressure will rise up to RV setting

and bypassed to tank.

Temp High Alarm will appear.

Open the Valve.

Switch off the

unit.

-

3. Pressure higher

than set value

(Isolation valve

closed)

Rupture of

tubes

Torque on motor will increase and

hence current will continue to

increase finally overload relay will

trip the pump.

- Pressure switch may be

incorporated to TRIP the

pump before overload relay

acts.

4. Pressure higher

than set value

(relief valve

choked)

Rupture of

tubes

Torque on motor will increase and

hence current through motor will

increase and overload relay will trip

the pump.

- Pressure switch may be

incorporated to TRIP the

pump before overload relay

acts.

5. Cooling motor OFF Temperaturewill increase.

Temp high alarm will appear. Switch ON theunit.

Start the cooling motor

6. Cooling motor

failure or not

running

Temperature

will increase.

Temp high alarm will appear. Switch off the

unit. Rectify the

cooling motor.

Include controller to trip the

pump or restart the cooling

motor

7. Sampling valve

leaks

Tank will be

emptied out

Level will go down and pump will

trip on low level

Immediately

switch off the

pump and rectify

the problem.

.


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8. Fire in power packs

having Polyol ester

hydraulic fluid due

to overheating of

the oil

Fire hazard Autogeneous ignition temp is

approx. 450 0C, so self-ignition

is not feasible for polyester

based fluid.

a. Immediately

switch OFF the

unit.

b. Use the fire

extinguisher keptnearby in the

facility to douse

the fire.

Include controller so that

- If temperature is 1 0C

above the set value low

level alarm (light and

annunciation).- If temperature is 5 0C

above the set value, the

pump should TRIP.

9. Fire in power packs

having mineral

based hydraulic

fluid due to

overheating of the

oil

Fire hazard Maximum operating

temperature will be limited to

65 0C.

a. Immediately

switch OFF the

unit.

b. Use the fire

extinguisher

kept nearby in

the facility to

douse the fire.

Include controller so that


above the set value low

level alarm (light and

annunciation).


above the set value, the

pump should TRIP.

10. Ingress of water

into tanks.

Damage to the

oil quality

The power pack is covered with

suitably sized hoods.

Replace the oil. Periodically check the water

content in the oil by aqua

sensor.

11. Ingress of water

into facility

Damage to the

equipment

Unit is installed about 350 mm

above ground so no ingress due

to flooding and hence no short

circuit.

12. Trapping of birds

etc between

dynamic rotors.

Dynamic components like

motor shaft and fans are

covered with coarse wire mesh.

Design Basis Accidents (DBA) and immediate actions needed.


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In this Zone

Normal Temperature = 285 0C

Abnormal Temperature = 300 0C

Deck Plate

Upper header room

Cold Air


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