Sodium fire fighting in Fast Breeder Test Reactor, Kalpakkam - challenges and

strategies

Ashish Jain1 , E Ramesh2, M. Thangamani3 and K G Subramanian4

Reactor Facility Group, Indira Gandhi Centre For Atomic Research, Kalpakkam, TN, India.

1. Industrial Safety Officer (Scientific Officer (E))

2. Head – Quality & Inspection Section
3. Head – Operation Section and Dy. OS.
4. Head and Supt. - Quality Assurance and Industrial Safety Division.

email:ashishjain@igcar.gov.in

Abstract
Hot Sodium is being handled in an inert environment Introduction
always, even when it is inside the reactor. When molten
Sodium fire is one of the potential fire hazards in FBTR
sodium leaks from any plant system, it reacts with the
(Fig2).
atmosphere and catches Fire immediately.
The total quantity of Sodium available in the plant is 148
Managing Sodium Fire involves a few unique but simple
Tons. Hot Sodium may leak from the defective valves in
techniques. The Sodium fire transfers a high temperature
the primary loops inside RCB, pipelines, or components.
at the point of contact. This property poses the possibility
Sodium may also leak in steam generator modules in SG
of significant structural damage when Sodium leaks on
into the casing and react with atmospheric moisture.
the metallic structure or concrete structure. The release of
Sodium deposits need to be cleaned for maintenance
toxic alkali fumes and aerosol causes burns in the skin
purposes. Also, leaked Sodium is to be cleaned.
and irritation to humans. In a closed plant, another cause
Sodium Fighting and sodium spill cleaning work require a
of concern is to contain and prevent the flow of toxic
trained and equipped team in the plant. There is a
sodium fumes from penetrating the critical operating area.
specially trained team for handling these emergencies.
In the most realistic scenario of any sodium-cooled
The plant ensures all necessary preparedness for
reactor, there is a high probability that leaked Sodium is
preventing sodium fire. The plant keeps ready the
radioactive initially for some time. In situations like this,
essential personal protective equipment and fire fighting
all the Hazmat operations have to be carried out remotely.
resources at strategic locations for handling possible
Reactor design and passive systems play a critical role in
sodium leaks and fires. All the non-routine maintenance
managing such kinds of situations.
and emergency repairs are carried out after hazard
This paper outline the Fire fighting and salvage crew
assessment and with safety procedures.
experiences in managing sodium leaks, sodium fire
fighting, and their disposal at Fast Breeder Test Reactor
(FBTR). Fig.1

Fig2: Sodium leak from secondary loop control valve

Fig1: Fast Breeder Test Reactor (FBTR)
 Fig2: Sodium Fire
Fig 4:Entrance for Purification cabin. Radiactive Sodium
About FBTR leak in Purification cabin – RCB – Sodium leak and
The Fast Breeder Test Reactor is a 40 MW t, loop type, cleaning
Sodium cooled fast reactor. The figure shows the
schematic flow sheet (fig3) of the heat transport circuits.
The heat generated in the reactor is removed by two
primary sodium loops and transferred to the
corresponding secondary sodium loops. Each secondary
sodium loop is provided with two once-through steam
generator modules. Steam from the four modules is fed to
a common steam-water circuit comprising a turbine
generator and a 100% dump condenser.

Fig 4 A: Purification cabin inner view.

2. Steam Generation Building

Fig3: Flow sheet of FBTR

FBTR’s most vulnerable Sodium fire locations

Sodium fires are possible mostly in the following two
buildings of FBTR -
1. Reactor Containment Building (RCB) (Fig 4 and Fig
4 A) – Sodium Control valves in purification cabin
cells.
2. Steam Generator Building (SGB) (Fig 5) –
Secondary Pipelines, Valves, Inside SG module –
Steam tube and joints.
1. Reactor Containment Building (RCB)
Fig 5. Steam generation module inside view – with leak
collection trays
The leak of Radioactive Sodium
If sodium leaks from the primary circuit, leaked Sodium
may be highly active. Activity may be higher at higher
power.
Since RCB is an enclosed building and components are
separated into individual cells (Fig 1 and Fig 2). Any
sodium leak has to be confirmed remotely using highly
sensitive sodium leak and aerosol detectors in this area.
There are sodium leak detection gadgets installed at
strategic locations. Smoke detectors are situated in
various cells and exhausts ducts.
After confirmation of sodium Leak, The reactor is to be
shut down manually by ordering Lowering of Control
Rod (LOR). The reactor building has to be isolated such
that radioactive gases do not escape from the building.
On the other side, the first priority of the operator is to
maintain the minimum necessary sodium inventory all the
time around the nuclear fuel to remove the decay heat of
the nuclear fuel in this reactor. Reserve sodium from
sodium flooding tanks floods the necessary Sodium in
the reactor. (Fig 6)
Sodium fire is largely controlled remotely by flooding the
affected component/cell area with inert gases. (Fig 7)
In case fire fighting is required, the intervening group
shall carry out the same after taking necessary actions
against Fire and radiation till the fire service personnel
take control of the situation.
Simultaneously precautionary measures should be taken
to minimize sodium leak and contain sodium leak/Fire.
Any intervention will be undertaken only after draining
Sodium and decay of radioactivity.
Fig 6 Sodium storage tank (flooding tank)
Fig 7: Inerting system
Passive and Active methods for handling
sodium leak and fire emergencies
Sodium leak is first leaked in spray form and a flowing
state. After the leak, it falls on the floor and gets collected
on the floor. The leak continues from the system until the
total Sodium of the pipe loop is dumped into a safe
storage tank.
When Sodium flows in large quantities, most of the
available Fire extinguishing media do not help practically
give complete blanketing to stop the sodium oxygen
reaction.
We keep Fire extinguishing media (Class-D power)
always ready for blanketing the small sodium leaks. We
apply the loose powder using a scoop over the hot
Sodium (pool fire). This is effective for small Fires.
Some time fire involves cable fire and sodium fire. In that
case, we use Dry Chemical Power instead of Class D
powder.
The class-D powder contains chloride content. All the
components in the Sodium system are made up of
Stainless steel. This Class D powder chloride attacks the
stainless steel components and may become the reason for
heavy corrosion and sudden failures in high temperatures.
Hence it is mainly preferred to use the Class- D powder
with caution.
Two other most effective methods are adopted for
handling sodium leaks; one is flooding the system with
inert gases, and the second is collecting leaked Sodium in
special leak collection trays (containers). Sodium leak
collection vessels have special provisions for
nitrogen/argon covering.
In RCB, double enveloped pipes and enclosed cells are
used to contain radioactive Sodium. The annular space
between pipes and enclosure is filled with inert nitrogen.
The design of the tray is such that it has a narrow closed
neck, with special perforations such that the leaked
Sodium can be collected in the trough with a minimum
area for ingress of air into the tray (fig 8).
If sodium leak occurs from SG shell, there is a provision
to inject argon in SG casing. (Fig 9 and 9A)).

