Leak testing of cryogenic components — problems and solutions

Abstract

A prototype of Cold Neutron Source (CNS) for Dhruva Reactor is being manufactured at Centre for Design and Manufacture (CDM), BARC, Mumbai for validating the mechanical and thermal engineering design aspects, besides checking the integrity of all joints and components at low temperature, 77K. Task of a Cold Neutron Source is to generate cold neutrons by cooling down the thermal neutrons, which are originally produced in a nuclear research reactor. The complete Cold Neutron Source system comprises a complex arrangement of moderator pot, transfer line (piping), pumps, refrigerators, storage tanks, a heat exchanger and associated controls and instrumentation. The heart of the system is moderator pot in which water (moderator) is cooled down by Liquid Nitrogen (LN2) being circulated through an annular cavity machined on the walls of the pot. Transfer lines for LN2 basically consist of two concentric Stainless Steel flexible pipes, which are joined to the inlet and outlet Aluminium tubes of the moderator pot through transition joints. Leak in any component may result in loss of liquid Nitrogen, degradation of vacuum, which in turn may affect the heat removal efficiency of the source. Hence, leak testing was considered a very important quality control tool and all joints and components were subjected to helium leak test using mass spectrometer leak detector (MSLD) at cryogenic temperature. During one of the earlier experiments, flow of LN2 through inner flexible pipe of the transfer line resulted in rise of pressure in the vacuum annulus and sweating on the outer flexible pipe. After investigations it was found that large thermal stress compounded with mechanical stress resulted in cracks in the inner pipe. Accordingly design was modified to get leak proof transfer line assembly. Further, during leak testing of thin wall moderator pot, gross leak was observed on the outer jacket welded joint. Leak was so large that even a small amount of Helium gas in the vicinity of the moderator pot was driving the MSLD out of range. Since it was very difficult to locate the leak by Tracer Probe Method, some other technique was ventured to solve the problem of leak location. Finally, it was possible to locate the leak by observing the change in Helium background reading of MSLD during masking/unmasking of the welded joints. This paper, in general describes the design and leak testing aspects of cryogenic components of Cold Neutron Source and in particular, the problems and solutions for leak testing of transfer lines and moderator pot.