Nuclear Engineering and Design 249 (2012) 419431

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Nuclear Engineering and Design
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Development of sodium leak detectors for PFBR
J.I. Sylvia

, P. Vijayamohana Rao, B. Babu, K. Madhusoodanan, K.K. Rajan

Indira Gandhi Centre for Atomic Research, Kalpakkam, Tamil Nadu, India
a r t i c l e i n f o
Article history:
Received 2 November 2011
Accepted 16 April 2012
a b s t r a c t
The 500 MWe Prototype Fast Breeder Reactor (PFBR) is under advanced stage of construction at
Kalpakkam near Chennai in India. The wide and high operating temperature, highly chemically active
nature of sodium and its reaction with air make the sodium instrumentation complex over the conven-
tional instrumentation. Over the years, traditional instruments such as wire type leak detectors, spark
plug type leak detectors were developed and used in different sodium systems. The redundant and diverse
leakdetection method calls for development of special instrumentation for sodium systems which include
sodium ionization (leak) detector for detecting minute sodium leak in addition to those systems based
on mutual inductance principle. For detection of sodium leak from reactor Main Vessel (MV), diverse
methods are used such as miniature, remotely locatable, Mutual Inductance type Leak Detector(MILD)
and specially modied spark plug type leak detector. The design of MILD is suitably modied for detecting
leak in double wall pipes and Diverse Safety Rod drive Mechanism (DSRDM). Steam/water leak in steam
generator produces hydrogen and leads to high pressure and temperature in the system. Rupture disc
is used as a safety device which punctures itself due to sudden pressure rise. To detect the discharge of
sodium and its reaction products at the downstream of the rupture disc due to bursting of the rupture
disc, cross wire type leak detector has been designed, developed and tested. The selection of the leak
detection system depends on the location where leak has to be detected. This paper describes the recent
developments carried out in leak detector systems to meet the challenges involved in developing robust
sensors for PFBR including miniaturization of leak detectors and the ability to locate or withdraw them
remotely through a long guide tube with complex prole.
2012 Elsevier B.V. All rights reserved.
1. Introduction
Sodium, because of its good heat transfer and nuclear prop-
erties, is used as coolant in fast reactors. Liquid sodium meets
almost all the requirements of a fast-reactor coolant with its high
thermal conductivity, reasonable specic heat, low neutron mod-
eration and absorption, and high boiling point at near atmospheric
pressure. Different types of leak detectors are used in PFBR for
detecting sodiumleak. As sodiumis good conductor of electricity,
sensors based on electrical conductivity are found very attractive
for sodiumleak detection system. Different types of leak detectors
are used for detecting sodium leak in single wall pipelines, dou-
ble wall pipelines, tanks and components in PFBR as discussed in
Vijayakumar et al. (2004).
The primary and secondary circuits of PFBR uses large inven-
tory of sodium as coolant. Leaks in sodium systems have the
potential of being exceptionally hazardous due to the reaction of
liquid sodium with oxygen and water vapor in the air. Sodium is

Corresponding author. Tel.: +91 044 27480500x22352; fax: +91 044 27480086.
E-mail address: sylvia@igcar.gov.in (J.I. Sylvia).
reactive with air and catches re depending on the temperature
of sodium. Temperature in the plant ranges from150

