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Reactor Facilities Group

Organization

Shri S. Sridhar
Director, Reactor Facilities Group

Mandate

The Reactor Facilities Group aims at safe and successful operation of Fast Breeder Test Reactor and KAMINI reactor. Fast Breeder Test Reactor is a test-bed for the irradiation of fuels and materials for the fast reactors and a training ground for mastering the challenges of sodium technology and fast reactor operation. KAMINI facilitates carrying out neutron radiography of radioactive and non-radioactive objects and neutron activation analysis.

Highlights

The Fast Breeder Test Reactor is a 40 MWt, loop type, sodium cooled fast reactor. The schematic flow sheet of the heat transport circuits. Heat generated in the reactor is removed by two primary sodium loops, and transferred to the corresponding secondary sodium loops.

The major characteristics of the reactor for the completed 29^th campaign are given in Table 1. Also preparatory works are completed for taking reactor target power to its design value of 40MWt & the estimated process parameters are given in Table-2. Stainless steel (SS 316) is the principal material of construction for the reactor and coolant circuits.

Main characteristics of the Fast Breeder Test Reactor

Parameters	Present Core (29^th Campaign)
Reactor type	Sodium cooled, loop type
Reactor power	32 MWt / 8 MWe
Fuel	Pu Carbide + U Carbide
Fuel pin diameter (mm)	5.1
No. of pins/subassembly	61
Maximum linear heat rating (W/cm)	400
Radiography Site 10⁶-10⁷ n/cm²/sec
Maximum burn-up (GW d/t)	155 (Mark I) / 100 (Mark II)
No. of pins/subassembly	61
Peak neutron flux (n/cm²/s)	3.5E15
No. of control rods	6
Control rod material	B4C (90% enriched in 10B)
Reactor inlet sodium temperature (deg. C)	380
Reactor outlet sodium temperature (deg. C)	471
Primary sodium flow (m³/h)	1160
Feed water temperature (deg. C)	190
Steam temperature (deg. C)	424
Feed water flow (t/h)	59.5
Steam pressure (kg/cm²)	124
Sodium inventory (t)	150
Steam generator	Once-through type, seven tubes in shell, serpentine shaped
Turbine-generator	16 Stages, condensing type, 16.4 MWe air cooled.
Bypass circuit	100% Dump condenser

It achieved first criticality in Oct 1985 with a core of 22 MK-I fuel (70% PuC, 30% UC) SAs, rated for 10.6 MWt.

SG was put into service in Jan 1993 and the reactor power was progressively raised to rated power in Dec 1993.

TG was synchronized to the southern grid in July 1997.

Valuable operating experience on reactor core, coolant systems, once-through steam generator, neutronic instrumentation, reactor protection and shutdown systems has been acquired.

The internationally unique, indigenously developed high Pu. mono-carbide Mark I driver fuel has been irradiated up to 155 GWd/t and one lead Mark I fuel SA attained a burn up of 165 GWd/t as a part of fuel SA endurance testing.

KAlpakkam Mini Reactor (KAMINI)

Kamini (Kalpakkam Mini) reactor is a Uranium-233 fueled, demineralized light water moderated and cooled, beryllium oxide reflected, low power nuclear research reactor located in the post irradiation examination facility of Radio Metallurgy Laboratory, Indira Gandhi Centre for Atomic Research, Kalpakkam, India.

This reactor functions as a neutron source with a flux of 10¹² n cm-2 s-1 at core centre and facilitates carrying out neutron radiography of radioactive and non-radioactive objects and neutron activation analysis. Facilities are also available in the reactor for carrying out radiation physics research, irradiation of larger samples and calibration and testing of neutron detectors. The location of the reactor in the post irradiation examination facility enables carrying out neutron radiography of spent fuel and other radioactive objects discharged from the neighbouring Fast Breeder Test Reactor without the need to transport radioactive material over long distances. Kamini reactor was designed and built jointly by Bhabha Atomic Research Centre and Indira Gandhi Centre for Atomic Research.

KAMINI- Main Characterstics

Power	30KW
Fuel	U-233 Al Alloy
Moderator & coolant	Light Water
Reflector	200mm Beryllium oxide Canned in Zircaloy Surrounded by water
Control	Two Absorber type Cadmium safety control Plates
Biological Shields	Ordinary & High Density Lead
Flux	Core Average -10¹²n/cm²/sec
	Radiography Site 10⁶-10⁷ n/cm²/sec
	Sample Irradiation Site 10¹¹-10¹² n/cm²/sec

Expertise

Salient Features of recent irradiation Campaigns

Irradiation of enriched U based and Plutonium based sodium bonded metallic fuel pins.
Irradiation of TRISO coated particles being developed by BARC for Compact High Temperature Reactor (CHTR) and disc specimens of CHTR structural materials (Nb-1% Zr 0.1% C) were completed.
Irradiation of structural materials for low dose irradiation for future Fast Reactors.
Testing of High Temperature neutron detectors developed by BARC for PFBR
Production of Strontium isotope for medical purposes

Seismic re evaluation

Seismic re evaluation of FBTR has been carried out. The seismic margin assessment indicates that the plant, in the current condition, is safe for 0.09g. With the retro-fittings recommended by the Review Committee, the Seismic Margin will improve to 0.3 g. Retrofitting work was completed.

