Fluid Power & Tribology Section Refuelling Technology Division Bhabha Atomic Research Centre Trombay, Mumbai - 85

Hydraulic systems are being utilized for various applications in DAE for high force applications like
sintering presses, extrusion presses, spent fuel choppers etc. Fuelling machine

In AHWR, Fuelling machine snout assembly with special cooling arrangement in a 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 area below 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 hydraulic fluid 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 temperature without 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. Hall 3.

 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 test Tribological 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)

 The facility is planned in the area outside Engg. Hall 3 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 pack 1 (PP-1): Y21 x Y22 to Z21 x Z22 Power pack 2 (PP-2): Y23 x Y24 to Z23 x Z24 Power pack 3 (PP-3): Y25 x Y26 to Z25 x Z26

Y Z Z 20 21 22 23 24 25 26 27 28

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

10 Liters x 1HP x 2.5 LPM Oil Hydraulic Power Pack The tank is fitted with The hydraulic power pack/test setup) consists of An axial piston pump of 3.5 cc/rev displacement a level switch and level indicator, temperature sensor, temperature 1 HP electrical motor, switch and alarm, A relief valve (operating range of 0-200 bar), Filler & air breather and A pressure line bonnet valve, Orifice, strainer with 100 micron rating . Pressure gauge with a snubber, a fan cooled radiator, and a sampling point with MINIMESS VALVE coupling.
Foundation Details of each power pack 590 mm X 460 mm X 12 mm, 4 bolts mounting

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

Safety features and devices

Design pressure of the power pack pressure line components is 200 bar. Pressure relief valve
Max. Operating pressure 200 bar Max. Flow capacity 120 lpm

Temperature High Lamp Alarm, wired provision for alarm to control room during remote control mode Tank level Low Trip 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 MCBs to prevent system damage Inventory of Oil limited to 10 litres per tank Material of construction of Tubes and isolation valves SS 304 Sample withdrawal through Minimess coupling, resulting in minimal penetration of the pressure boundary.

Details of the hydraulic components

Sr. No. Categ. of item 1. Mech. Hydraulic Pump

Type Pressure Rating Displacement Permissible speed Make Model No. 2.

Item description
Positive displacement axial piston pump 315 Bar 2.5 cc per revolution 1500 rpm Shanghai Xiaoli Hydraulics Co.,Ltd 2.5-MCY-14-1B

Mech.

Pressure relief valve

Pressure Rating Max Flow capacity Make Model No: 200 bar 100 lpm Rexroth DBDH-10-200

3.

Mech.

Pressure gauge
Pressure Range Dial Size Make 0 160 bar 0-4 WIKA

Connections
4.

BSP

Mech.

Union Bonnet Valve

Type Pressure Rating Connections Operating temperature Material Stem type needle valve(Regulating) 200 bar 3/8 NPT (F) x 3/8 NPT (F) Ambient to 120 0C SS 316

Details of the hydraulic components

5.

Mech.
Mech. Mech.

Tank Material
Make

SS - 304 Shop fabricated 100 micron - Hydroline LG6-03

6. 7.

Suction strainer
Mesh size

Level Gauge
Make Model No

8.

Mech. Elect.

Air breather
Make Model No Hydroline FSB- 05

9.

Electrical motor
Power rating Phase and voltage rating Speed Frequency Make 1 hp 3 Phase, 415 V Electric Supply 1450 RPM 50+1% Hz Siemens

10.

Mech. & Air cooled radiator Make elect. Heat removal capacity
Type Electric motor

Falls 1 HP Radiator 3 Phase, 415 V, 56 W x 2800 RPM, 50+1% Hz - Selec controls PT 100 - 5VA @ 230V AC

11.

Elect.

Temperature sensor and indicator

Make Type Power consumption

12.

Mech. elect.

Details of the hydraulic components & Float Switch

Type Model No Material of construction Max working temp Max switching current Switch rating Top mounted magnetic level switch - VMT-04-F65-PG9 Wetted part : SS 304 Float : SS 316L 120 deg C 3 amp 0.5 amps at 230 V or 100 VA SS- 304 Pressure line - Minimum 200 bar, Return line - 20 bar

13.

Mech.

Tubes
Material Pressure rating Sizes Suction line Pressure line Gauge line

1 x 1.6 mm thick x 1.5 mm thick x 1 mm thick

350 bar Panel installation 1/4 BSP Minimess coupling SS-304 BSP 630 bar

14.

Mech.

Gauge Isolator
Operating Pressure Mounting Connections

15.

Mech.

Sampling Valve
Type Material Connection Working pressure

 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% Hz electric motor for hydraulic pump 3 Phase Electric Supply, 415 V, 56 W x 2800 RPM, 50+1% Hz electric 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 the gadgets of each test set-up.