C to 550

C.
Leaked sodium also reacts with concrete leading to damage and
loss of strength. Steam/water leak into sodium in steam genera-
tor produces hydrogen and leads to high pressure and temperature
in the system. Even though these systems are designed to make
sodium leak most improbable, it is essential to detect the leaks at
anearly stage. Detectors are providedsuchthat leak is detectedand
contained before any possible damage could occur.
As per standards on performance requirements for sodiumleak
detectors stipulated by ASME Boiler and Pressure Vessel Code, Sec-
tion XI, Division 3; a leak rate of 100g/h of sodium in air lled
vaults must be detected in 20h and a leak in inert vault within
250h.
2. Detectors based on electrical conductivity of sodium
Wire type, spark plug type and Extended spark plug type leak
detectors (ESPLD) work on the principle of electrical conductiv-
ity of sodium. The detector wire or detector electrode makes a
short circuit during sodiumleak with the pipeline which is already
electrically earthed and results in grounding.
0029-5493/$ see front matter 2012 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.nucengdes.2012.04.010
420 J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431
Fig. 1. Wire type leak detector.
2.1. Wire type leak detection system
This is the simplest method of leak detection systememployed
in the experimental sodiumsystems, single walled pipelines, com-
ponents and tanks of secondary system of PFBR. It consists of a
metallic Nickel wire insulated with ceramic bead insulators. The
cross shapedceramic insulator is stung over the wire andthis string
is laidonthesurfaceof thepipeall alongits lengthas showninFig. 1.
The exposed portion of the wire is in close proximity to the pipe
surface. Sodium leaks from the pipe make contact with the wire
and bridges the small air gap between the wire and the pipe sur-
face results in earthing. The electronics systemdetects the earthing
and gives sodiumleak alarm.
In order to make the leak system more effective, the ceramic
insulatedwireis laidunderneaththehorizontal pipelines of smaller
diameter. For larger pipes of sizes 250mmandabove(not invertical
run) the wire type leak detectors are provided at 90

