TESTING AND OPERATIONNAL EXPERIANCE OF SF6 GAS HANDLING

SYSTEM FOR 3 MeV, 30 kW DC ACCELERATOR AT EBC, KHARGHAR,

NAVI MUMBAI
Shyam Rao Ghodke, Mahendra Kumar, Rajesh Barnwal, Susanta Nayak, D Jayaprakash, Vijay
Sharma, S. K. Srivastava, R I. Bakthsing, Rehim Rajan, D K Sharma, S Devangan, Dr. K. C. Mittal
and Dr. L. M. Gantayet

Electron Beam Centre, Accelerator & Pulse Power Division, BARC, Mumbai – 400085
e-mail: ghodke_barc@yahoo.co.in

Abstract: The 3 MeV Accelerator Project involves insulation and efficient cooling. Hence there is a need of

designing, fabrication, installation, commissioning and SF6  gas   and   its   handling   system.   Normal   operating
operation of a 3 MeV, 30 kW Industrial Electron Beam pressure   inside   the   accelerator   is   6   kg/cm 2.   The
Accelerator with a terminal voltage of 3 MV and is
accelerator tank has to be evacuated up to vacuum of 1
housed inside the ‘Electron Beam Centre’ (EBC) building
at Kharghar, Navi Mumbai. The Accelerator has mbar   before   filling   the   gas.   Detail   design   [2]   and
capability of delivering electron beam of 3 MeV energy fabrication   [3]   of   the   accelerator   pressure   vessel   using
for radiation processing application for ecological and ASME B&PV Code SEC­VIII, DIV­1, reported earlier.
economical reason the SF6 gas is reincorporated into
closed cycle because gas should not be released into the
atmosphere. The aim of the SF 6 Gas Handling System is
to introduce the gas at high pressure to the accelerator
pressure vessel after evacuation and to bring back into the
storage tanks with minimum loss. The gas handling
system also provides purification of gas, prevention from
mixing with air or any other substances, which may
contaminate and thus bring down the high voltage
insulation characteristics of the gas. Accelerator is tested
up to 1.6 MeV Voltage with SF 6 gas. SF6 gas transfer
system involved design of pressure vessel as well as
piping. This paper discusses about vacuum testing,
pressure testing, methods adopted to reduce leakage and
helium leak testing of Accelerator pressure vessel
(Height: 7 m, Diameter: 2.1 m). It tells about filing and
transfer of SF6 gas with minimum loss and recovery of
gas. Operation and safety of different components of SF6
gas handling system is also discussed in the paper.