Fig 8 – leak collection trays below secondary sodium
lines
Fig 9. Leak Collection in SG.(Closed)
Fig 9A. Leak Collection in SG.(Open)
Fig 8 A leak collectray line diagram
Personal protective equipment and Respirators
for Sodium Fire Fighting and Burn Effect on
the human body on Sodium exposure
1. PPE needed during the inspection -
Once sodium leak detectors detect a leak, the specialist
operations crew must physically confirm the leak and
assess quantity by opening a window while the Steam
generator is hot. For inspection purposes, the team needs
a proximity suite. Self-contained breathing apparatus with
full face mask as argon (inert gas) is injected in the SG
module to prevent further fire propagation.
Nitrogen and other inert gases for purging in RCB fire
may cause the hazard of asphyxiation in B2 / purification
cabins if adequate exhaust and ventilation are not
maintained.
Handling radioactive Sodium needs supplied-air
respiratory mask airline system and alkali resistance
protective coverall (suite).
2. PPE needed during the cleaning operations -
Sodium gets leaked and spread all over the nearby walls,
pipes, and equipment. After cooling, this frozen Sodium
has to be scooped out and cleaned manually.
Cleaning team members have to wear special protective
suits and coveralls for cleaning Sodium. While cleaning,
sometimes accidentally fine sodium dust and aerosols
may fly and find their way into the body parts, eyes, etc.
These particles enter into the suits through fine openings
of the suites (if not seal-tight).
Sodium aerosols and dust cause thermal and alkali burn
on the skin. Sodium hydroxide is generated due to body
moisture, and it penetrates the skin/tissues.
Sodium burn requires only conventional burns like
washing whole/body (or exposed part) using body
showers with plenty of running water for at least 15
minutes.
Sodium oxide or hydroxide mist due to a large sodium
fire irritates the lungs and throat and causes cough.

Ventilation systems are stopped during cleaning

operations to prevent the spread of sodium aerosol. The
unavailability of air circulation creates a humid
environment in the cleaning area. Sodium reacts with
body sweat and causes skin burn wherever the fine
cleaning dust/aerosol touches. Hence coverall is needed.
This again increases the humidity and heat for the wearer
if ventilated coveralls are not used.

3. PPE needed during the disposal operations -

Sodium is disposed of by burning the Sodium using a
water hose from a safe distance in an open disposal yard.
Disposal of Sodium requires proximity suite with heat
resistant face shield.

CONCLUSION
Fast Breeder Test Reactor (FBTR) is crossed its 36 years
of age. However, FBTR is continually upgrading the plant
to avoid failure or leaks from the aged components.
FBTR experienced most of the sodium leak problems in
the steam generators and secondary systems.
FBTR has upgraded the plant with modern sodium leak
detection gadgets like sodium aerosol detectors. FBTR
uses advanced materials, manufacturing for its
components and follows comprehensive in-service
inspection.
During the sodium leak emergencies, for the initial few
hours or days, humans cannot access the sodium leak
physically for the fire fighting and salvage operations
until radioactivity, temperature, and alkali fume are
removed using remote systems/methods. Hence the
development of remotely operated fire fighting and
salvage tools is need of the hour for such conditions.
There is undoubtedly a need for consistent innovation and
development, especially in personal protective equipment
and respiratory products for the safety of fire fighting and
salvage teams during their handling of sodium leaks and
fire.

REFERENCES
[1] OPEC03, Rcv07,“EMERGENCY OPERATING
PROCEDURE FOR SODIUM LEAK FROM PRIMARY
SODIUM SYSTEM”, 2018
[2] OP-26, Rcv0,“PROCEDURE FOR CLEANING SODIUM
FROM LEAKY FROM STEAM GENERATOR MODULE
(SGna600B)”, 2017