, 180

and
270

taking top as 0

. These three leak detectors along the length of

5mhelps in reducing the distance between the leak point and the
detectors. For vertical run of the pipe wire type leak detectors are
woundhelicallywiththe pitchof 0.5msothat the maximumlength
between a leak point and a detector is less than 0.5m. They are
grouped in series to minimize the number of electronic channels.
The series grouping ensures healthiness of system as any fault in
the circuit is also indicated as a leak alarm.
2.2. Spark plug type leak detection systems
Spark plug type leak detectors are used for detecting sodium
leak in enclosed space like bellowsealed valves and thermowell. It
is mounted in a small trough/pocket into which the leaked sodium
collects and causes electrical short between its insulated central
conductor and the body. It is typically used to detect sodium leak
from the double wall pipelines and vessels of fast reactor system
with the inter-space containing nitrogen gas. The leak detector is
mounted in a small trough at the bottommost level of the envelope
surrounding the capacities such as reactor vessel. Same electronics
is used for detection of leak.
2.2.1. Extended spark plug type leak detector (ESPLD)
For detecting leak from Main vessel, two diverse methods are
used. One of which is based on electrical conductivity and other is
based on Mutual Inductance principle. Two numbers of ESPLDs are
used which works on electrical conductivity principle. Sensing end
of the leak detector is located at bottom most point inside safety
vessel where sodiumis getting collected. The active sensor portion
is as showninFig. 2. It consists of acentrecapillarysyringeinsulated
from the outer Stainless steel (SS) tube by alumina. The ceramic
to metal brazing was done in vacuum. The overall dimension of
the active sensor portion is 4mm dia. and 49.5mm long which is
limited by the complex guide tube prole in the Safety Vessel (SV).
25m long MI cable was brought through a 4mm dia thin walled
extension tube to protect the cable fromdamage and also for ease
of insertion/withdrawal. SS sheath of MI cable was removed for
a length of 30mm and the SS conductor was passed through the
ceramic insulators to the detector sensor portion and welded to
the end using laser beamwelding. The active sensor portion (1mm
SS tube) is protected fromdamage by welding an SS protective cap
during insertion and withdrawal. Once the leaked sodiumbridges
the SS protective cap and the centre capillary syringe leak will be
detected. The sensor in assembled condition is shown in Fig. 3.
As per ASME code, a leak rate of 100g/h of sodium should be
detected in 250h in the inert atmosphere. After leaking from MV,
sodiumis collected at the bottomof the SV. 25kg of liquid sodium
takes a level of 20mm from the bottom of the MV. As the active
portion of the sensor is 4mm dia, 4mm height of leaked sodium
can be detected using this sensor which is much earlier than 250h.
Fig. 2. Sensor portion of ESPLD.
J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431 421
Fig. 3. ESPLD in assembled condition.
2.3. Electronics for leak detectors
The wire type and spark plug type leak detectors use the similar
electronics for processing the leak signal. Wire type leak detectors
are directly connected to Field Terminal Boxes (FTB) where two
resistors, one is 100 ohm and other is 470 ohms are connected
as shown in Fig. 4. The control card located in the control bin is
the heart of LD system where all the signals are processed, stored
and manipulated. The Control Bin consists of RT20 CPU Card, VME
Ethernet Controller Card for communicating the data through Eth-
ernet, memory card to store the database and conguration, I/O
interface board to convert VME bus to I/O bus where leak detector
cards (analog input) and Relay output cards are located.
Each Leak detector card consists of 32 analogue input chan-
nels in which four channels are used for diagnostics purpose. This
card, after receiving eld signals, converts analog signals to dig-
ital signals. The set values are shown in Table 1. Digital signals
Table 1
Set values of ESPLD.
Condition Voltage (V) Output value in
digital form
Normal 4.2 0100
Leak 1.02 0010
Wire open 11.96 1000
Wire short .020 0001
Undened Other than above values 0000
which represent eld leak conditions are compared with set values
stored in Erasable Programmable Logic Device (EPLD). This sys-
tem consists of one Relay output module and depending on the
group conguration, if any one of the leak detector shows leak or
any unhealthy condition, the relay will be energized to alert the
operator through AlarmAnnunciator window. This electronics was
Fig. 4. Schematic of electronics.
422 J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431
Table 2
Sensor specication.
S. no. Leak detector Sensor specication
Sensor Pocket Winding details/features
Material Size Material Size
1. Main vessel leak detector
(miniature & remotely
locatable)
SS410 (magnetic material
improves the sensitivity)
Dia. 5.0mm
Active length 20mm
Total length 25mm
SS316L OD 7.5mm
ID 5.5mm
0.5mmdia. M.I. cable in two layers
in bilar fashion.
Primary: 10 turn
Secondary: 10 turn
Remotely locatable
22mlong free leads inside the
extention tube of 4mmOD and
3.6mmID
2. DSRDMleak detector
(miniature)
SS410
(magnetic material
improves the sensitivity)
Dia. 5.0mm
Active length 20mm
Total length 22mm
SS316L OD 7.5mm
ID 5.5mm
0.5mmdia. M.I. cable in two layers
in bilar fashion.
Primary: 10 turn
Secondary: 10 turn
15mlong free lead installed inside
the EM
3. DWP leak detector SS316L Dia. 32mm
Active length 22mm
SS316L OD 42.16mm
ID 36.62mm
1mmdia. M.I. cable
Primary: 1 layer
22 turns
Secondary: 2 layer
22 turns/layer
developed in-house and tested in the sodiumrigs available in Fast
