Case Studies
ECCS Compressor System
Project Overview
Core Energy Systems Limited successfully developed and supplied the ECCS (Emergency Core Cooling System) Compressor Package for NPCIL projects at TAPP-3&4, KAPP-3&4, and RAPP-7&8 through Punj Lloyd Limited.
The system forms a critical component of the Primary Heat Transport (PHT) safety design in Pressurized Heavy Water Reactors (PHWRs), ensuring rapid pressurization and coolant injection during a loss-of-coolant accident (LOCA).
Project Scope and Functional Overview
The ECCS Compressor System is engineered to pressurize and deliver light water as part of the emergency injection sequence. This approach replaces traditional inert gas or heavy water-based systems, improving reliability, operational safety, and simplifying emergency inventory management.
Key Engineering Highlights
- Design Flow & Pressure: 81 Nm³/hr @ 45 bar(g)
- System Role: Supplies high-pressure compressed air for emergency light water injection
- Cooler Design: Air-cooled heat exchangers designed as per API 661
- Seismic Compliance: Qualified through analytical simulation and shake table testing
- Regulatory Integration: Designed in line with AERB safety guidelines
- Standardized Reactor Feature: Adopted in upcoming PHWR installations
- Operational Optimization: Eliminates nitrogen inventory requirement
Engineering Challenges and Solutions
- Standby Redundancy: Integration of heavy-duty nitrogen cylinder banks as emergency backup without compromising plant layout.
- Inspection & Reliability: Designed to support periodic inspection and testing protocols for long-term operational performance.
Commitment to Safety and Innovation
The ECCS Compressor System is a vital safety component ensuring effective mitigation during reactor cooling emergencies. Its permanent inclusion in PHWR designs reflects strong engineering integrity, regulatory compliance, and operational reliability.
By replacing inert gas-based methods with a light water-driven safety mechanism, Core Energy contributes to more sustainable, maintainable, and future-ready reactor designs.