INTRODUCTION: A   3   MeV,   30   kW   DC   industrial

electron accelerator has been designed and is working at
1.6 MeV energy & 5 kW power at Electron Beam Centre,
Kharghar, Navi Mumbai. Schematic of the accelerator is
shown in Fig. 1. [1­3] 
The   accelerator   and   its   high   voltage   power
supply are housed in a pressure vessel filled with Sulphur
Figure 1: Schematic diagram of 3MeV DC accelerator
Hexa   Fluoride   (SF6)   gas   as   a   high   voltage   insulating
The basic function of a gas handling or recovery
media at 6 kg/cm2. [1] 
system is to reclaim the insulating gas from an accelerator
The Accelerator Pressure vessel [2] is the main
vessel,   purify,   and   store   it   in   storage   tanks   until   the
body   of   the   Accelerator,   which   houses   high   voltage
internal modification have been completed, evacuate the
multiplier   columns, RF  electrodes,   corona   shields,  high
air from the accelerator vessel and then recharge it with
voltage   terminals,   electron   gun,   accelerating   tubes,   RF
insulating gas, in a minimum time. From a practical point
transformer etc. All of these components require SF6 gas
of view of accelerator working, it is very desirable that
the cycle time be a small fraction of a working shift, so
that the trouble can be diagnosed and corrective measure
can be taken. SF6 gas has been handling with the help of
compressor and vacuum pump. Both of these components
are fifty metre away from two numbers of storage tanks
and main accelerator tank. To increase the conductance of
pipeline, hence reducing the evacuation time, selected 3”
NB,   Schedule   40,   SS   304   L   pipe   line.   Different   sub
systems and processes are discussed below.
Accelerator tank and storage tanks: The
accelerator tank and storage tank are made of ASME SA
516   Gr­70   Boiler   grade   Carbon   Steel   plates.   Both
accelerator and storage tanks are designed for 10 kg/cm 2
of internal pressure and vacuum as external pressure as
per ASME B&PV Code Sec VIII Div I [2]. The size of
accelerator  tank  is  2120  mm   internal  diameter,   20  mm
wall  thickness, 7 m height. The size of storage  tank is
1760 mm internal  diameter, 15.0 mm wall  thickness &
7000 mm  length. Figure 1 shows accelerator  tank with
accelerator components.  of 3000 lpm capacity water­cooled double stage Rotary
Charging: Vessel, dryer, filter and pipe line evacuated
up to 1 mbar before charging the gas in accelerator tank.
First   time   charging   in   the   accelerator   vessel   was
accomplished by pressure equalisation between the newly
procured SF6  gas in cylinders and the accelerator vessel.
For   recharging   of   the   accelerator   vessel,   pressure   was
equalised   between   storage   tank   and   accelerator   tank.
During recharging the gas passes from the storage tanks
to the accelerator vessel through the particulate filters. We
are storing the gas at a pressure of 6 kg/cm 2g in storage
tanks.   Liquid   storage   is   not   preferred   to   avoid   brittle
fracture of storage vessel at low temperature (below zero
degree   Celsius)   due   to  adiabatic   expansion   of   gas.  For
further   pressurization   air   compressor   is   used.   Final
pressure in accelerator tank should be 6 kg/cm 2g. SF6 gas
is procured from M/S Solve Flore, Germany conforming
to DIN IEC 376 with 99.9 percent purity.
Recovery:  For   recovery   of   SF6  gas   from   accelerator
tank   to   storage   tank   we   have   to   do   equalisation   of
pressure and then removal with the help of compressor up
to   1   kg/cm2g   pressure   in   accelerator   tank.   When   the
accelerator   pressure   drops   below   zero   psig   the   flow   is
diverted through the vacuum pump to maintain the inlet
pressure   to   the   compressor   near   atmospheric.   Vacuum
pump   will   be   isolated   from   gas   transfer   line   up   to   1
kg/cm2  pressure   in   the   accelerator   tank   and   pipe   line.
After this it is connected with transfer line by opening the
valve and it is throttled until the compressor inlet pressure
reaches above atmosphere to match the pumping speeds
of   the   compressor.   During   the   evacuation   phase,   the
vacuum pump outlet is goes through the mist eliminator
or oil filter made of charcoal, which prevents mixing of
pump   oil   with   SF6  gas.   With   this   mechanism   we   can
achieve ultimate vacuum inside accelerator tank up to 1
mbar. At atmospheric pressure 155 kg of SF 6 gas will be
remain   but   because   of   above   mechanism   at   1   mbar
pressure   only   0.22   kg   of   SF6  gas   remains   in   the
accelerator tank. This gas will be thrown to atmosphere
with   the   help   of   Nitrogen   purging   up   to   1   bar   and
evacuation. 
The   main   function   of   vacuum   pump   is   to
minimize   the   loss   of   SF 6  gas   during   maintenance   of
accelerator, storage tanks, dryers, filters, pipe lines, etc.
SF6  gas   handling   room   is   50   meter   away   from   main
accelerator and storage vessels. We have to evacuate the
accelerator and storage tank from this room with the help
vane Pump.
Drying:  The SF6  breakdown products are known to be
completely removed by passing the gas through activated
alumina.   Aim   is   to   achieve   dew   point   better   than   ­36
degree   Celsius.   During   non   operation   period   of   the
accelerator,   the   SF6  gas   is   circulated   through   a   large
activated   alumina   dryer.   This   is   primarily   done   to
maintain the moisture content in the gas within tolerable
limits for proper operation of the accelerator. However, it
also helps to minimize breakdown product contamination
introduced by corona point’s discharge. Moisture level in
SF6 gas at 10, 0, ­10, ­20, ­30 & ­40 degree Celsius will
be   1492,   744,   316,   126,   46   &   16   ppm   by   weight
respectively.
Vertical   vessel   twin   column   activated   alumina
filled   dryer   is   used   for   removal   of   moisture   and
