Salvation of S. S. Surge Tank for HTHP Loop

As constituents of nuclear industry, we all know the significance of the stringent specification to the practical level on the manufacture of nuclear components. More so for the primary system of High Temperature High Pressure Loop (HTHP) situated at Water & Steam Chemistry Division (WSCD). The pressurizing of the system is done by heating through immersion heaters provided in the surge tank. The surge tank, at its rated condition, has steam on the top, above the water level. The surge tank has got a l5 0 NB size nozzle at the bottom dished end. A 1500 # flange is welded to this nozzle. The heater unit of the surge tank is connected to this flange. The heater unit consists of a 150 NB, 1500 # blind flange (tube sheet) with eight number of SS U-type immersion heater pins welded to it. Welding of stainless steel heater pin is a demanding task. The task becomes even greater when the job involves welding of 16 pins with a triangular pitch of 25 mm, such as those for the high temperature & pressure loop. Actually, the tank was manufactured by a private firm. During final leak testing, it was found that there were leaks through the heater pins to sleeve welding in three of the heater pins. They could not rectify the leak. Subsequently, the rectification of the weld was referred to CWD. A novel technique was developed and due care was taken to weld the heater pins. The tank was successfully salvaged and tested hydrostatically at 170 bars and pneumatically at 7 bars. The method of fabrication of heater assembly, problems anticipated, problems encountered and measures taken to solve them are dealt with.