Evolution of criteria for repair work on helium lines of Cirus reactor

The research reactor CIRUS uses light water as coolant and heavy water as moderator and is rated for a thermal power of 40 MW. This reactor has been in operation since 1960 and has undergone refurbishment work recently. In the CIRUS reactor, helium gas is utilised as the cover gas. The helium lines are connected with the tube sheet at the top of the calandria. There are eight such helium lines at the top of the calandria, out of which four are connected to one ring header, three to another ring header and the remaining one is single line. These helium gas lines have tongue and groove joints for connecting the stainless steel piping with the aluminium piping. With the prolonged operation of the plant, leakage was observed at these joints. As a part of reactor refurbishing work, these joints were required to be repaired. Since these joints are situated in an inaccessible area, the entire job was to be carried out remotely and therefore, a fail-safe scheme was to be evolved based on computer simulation and analytical work. The entire analysis work had many challenging aspects hence, utmost care was exercised while analytically formulating the scheme for the tightening of these flange joints by postulating the various possible scenarios and by maintaining the stress level within the limits, particularly at the fillet welds between the aluminium pipe and calandria tube sheet. Another challenging aspect of this job was to take care of various uncertainties regarding the prevailing status of the joints. This report highlights the methodology adopted to arrive at the optimum amount of tightening and sequence of tightening. This report also highlights how analytical simulation of actual site scenario was carried out based on site feedbacks at various stages of tightening operations and how strategies were formulated to overcome various challenges and also to take care of various uncertainties in the input information being reported by the site. The tightening work undertaken at the site, based on the analysis of these helium piping systems alongwith the ring header, using the specialized piping software CAESAR-II, resulted in a substantial helium leakage reduction by around 80-85% at the site. The remote repair work carried out with the evolved procedure on these helium lines resulted in significant achievement in terms of savings in man-rem consumption, overall cost and time. (author)