Testing and qualification of Control & Safety Rod and its drive mechanism of Fast Breeder Reactor

Prototype Fast Breeder Reactor (PFBR) has two independent fast acting diverse shutdown systems. The absorber rod of the first system is called Control & Safety Rod (CSR). CSR and its Drive Mechanism (CSRDM) are used for reactor control and for safe shutdown of the reactor by scram action. In view of the safety role, the qualification of CSRDM is one of the important requirements.CSR & CSRDM were qualified in two stages by extensive testing. In the first stage, the critical subassemblies of the mechanism, such as scram release electromagnet, hydraulic dashpot & dynamic seals and CSR subassembly, were tested and qualified individually simulating the operating conditions of the reactor. Experiments were also carried out on sodium vapour deposition in the annular gaps between the stationary and mobile parts of the mechanism.In the second stage, full-scale CSRDM and CSR were subjected to all the integrated functional tests in air, hot argon and subsequently in sodium simulating the operating conditions of the reactor and finally subjected to endurance tests. Since the damage occurring in CSRDM & CSR is mainly due to fatigue cycles during scram actions, the number of test cycles was decided based on the guidelines given in ASME, Section III, Div. 1. The results show that the performance of CSRDM & CSR is satisfactory. Subsequent to the testing in sodium, the assemblies having contact with liquid sodium/sodium vapour were cleaned using CO2 process and the total cleaning process has been established, so that the mechanism can be reused in sodium. The various stages of qualification programmes have raised the confidence level on the performance of the system as a whole for the intended and reliable operation in the reactor.