Development of polymeric applications for sodium cooled Fast Breeder Reactors: Chronicles of inception, progress and achievements

The collaborative programme on development of important polymeric applications of Indian FBRs is chronicled from the days of motivation to its present state. Failure of inflatable seals of FBTR RPs (1985) and adoption of all-elastomer sealing concept for PFBR RPs (early 1990s), coupled with the unique characteristics of elastomeric materials, led to inception of the programme at IGCAR (1998) which involved DMSRDE as the first partner (1999). The planned initiative, which eventually involved more than 15 other Indian agencies, resulted in complete development of FKM backup seals for PFBR RPs which has been installed in reactor recently. Coated FKM and EPDM inflatable seals for PFBR and FBTR RPs have been developed, produced and evaluated up to ∼2 m diameter. Development methodologies for other critical polymeric applications of PFBR, FBTR and FCF have been formulated. Accomplishments and novelties of the development include EPDM and FKM compounds and designs for inflatable and backup seals, a common FEA procedure for elastomeric ring seals, PECVD based Teflon-like coating technology up to 7 m seal diameter, seal production process by cold feed extrusion and continuous cure, a robust quality control framework and the new facilities developed to support the programme. Future developments are focused on delivery of validated inflatable seals, life assessment and development of new elastomeric compounds which include silicone rubber and perfluoroelastomer, PECVD based coating on stainless steel and development of adhesionless joining of FKM. The achievements and future research will standardize the design and development of the elastomeric seals of Indian FBRs, PHWRs and AHWR based on a few well-characterized compounds, a common FEA method and PECVD based coating technology which can result in a universal design code.