breakdown   products.   Each   dryer   column   having100   kg
Alumina   balls   get   saturated   after   absorbing   1   litre   of
water.   Activation   of   alumina   balls   is   done   by   passing
preheated air at 1500C through alumina bed via blower &
heater.   It   takes   6   hours   to   regenerate.   Coarse   and   fine
filters   are   provided   to   make   sure   that   dust   free   gas   is
circulated through the accelerator column. Coarse filter is
Pleated  Bag  type   filter  suitable  for  filtering   0.3­micron
size   dust   particles.   Fine   filter   is   a   cartridge   type   filter
having borosilicate glass fibre cartridge mounted into SS
housing,   suitable   for   filtering   0.01   micron   size   dust
particles.  with respect to safety aspect of the human occupancy.
Air compressor system: This   system   consist   of   air
compressor   with   motor   &   flywheel,   after   cooler,   its
cooling   system,   air   receiver,   control   panel,   skid   frame,
etc.   In   3   MeV   accelerator   compressed   SF 6  gas   will   be
required   at   6   kg/cm2  at   accelerator   tank   and   up   to   8
kg/cm2  in storage tanks. Before filling the gas, SF 6  gas
handling   system   has   to   evacuate.   Vacuum   pump   outlet
will   be   given   to   compressor   system   to   evacuate   the
system and transfer remaining SF6  gas into storage tank.
During pressurization of accelerator tank we equalize the
pressure   of   accelerator   tank   and   storage   tank   without
using compressor system. Equalization pressure will be ~
3   kg/cm2.   Compressor   system   will   do   further
pressurization   of   accelerator   tank.   Compressor   system
will do recirculation of SF6 gas through moisture removal
system for purification. Compressor system is the main
engine of SF6 gas handling system.  of 4 hours to observe many joints. No leakage and drop in
Method to reduce leakage:
I. We have used forged and machined weld neck flanges
of outer diameter 2400 mm in accelerator vessel to make
possible 100% radiography. We have used 30 numbers of
pad type nozzles to make butt weld between nozzle and
accelerator shell. It insures 100% radiography in welding
of nozzle and accelerator shell.  Safety features:  SF6  gas   if   released   into   the
II. In 3” NB Schedule 40 pipe line of length 200 meter, all
joints are gasket joints with weld neck flanges to do 100%
radiography. We have not used threaded joints in SF 6 gas
transformer   system   except   for   pressure   gauge,   quarter
inch ball valves and pressure transmitter.
III. Pipe line materials are tested for  Chemical, Physical
and   Inter   Granular   Corrosion   (IGC)   test.   Purging   of
Argon gas inside the pipe line also ensures sound weld.
All welded joints are dye penetrant and radiographically
tested.
IV. Most of the places we have use butterfly valve for
controlling the flow but at specific locations where bulk
SF6  gas is stored, we have used ball valves with better
leak tightness.  2000   ppm   range   based   on   infrared   absorption
VI. For checking the leakage we have used pressure drop
test, soap bubble test, Helium sniffer test, halogen sniffer
test,   vacuum   decay   test   and   Mass   spectrometer   leak
detection (MSLD) test.
MSLD leak testing in pressure and vacuum
mode:
Leak testing of the accelerator tank is undertaken
Since the operation team has to go around the accelerator
for surveillance as well as verification of operational
parameters, during the conditioning and beam trial
experiments; ambiance presence of SF6 gas need to be
maintained well below the allowable threshold limit value
at 20 ppm. Allowable threshold limit value of new SF6 is
1000 ppm. Helium leak testing of the accelerator tank in
pressure mode is done in the sniffer mode of the leak
testing, employing a mass spectrometer leak detector
(MSLD).
Tank   is   pressurized   at   6   kg/cm2  with   a   mixture   of
Nitrogen and Helium (85:15) by volume. Sealing all the
ports and the main flange couplings with polythene bags,
leaked out Helium is collected in 12 hours. Leaked out
quantity   of   helium   is   registered   in   an   MSLD,   using   a
sniffer probe. Three leaks are detected and rectified later.
Hydro and pneumatic testing:  pressure vessels are
hydrostatically tested at a pressure of 13 kg/cm 2g. During
hydrostatic testing entire assembly were held for a period
pressure   was   observed.   Test   was   found   satisfactory.
Pneumatic testing of vessel is conducted at a pressure of
11 kg/cm2g. At this pressure soap solution was applied on
welded joints and no leakage was observed for 4 hours.
Thereafter pressure was reduced to 10 kg/cm2 and held for
another 8 hours. 
atmosphere,   tend   to   accumulate   in   low­   laying   areas
where   there   is   no   natural   ventilation   and   may   cause
asphyxiation. Individual breathing in such an atmosphere
may   experience   symptoms   which   include   headaches,
ringing   in   airs,   dizziness,   drowsiness,   unconscious,
nausea,  vomiting and  depression   of all   the  senses.  The
skin of a victim of overexposure may have a blue color.
The purity should be more than 97%, the moisture content
should be better than ­36 0C and SO2 should be less than
50 ppm. We are maintaining above values with the help
of M/s WIKA make  ‘Breaker  Analyser.  The maximum
permissible leakage of 0.5% per year should be allowed
as   per   IEC   standard.   Area   monitoring   systems   with   0­
spectroscopy have been installed at the various locations
of the accelerator and gas storage rooms and sensor kept
at low level. Portable leak detectors with 0­50 ppm range
based on infrared absorption spectroscopy has been used
for detecting the leak tightness. The gas quality has been
monitored for purity, moisture and acid after recycling the
gas through moisture removal system. We have prepared
handling procedures and instructions. Risks and warning
signs are provided. 