Reactor Technology group (FRTG).
It was experimentally proved in FRTG that the highest detec-
tion time observed was about 6h for a sodiumleak rate of 222g/h
as discussed in Vijayakumar et al. (2011). A relationship between
leak rate and detection time was established fromthe experimen-
tal results and found that sodiumleak rate of 100g/h is likely to be
detected in 11h which far better than the stipulated value of 20h
in ASME code.
3. Leak detector based on mutual inductance (MI) principle
Mutual InductancetypeLeakDetector (MILD) works ontheprin-
ciple of decrease in mutual inductance between two coils when
sodium surrounds it. The primary coil is excited with AC constant
current of 100mA and an emf will be induced in the secondary coil
of the sensor. The secondary coil emf will be reduced when sodium
surrounds the pocket. The reduction in secondary emf indicates
sodiumleak.
MI type sensors have several advantages such as (i) non contact
operation with sodium as it is located inside a thimble; (ii) facili-
tates maintenance, as the sensor canbe removedfromits pocket for
inspectionand/or replacement; (iii) the sensor needs tobe installed
into the thimble only prior to sodium-lling of the vessel and not
during the integrity (pressure/vacuum) testing, normally carried
out on the vessel after fabrication at the manufacturers premises;
and (iv) immune to sodiumwetting. All the above factors weighed
in favour of developing a leak detector based on the MI principle.
This leak detector forms a redundant and diverse method of leak
detection. As remote handling and miniaturization is possible with
this type of detectors it is used for detecting sodium leak in main
vessel, double walled pipes, electromagnet of diverse safety rod
drive mechanismetc. bysuitablymodifyingthe designof the sensor
as indicated in Table 2.
3.1. MI type leak detector (MILD) for main vessel (MV) of PFBR
This is one of the diverse methods for detection of leak, from
the Main Vessel (MV) of PFBR for the safe operation of reactor. In
case of sodiumleak fromthe Main Vessel (MV), the leaked sodium
collects inthe Safety Vessel (SV). One of the detectors developedfor
this purpose is miniature, remotely locatable Mutual Inductance
type Leak Detector. MILD will be positioned at the bottom most
elevation of the inner surface of SV through a guide tube fromthe
top of the reactor vault. Since unhindered space for the in-vessel
inspection vehicle has to be provided, the size of the guide tube
is small and this puts a limitation on the size of the probe bobbin.
The challenges involved in developing this sensor for PFBRincludes
miniaturization of leak detector and the ability to locate/withdraw
themremotely through a long complex guide tube prole.
3.1.1. Design of MILD
The guide tube with three different segmented proles suitable
to the reactor is shown in Fig. 5. The sharp bending radius of the
guide tube is of the order of 350mm. For easy insertion and with-
drawal of the sensor a cylindrical bobbin of 2.8mm diameter and
20mmlong was selected.
The insertion and withdrawal of the probe inside the guide tube
assembled with three different segmented proles suitable to the
reactor has been tested and conrmed. However, the miniature
probe has a limitation on sensitivity of the probe. In order to eval-
uate the sensitivity, sensor with different bobbin material namely
SS316L andSS410 (magnetic) were fabricated. The probe coils were
wound on a cylindrical bobbin of 2.8mm diameter and 20mm
long made up of either SS316 or SS410 using 0.5mm diameter SS
sheathed, MgO insulated, copper conductor (MI) cableover two lay-
ers inbilar fashion. Inorder toevaluatethesensitivityof theprobe,
two probes are fabricated with short free leads of identical dimen-
sions but of different bobbin material namely SS316 & SS410. The
preliminary experiment was carried out in brick sodiumwith two
probes. The sensitivity obtained was around 7% for the probe made
of SS316 material whereas the sensitivity of sensor made of SS410
material was around 30% which is sufcient to provide threshold
setting in the electronics. Therefore SS410 is selected as material
for MILD.
This was again validated by simulation using Finite Element
Modeling and the ux pattern at 5.25kHz for SS410 bobbin with
and without sodium is shown in Fig. 6. The sensitivity obtained is
50% for SS410 bobbin but for SS316L sensitivity is only 9%. Hence
miniature MI probes are designed with SS410 bobbin. The SS410
gives more sensitivity compared with SS316. This is because SS410
is having better permeability compared with SS316. Hence more
ux is generated in SS410 which results in increase in sensitivity.
J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431 423
Fig. 5. Location of MILD probe in Safety Vessel (SV) of PFBR.
At one end of bobbin, a collar is provided for attaching to a
thin-walled tube of 4mm OD and 3.6mm ID. MI cable leads from
the probe are brought through the capillary tube. Fig. 7 shows the
photograph of the sensor.
3.1.2. Experimental procedure
The detailedexperiments were carriedout inpure sodiumsimu-
lating the various reactor conditions. Fig. 8 shows the experimental
set up and Detail-A shows the MI type leak detector probe. This
experiment was carried out to nd optimum frequency at which
the sensitivity is maximum. The guide tube is closed at the bottom
and welded with one SS block which simulates the PFBR safety
vessel thickness. The guide tube carrying the MILD is held by gland
and nut arrangement mounted on the top of the ange, which also
provides the leak tightness for the argon cover gas. L1, L2, L3 are
sodiumlevel indicators. Level of sodiumincreases slowly up to the
operating level (L2). The loopis initially lledwithsodiumat 150

