Design optimization of backup seal for sodium cooled fast breeder reactor

Abstract Design optimization of static, fluoroelastomer backup seals for the 500 MWe, Prototype Fast Breeder Reactor (PFBR) is depicted. 14 geometric variations of a solid trapezoidal cross-section were studied by finite element analysis (FEA) to arrive at a design with hollowness and double o-ring contours on the sealing face. The seal design with squeeze of 5 mm assures failsafe operation for at least 10 years under a differential pressure of 25 kPa and ageing influences of fluid (air), temperature (110 °C) and γ radiation (23 mGy/h) in reactor. Hybrid elements of 1 mm length, regular integration, Mooney–Rivlin material model and Poisson’s ratio of 0.493 were used in axisymmetric analysis scheme. Possible effects of reduced fluoroelastomer strength at 110 °C, ageing, friction, tolerances in reactor scale, testing conditions during FEA data generation and batch-to-batch/production variations in seal material were considered to ensure adequate safety margin at the end of design life. The safety margin and numerical prediction accuracy could be improved further by using properties of specimens extracted from seal. The approach is applicable to other low pressure, moderate temperature elastomeric sealing applications of PFBR, mostly operating under maximum strain of 50%.