Acknowledgement:    The   authors   are   thankful   to   the

staff   of   electron   Accelerator   at   EBC,   Kharghar,   Navi­
Mumbai. Authors gratefully acknowledges Mr. S K Gupta
and   Mr.   Arun   Agarwal   for   the   technical   support   and
sharing operational experience of SF6 gas transfer system
of FOTIA, BARC, MUMBAI.

Conclusion:  SF6  gas handling system  is indigenously

developed and being operated at  Electron Beam Centre
(EBC),   Kharghar,   Navi   Mumbai.   All   components   are
fabricated   from   local   vendor   of   Mumbai.   Vacuum   and
pressure testing of pressure vessels and piping is done for Fig. 3: Air compressor for SF6 transfer
leak tightness and integrity of vessel. The SF 6 gas quality
is being regularly monitored before accelerator operation.
Emission/leakage of SF6  is maintained below TLV. SF 6
gas recovery is achieved up to 1 mbar pressure, only 0.22
kg loss in 1100 kg of SF6  gas. SF6  safety systems and
monitors   are   installed   at   site   and   tested.   SF 6  cooling
system is also a part of SF6 handling system which is not
discussed in the paper. 3 MeV Accelerator is working at
1.6 MeV energy and 5 kW power. Efforts to raise energy
and power are going on.

Reference:

[1] Ghodke S R, et al, (2003), Tank Design for 3 MeV, 30

kW Industrial Electron Accelerator, InPAC 2003, Indore,
India, 249. Figure 4: 3000 lpm rotary vacuum pump and root pump
[2] Ghodke S R, et al, (2007), SF 6 Gas Handling System of   capacity   4166   lpm.   Only   rotary   vacuum   pump   is
for 3 MEV, 30 KW Electron Beam Accelerator at EBC, sufficient to give vacuum up to 1 mbar in 2.5 hours.
Kharghar, Navi Mumbai, APAC 2007, Raja Ramanna
Centre for Advanced Technology (RRCAT), Indore, India,
779.
[1] K C Mittal, et al, (2007), Development of 3 MeV, 30
kW DC Electron Accelerator at EBC, Kharghar, APAC
2007, RRCAT, Indore, India, 682.

Fig 5: Moisture removal system with control Panel

Fig. 2: SF6 gas storage tanks

Fig.6: Assembly of Accelerator before filling SF6 gas

Fig.7: Assembly of Accelerator components