 Install the power pack mounting bolts. Fill hydraulic oil FRHF or Mineral oil into the reservoir of respective power 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.

General operating conditions

Operating pressure 0 80 bar Operating temperature range 30 0C to 120 0C Ambient temperature 10 0C 45 0C PP - 1
Operating Fluid Polyol ester based FRHF (flash point 296 0C) 80 bar 65 0C

PP - 2
Hydraulic Mineral Oil (flash point 206 0C ) 80 bar 65 0C

PP - 3
Polyol ester based FRHF (flash point 296 0C) 80 bar 90 0C

Operating pressure Operating Temp

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.

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.

Relief Valve

Elect. Motor

Temperatur e transmitter

Level gauge
Tank Control panel

Pressure gauge

Radiato r

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

 Fire extinguishers (Foam type and DCP type) are planned for the facility Fire Section has been intimated to provide adequate 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 packs are proposed to be
installed 350 mm above the ground and covered with sufficiently sized canopies.

Equipment kept at 1.5 m distance apart.

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.

Troubleshooting
Sr. no. 1. Trouble Rise Temperature Cause in Slippage in the pump Pressure setting high. Oil level low Oil contamination level high Remedy Replace the pump. Check and adjust. Top up oil. Check. Filter. Replace. Check and take action Check the oil level. Check pumps oil seal. Check suction joints. Check and adjust. Replace strainer.

Cooler motor not running

1. Rise in noise level Starvation of the Pump Aeration of pump

Pressure setting high. Cavitation due to strainer choke.

1.

Loss of Pressure

Vibration of the pipes Pressure Relief Valve sticky. Pump worn out. Relief valve poppet does

not

Locate and clamp. Open and clean. Replace the pump. seat Service the valve by

Design Basis Accidents (DBA) and immediate actions needed.

Sr. no..
1.

Accidents

2.

facility/ Action needs to Any improvement planned be action at the instant Coupling breaks Enclosed in bell housing, so no Switch off the projectile. unit and replace the coupling. Union Bonnet Rupture of Pressure will rise up to RV setting Open the Valve. Isolation valve tubes and bypassed to tank. blocked Temp high due Temp High Alarm will appear. Switch off the to RV throttling unit.
Pressure higher Rupture than set value tubes (Isolation valve closed) Pressure higher Rupture than set value tubes (relief valve choked) Cooling motor OFF Temperature will increase. of Torque on motor will increase and hence current will continue to increase finally overload relay will trip the pump. of Torque on motor will increase and hence current through motor will increase and overload relay will trip the pump. Temp high alarm will appear. Pressure switch may be incorporated to TRIP the pump before overload relay acts. Pressure switch may be incorporated to TRIP the pump before overload relay acts.

Ultimate result that may happen Generation of projectile

Safety feature equipment

in

3.

4.

5. 6.

Switch ON the Start the cooling motor unit. Include controller to trip the pump or restart the cooling motor .

7.

Cooling motor Temperature Temp high alarm will appear. Switch off the failure or not will increase. unit. Rectify the running cooling motor. Sampling valve Tank will be Level will go down and pump will Immediately leaks emptied out trip on low level switch off the pump and rectify the problem.

Design Basis Accidents (DBA) and immediate actions needed.

8. Fire in power packs Fire hazard having Polyol ester hydraulic fluid due to overheating of the oil Autogeneous ignition temp is a. Immediately Include controller so that 0 approx. 450 C, so self-ignition switch OFF the - If temperature is 1 0C is not feasible for polyester unit. above the set value low based fluid. b. Use the fire level alarm (light and extinguisher kept annunciation). nearby in the - If temperature is 5 0C facility to douse above the set value, the the fire. pump should TRIP. Maximum operating a. temperature will be limited to 65 0C. b. Immediately Include controller so that switch OFF the - If temperature is 1 0C unit. above the set value low Use the fire level alarm (light and extinguisher annunciation). kept nearby in - If temperature is 5 0C the facility to above the set value, the douse the fire. pump should TRIP. Periodically check the water content in the oil by aqua sensor.

9.

Fire in power packs Fire hazard having mineral based hydraulic fluid due to overheating of the oil

10.

Ingress of water Damage to the The power pack is covered with Replace the oil. into tanks. oil quality suitably sized hoods. 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. Dynamic components like motor shaft and fans are covered with coarse wire mesh.

11.

12.

Trapping of birds etc between dynamic rotors.

Cold Air

Deck Plate Upper header room

In this Zone Normal Temperature = 285 0C Abnormal Temperature = 300 0C