C
and the reading is taken fromthe probe (secondary output is mea-
sured in mV). Then the sodium level is quickly drained below the
guide tube end and the reading is again taken. The difference in
readings is the reduction in secondary output of MI probe. This
operationis for one temperature and frequency. Similarly the oper-
ations have to be repeated for temperature upto 550

C in steps
of 50

C and the frequency was varied from 2 to 8kHz in steps of

0.25kHz.
3.1.3. Experimental results
The experiment was conducted up to 8kHz for the temperature
from 150

C to 550

C. It was observed from Fig. 9 that at 550

C
the sensitivity is maximum of 49.5% at a frequency of 5.25kHz.
Sodiumtests of the probe have revealed a sensitivity ranging from
40 to 50% over the sodium temperature range of 150550

C and
the electronics is provided with alarmthreshold corresponding to
the probe output at 550

C (probe fully covered with sodium).

Skin depth corresponding to the frequency of 5.25kHz is
3.8mm. The thickness of sodiumequal to twice the skin depth cor-
responding to the operating frequency is virtually equivalent to an
innite sea of sodium as discussed in Mcgonigal et al. (1971). The
height of the guide tube (8mm) andthe height of the leakedsodium
above the guide tube (8mm) contributes to a total height of 16mm
whichcanbe detectedusingthis sensor. Hence the detectiontime is
earlier than the 20mmheight thereby meeting the recommended
ASME standard.
3.2. MI type leak detector for DSRDM
In PFBR there are two shutdown systems, one of the systems is
DiverseSafetyRodDriveMechanism(DSRDM). Inbottomportionof
the DSRDMthere is a dissimilar weldjoint, betweenElectro Magnet
(EM) made of iron and stainless steel. The failure of weld can result
in entry of sodium inside the electro magnet, which can increase
the response time of electromagnet, thereby increasing Shutdown
Control Rod Accelerated Drive Mechanism (SCRAM) time. So it is
necessary to detect the entry of sodium inside the EM. Consider-
ing the space, Miniature MILD was required for detecting the leak.
As remote handling is not required as in MILD for MV, extension
tube over the free leads are not provided. But 15m long MI free
leads are required to mount the sensor within the electromagnet
housing.
Miniature MI type sodium leak detector to detect the sodium
leak in electromagnet housing in DSRDM is indigenously devel-
oped and fabricated. The sensor construction is same as that of
MILD for MV except the mounting arrangements. Special jig was
fabricated for winding the M.I. cable on the bobbin without twist-
ing and damaging the MI cable sheath. Jig was fabricated in such
a way that during winding, the free lead (15m) also rotate along
withthe bobbinandthe MI cable sheathshouldnot touchanymetal
part, otherwise the sheath will get damaged (sheath thickness is 50
microns). Special jig facilitates to get the repeatability of winding
without damaging the free leads of the M.I. cable.
The detailed assembly drawing is shown in Fig. 10. After wind-
ing the bobbin the free leads are inserted through bobbin support
tube and sensor ange which is having 4 holes of 0.8mmdiameter
on 2mm PCD. The bobbin was welded with the support tube by
Laser beamwelding. The primary and secondary leads are twisted
to cancel the noise. Then the sensor assembly will be inserted into
the pocket and tack welded between pocket and sensor ange to
avoid rotation. Insert the cap over the sensor ange and x with 3
screws. The screws and the cap are tack welded to avoid unscrew-
ing during vibrations inthe DSRDM. The coldends are preparedand
sealed after improving the insulation value. The insulation value is
measured at every stages of assembly.
424 J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431
Fig. 6. Flux pattern in sodium& air at 200

C for SS410 bobbin.

Fig. 7. MILD Sensor for Main Vessel (MV). Fig. 9. Frequency vs sensitivity of the probe at 550