Modification in the plant to take care of Tsunami incident

Subsequent to the Tsunami of Dec 2004, a study was carried out by IIT Madras for Kalpakkam site. FBTR being far away from the coast (~1 km) the Design Based Flood Level for tsunami has been estimated to be less compared to the cost. This is also borne out by the fact that there was no water ingress in FBTR-RML complex during the tsunami of 2004. However modifications were completed to avoid direct entry of water into the complex. Earth Quake Notification system (ENS) is installed in FBTR control room, MAPS control room and KARP control room which will alert the operator about possibility of Tsunami. Sufficient warning time is available to shut down the reactor and cool the core. Also Seismic sensors are installed in FBTR to provide safety action on high seismic event

Modification in the plant to take care of Flood

The study by IIT Madras indicates that under the cyclonic conditions combined with heavy precipitation and high tide, the flood level can reach 600 mm above the Finished Floor Level of FBTR. To avoid water entry to FBTR, all entry points to FBTR have been elevated by 600 mm.

Modification in the plant to take care of extended Black-out scenario

FBTR is procuring two additional air cooled DG sets to meet the power requirements in case of Extended Black-out scenario. These DGs will be located around 2 meters above ground floor in a newly built Seismically qualified Flood Safe Building (SFSB) so that flood and Tsunami will not affect their performance. In addition, two mobile DGs are procured which were located in the first floor of the buildings.

Achievements

KAlpakkam Mini Reactor (KAMINI)-NEUTRON RADIOGRAPH

Irradiated Fuel pins, Control rods
Experimental Assemblies and Capsules
Tomography
Non-radioactive Objects
Pyrotechnic devices and explosives
Hydrogen in steel
Study of fluid flow patterns in devices
Plastics and Composites

Milestones

Year	Milestones
18 thOctober 1985	First criticality
November 1989	Sodium valved in into SG
January 1993	Water valved in into SG
December 1993	Power raised to 10.5 MWt
1994-1995	Safety related Engineering Experiments
May 1996	Mark-I burn-up of 25 GWd/t
July 1997	TG synchronized to grid
1998 -1999	Zr-Nb irradiation for PHWR
April 1999	Mark-I burn-up of 50 GWd/t
March 2002	Power raised to 17.4 MWt
September 2002	Mark-I burn-up of 100 GWd/t
July 2003	Start of PFBR Test Fuel Irradiation
October 2005	Mark-I burn-up of 150 GWd/t
July 2006	Mark I burn-up of 155 GWd/t without failure The PFBR test fuel burn-up of 59.5GWd/t
Feb 2007 to Jan 2008	8 High Pu MOX SAs inducted into the core The PFBR test fuel burn-up of 80.76GWd/t validation of DND PFBR single pin irradiation for studying Grid plate flux measurement Grid plate material irradiation Testing of Kalman filter technique PFBR neutron detector testing in detector pit Irradiation of D-9 (Continuing)
September 2008	A special SA (IFZ-100) for trial production of the medical isotope Sr89
March 2009	The PFBR test fuel burn up of 85.3GWd/t The SG was operated with three water tubes blanked. Based on the PIE of the SA MK-I burn-up of 160GWd/t TG connected to grid, generating a maximum power of 18.6MWt / 3MWe
Dec 2009	PFBR test fuel to its target burn up of 112GWd/t at LHR of 450W/cm Closing of fast reactor fuel cycle as one of the fresh fuel SA has pins made of the recycled from FBTR SA.
Feb 2010 to Oct 2010	Testing of PFBR in-core detector & Measurement of neutron flux in experimental canal using foil irradiation measurement of gamma inside CCP. Testing of detector at 16MWt and 400kWt
July 2011 to Jan 2012	Irradiation of Yttria in IFZ100 Testing of High Temperature Fission Chamber for PFBR Testing of Kalman filter based instrument for drop time measurement of DSRDM of PFBR Initiation of irradiation of test pins of sodium bonded metallic fuel
2013-2014	Irradiation of Yttria Irradiation of Natural U-Zr sodium bonded metal fuel pins Irradiation of Capsule with Ferro-Boron Impact specimens of 304LN & 316LN for low does irradiation Irradiation of U metal pins Short term irradiation of the sphere pack fuel HTFC Testing Kalman filter reactivity meter testing Irradiation of Ternary fuel pin U-Pu-Zr.
Dec 2015 - March2017	Yttria for production of 90Sr isotope Sodium bonded Ternary fuel 14.3% EU and Natural U-Zr metal fuel pins Impact specimens of 304LN& 316LN for low dose irradiation Continuation of long term irradiation of D-9
March2017 to Feb 2018	SG Replacement
March 2018	Power raised to 30 MWt
8 October 2018 - 4th September 2020 (upto 29^th campaign)	Power raised to 32 MWt for continuing the metallic fuel pin irrdiation
March 2022	FBTR attains the design power level of 40 MWt
2023	FBTR successfully completed two irradiation campaigns (31^st & 32^nd irradiation campaigns) for the irradiation of various sodium bonded metallic fuel pins, D9 structural materials and production of radioisotope (Sr89) for societal applications etc. Reactor was operated for about 120 days at 40 MWt and electricity generated was 21.5 Million Units.

Facilities

Facilities available for neutron radiography

Carriage and drive system to lower radioactive samples from hot cell into the beam path
Sample holding facility and positioning system
Direct and indirect image recording films and film processing facilities
Real time radiography camera and image recording facilities

Facilities available for neutron activation analysis

Pneumatic sample transfer system with microprocessor based control system for sending and retrieving samples sample volume 5 cc or less
Irradiation thimbles for irradiation of larger samples up to 50 cc in volume
Laboratory with fume hoods for sample preparation and receipt of radioactive samples
Counting facilities with Ge-Li detector and PC based multichannel analyzer
Radioactive waste disposal facilities

Radiation Physics research

Study of composite shields
Radiation transport studies
Evaluation of new detectors