Project Overview

Core Energy Systems Limited successfully executed the design, development, and supply of the Helium Liquid Return and Control (LRC) System for NPCIL projects at KAPP-3 & 4 and RAPP-7 & 8 through Punj Lloyd Limited.

The system plays a critical role in supporting D₂O (Heavy Water) control and measurement within reactor systems, ensuring safe and efficient performance under both normal and transient conditions.

Key Engineering Highlights

• Flow Capacity: Designed for 125 Nm³/hr at 12 bar(g).
• Design Code: Fabricated and certified as per ASME Section III, ND.
• Performance Validation: Tested with air at 74°C and helium under real operating conditions.
• Prototype Qualification: Functional prototypes developed and validated before production.
• QA/QC Compliance: In-process inspections, pressure testing, and seismic checks aligned with approved QAP.

System Functions and Application

The Helium LRC System ensures precise control, distribution, and recovery of helium used as a blanket and purge gas in D₂O systems. By maintaining gas purity and pressure in closed-loop circuits, it enhances both safety and operational efficiency in PHWR-type reactors.

Challenges and Engineering Solutions

• Seismic Qualification: Designed and tested to meet Operating Basis Earthquake (OBE) requirements ensuring performance during seismic events.
• Leak Tightness: Developed forged components to achieve vacuum leak standards better than 10⁻⁷ mbar for maximum containment integrity.
• Material Compatibility: Selected materials suitable for high-purity helium service and long-term pressurized conditions.

Commitment to Nuclear Standards

The system was engineered in strict compliance with NPCIL standards and nuclear regulatory requirements. All components underwent rigorous testing, inspection, and documentation processes to ensure seamless integration into critical nuclear infrastructure.