C.
Fig. 8. Experimental setup & probe.
J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431 425
Fig. 10. Assembly drawing of DSRDMleak detector.
The above assembly is qualied in three stages. Before fabri-
cation, chemical composition of raw materials and dimensional
checks are carried out, welding procedures are qualied and
approved. During fabricationdimensional checkof fabricatedparts,
surface treatments and welding qualication are carried out. After
fabrication, visual inspection and Liquid penetrant inspection of
weld joints, dimensional inspection of nal assembly, and perfor-
mance checking of sensor were carried out. Three numbers of leak
detectors are successfully fabricated with qualication procedures
as showninFig. 11. Thesensor was not onlyindigenouslydeveloped
and fabricated but also l it was nally installed inside the DSRDM
for deployment in PFBR.
3.3. MI type leak detector for double walled pipeline
In the double wall piping the leaking sodium spreads and
reaches the pocket since the piping is with little inclination. Since
the guard pipe is provided with pockets for every compartment,
the maximum distance sodium is to travel is the length of the
compartment before reaching the pocket. MI type leak detectors
are provided where the leaked sodium gets collected in a pocket
designed for the purpose. The main function of the MI type leak
detector is to detect the leak of sodium from the main pipe line
into the annulus space lled with Nitrogen envelope in the pipe.
The primary and secondary coils of the detector are wound on
a cylindrical bobbin of length 22mmand diameter of 32mmusing
SS sheathed 1mm dia. MI cable, with copper conductor and mag-
nesium oxide insulation. The sensitive portion of the detector is
of hollowcylindrical cross section made of SS316. This detector as
shown in Fig. 12 is a probe type, which can be kept inserted into a
thimble fromthe pocket bottom.
The electronics as shown in Fig. 13 is made simple as tempera-
ture compensation over an operating range from150

C to 550

C is
not required as the length of the probe is much smaller. The sodium
leak of the order of 100gm/h can be detected in a few hours with
this detector.
4. Sodiumionization detector (SID)
SIDis usedas global leakdetectionsysteminPFBRsecondarycir-
cuit area. Details of developmental works related to SID is given in
Elumalai et al. (1984). Sodiumcooled fast reactors have numerous
requirements for instrumentation capable of detecting the leakage
of sodium from component or piping faults into the surrounding
gaseous atmosphere. Detection of these leaks by a sensitive early
warning system is highly desirable to limit piping deterioration,
component destruction, re damage or corrosive effects from the
sodium. The amount of oxygenandwater impurities guarantee that
any leaking sodiumwill be partially reacted to oxide or hydroxides
and that sodium aerosol will be generated in addition to sodium
vapour. Therefore the leak detector should be capable of respond-
ing to sodium compounds as well as to elemental sodium. One of
the major advantages of SIDis its operating simplicity. Detection of
leak is obtained under ambient atmospheric conditions.
Fig. 11. Photograph of DSRDMleak detector.
426 J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431
Fig. 12. Leak detector for double walled pipeline.
Fig. 13. Electronics for MILD.
4.1. Theory of operation
The SID works on the principle of preferential ionization of
aerosols of sodium and its compounds (oxides and hydroxides) in
carrier gases such as argon, nitrogen and air. The schematic of SID
is as shown in Fig. 14. The detector carries a heated lament on
which the sodium aerosols in the carrier gas fall and get ionized.
These ions are then collected on an adjacent electrode which is
maintained at a negative potential relative to the lament, leading
to readily detectable current. In the absence of an easily ionisable
substance like sodium near the lament, the SID produces only
a small background current, arising primarily from alkali metal
impurities inthe lament material as discussedinRef. Bauerle et al.
(1976).
The most critical and also the most complex aspect of SID oper-
ation involve the detailed processes by which the sodiumparticles
are converted to free sodiumions. This can be thought of as occur-
ring in the following steps:
[1] The collision of sodiumparticles with the hot lament surface
and their subsequent Melting. The rapid surface diffusion of the
melted sodium over the lament to form a layer of adsorbed
sodiumatoms
[2] The transfer of valence electrons from some of the adsorbed
sodium atoms to the lament, converting them to adsorbed
sodiumions
[3] The desorptionof these sodiumions fromthe surface tobecome
free ions; also the desorption of neutral sodiumatoms.
The rst andsecondsteps produce a monolayer of sodiumatoms
in the lament surface. In the third and fourth steps, these atoms
are theneither thermallyionizedtobecome free sodiumions, or are
evaporated as neutral sodiumatoms. Only the free ions contribute
to the SID response. Temperature of the lament contributes to
the ionization efciency. The work function of the lament metal
Fig. 14. Schematic of SID.
J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431 427
Fig. 15. Photograph of SID.
surface should be greater or comparable to the ionizationefciency
of the sodiumatoms.
4.2. Sensor design
The optimumsensor designusedinPFBRis toachieve maximum
sensitivity with minimumbackground sodiumion current. The SID
as shown in Fig. 15 scores over other detectors in the sense that it
can detect a quantity of as lowas one nanogramof sodiumpresent
in a cubic centimeter of carrier gas.
Filament used : platinumlament of 50mmlong, 25
micron thick and 1mmwidth
Collector plate material : perforated cylinder made of Stainless
Steel (12mmOD 10mmID, 35mm
long) 1.8mmdia perforated hole
Filament to collector spacing : 5mm
Collector voltage : 200V
Filament temperature : 9501000

C
Carrier gas ow : 1l/min
Maximumbackground current : 0.08nA
Sensitivity : varies from0.1 to 1 nanoampere per
nanogramof sodiumper cubic
centimeter of gas
Minimumdetectable sodium
concentration
: better than 0.3 nanogramof sodium
per cubic centimetre of gas
4.3. Electronics for the SID
The electronics unit for the SID consists of
[1] an adjustable current source for heating the lament
[2] a mediumvoltage power supply to provide the electric eld for
collecting the sodiumions
[3] a wide range electrometer (10
12
to 10
6
ampere) for measur-
ing sodiumion current
[4] Thermal cycling circuitry to maintain the sensitivity of the la-
ment
The electronics chassis was qualied for immunity level to EMI
noise. To maintain the sensitivity of the lament, thermal cycling
circuit has also been incorporated in the SID electronics.
4.4. Sampling system
The SID system consists of SID sensor and the sampling sys-
tem with uted pipelines as shown in Fig. 16. Hence a single
detector can cater to many locations through sampling of the
carrier gas. The inherent response time of the SID to a single
Fig. 16. SID as area monitoring.
428 J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431
Fig. 17. Sensitivity of SID with long sampling lines.
aerosol particle should be comparable to the ion drift time between
the lament and the collector, typically less than a millisecond.
In a practical detection system employing aerosol sampling line,
however the time response is controlled by the much slower
processes of gas ow to the sensor chamber and mixing in the
chamber as discussed in Swaminathan and Elumalai (1984). The
sensitivity of SID system using long sampling lines, has been
demonstrated experimentally as shown in Fig. 17. The SID work-
ing on sampling method has been used in experimental area and
secondary circuit area of PFBR. The installation of SID is shown
in Fig. 18. The response of SID to burning 5g of sodium in the
experimental area is shown in Fig. 19. Every time the test is car-
ried out, the alarm threshold set at 1nA is exceeded by the SID
response, conrming the sensitivity and effectiveness of the SID
system.
During the operation of SID system it was observed that
there was an increase in background value crossing the thresh-
old limit. After cleaning the sensor, sampling lines and blower
with water the background started coming down. As part of the
surveillance periodic cleaning of sensor and sampling system is
recommended.
Fig. 18. Installation of SID.
Fig. 19. Sodiumre test.
5. Cross wire type leak detector
The main function of the Cross Wire type Leak Detector (CWLD)
is to detect the discharge of sodiumand its reaction products at the
downstreamof the rupture disc due to bursting of the rupture disc.
This provides the informationonsodiumwater reactioncauseddue
to water/steamleak inthe SteamGenerator (SG) and the developed
hydrogen gas pressure bursts the rupture disc. Literature survey
shows that this type of sensor is deployed in Monju reactor works
on bursting technique as in Takahashi et al. (1983). These S. S. foils
are located at the downstream of the rupture disc in the vertical
pipe as shown in Fig. 20. When sodium/sodium reaction products
ow past the S. S. foils break themand the loss of electrical conti-
nuity of the foils is detected and alarm signal is given. The CWLD
was designed with following specication and the functionality
was checked in experimental water test setup.
5.1. Sizing of SS foil
Based on calculations the width and thickness of the SS foil
were xed to 15mm& 50 microns respectively. Experiments were
carried out to optimize the design of the foil. Based on these exper-
iments, the depth and number of V-notches were determined. The
effect of thermal stress in the foil due to the temperature difference
between pipe and foil was studied by numerical simulation. It was
foundthat, inorder toavoidyieldingof the foil due tothermal stress
J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431 429
Fig. 20. Location of CWLD.
Fig. 21. Dimensions of CWLD.
430 J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431
the foil temperature (whichwill be nearly equal to the temperature
of argongas surrounding the foil) shouldbe limitedto 15

Conly. As
this is difcult toachieve, slight extra length(23mm) of foil will be
provided. This will prevent any thermal stress getting developed in
the foil and thus prevent the breakage of the foil due to differential
temperature.
5.2. Specication of SS Foil
Material : SS304
Length of foil : 338mm
Width of foil : 15mm
Thickness : 0.05mm
Number of V notches : 7 NOS.
Depth of V notches : 6mm
V notches are kept at a distance of 40mmas shown in Fig. 21.
5.3. Experimental setup
In order to validate the design, experiment was carried out. The
experimental test set up for testing the S.S. foils along with the
detector electronics is shown in Fig. 22. The tests were carried out
in a water loop in Engineering Hall-II by suddenly allowing water
at some pressure to owover the foils. To measure the pressure in
the pipeline at the time of opening of the valve, a dynamic pressure
Fig. 22. Experimental test setup of CWLD.
transmitter is installed. Inthis set-up, all the 3 foils are installed ina
pipe at uniformgap of 10mmand 60 degree apart without making
contact with each other. To electrically insulate the foils from the
metallic pipeline, a spark plug is installed in pipe with the help of
Fig. 23. SS foils before and after breaking.
Fig. 24. Graph showing specimen vs. breaking pressure.
J.I. Sylvia et al. / Nuclear Engineering and Design 249 (2012) 419431 431
sleeves. A triangular piece welded to the central electrode of the
spark plug is used to hold the foil rmly. Electronic connections
are given to the terminals of the spark plug. Fig. 23 shows the SS
foils before and after breaking. The breaking of these SS foils are
detected electronically using two out of three logic.
It was found from the hydraulic experiments repeated over
42 trials that all the SS foils break at an average pressure of
0.150.25MPa which corresponds to a velocity of 2m/s as shown
in Fig. 24. The expected minimum pressure and velocity in PFBR
is 0.37MPa and 2m/s respectively. It is found that the results are
conservativeandthesnapping/breakingtechniqueof theCWLDhas
been demonstrated successfully.
6. Conclusion
As the commercially available conventional sensors cannot be
used for sodium leak detection, the sensors and instrumentation
are specially designed using the state-of-art technology to suit this
hostile environment. Wire type and spark plug type leak detectors
working on earthing principle is used on pipelines and different
capacities such as bellow sealed valves and leak collection trays
respectively with improved electronics in PFBRs. Miniature Mutual
Inductance type leak detectors with remote insertion/withdrawal
facility was developed for MV leak detector of PFBR. The selec-
tion of SS410 bobbin for improving the sensitivity of this sensor
was experimentally proved. ESPLDs are used as diverse method
for detecting leak in Main vessel. The sensor was assembled and
tested for its functionality and easy insertion and withdrawal. The
DSRDM leak detectors with longer length of free leads (15m) has
been fabricated, qualied and installed in the DSRDMelectromag-
net successfully. For double walled pipe line where pockets are
provided at the lowermost elevation, MI type leak detectors of
larger size was designed and used in multiple numbers. This type
of leak detector is non-intrusive and easily replaceable and hence
it gains importance for usage in the reactor systems. Sodium Ion-
isation leak detectors with improved electronics have been used
in secondary system as area monitoring in PFBR. As this sys-
tem has been employed in sodium facilities, lot of expertise has
been gained in maintaining the same. The Cross wire type leak
detectors are designed and experimentally tested at required pres-
sure of PFBR. The different types of sodium leak detectors were
designed, developed and tested in various sodiumfacilities which
gave us enough condence for deploying themin PFBR and future
FBRS.
Acknowledgements
Authors acknowledge the encouragement, guidance and sup-
port received from K. Swaminathan, Former Head, Component &
Instrumentation Development Division, FRTG, Shri S.C. Chethal,
Director, Indira Gandhi Centre for Atomic Research (IGCAR) and
all other agencies who supported during the course of this
work.
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