Engineering topics

Sanborn, Scott E.

Publications and source records attributed to Sanborn, Scott E..

8 records

DOE OSTI2015

A summary of the Hanford single-shell tank structural analysis of record - 15526

Washington River Protection Solutions, LLC (WRPS), the US DOE Hanford Site tank contractor, developed an enhanced Single-Shell Tank Integrity Project (SSTIP) in 2009 to better understand the integrity of the single-shell tanks (SSTs). A panel of experts from industry and academia was created to recommend project activities in four main areas: structural integrity, liner degradation, leak integrity and prevention, and contamination migration. One of the panel's primary recommendations was to perform a detailed structural integrity analysis of the SSTs. WRPS and the U.S. Department of Energy, Office of River Protection commissioned the Pacific Northwest National Laboratory (PNNL) to perform this structural integrity analysis of record for the Hanford single shell tanks. This is one of seventeen panel recommendations that form the M-45-10-1 Change Package for the Hanford Federal Agreement and Compliance Order; also known as the Tri-Party Agreement. Finite element analysis was used to predict the structural response of the SSTs to the historical thermal and operating loads, plus design basis seismic loads. Bounding thermal histories were established from waste temperature records and applied to the model to include the thermal degradation of concrete modulus and strength, plus cracking due to differential thermal expansion while under in situ static loading conditions. PNNL contracted with Becht Engineering to evaluate the dynamic response of the tanks to a design basis earthquake. The degraded stiffness of the reinforced concrete was also incorporated in the seismic analysis. The combined response to static and seismic loads was then evaluated against the design requirements of the American Concrete Institute standard, ACI-349-06, for nuclear safety-related concrete structures. Specific analyses were performed for the four major tank designs.This paper presents an overview of the analysis methods used and it summarizes the major analytical findings that are common to the tanks and others that are specific to the individual tank designs. The analyses of record determined that including the bounding effects of their operating histories, each tank design currently satisfies the ACI-349-06 structural integrity design requirements. Although leak tightness is not directly addressed in the structural integrity analysis, this analysis will be a key input in the formal tank integrity assessment due in 2018. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

Sensitivity Studies on UNF Cladding Structural Integrity under NCT Loading

This work describes the sensitivity analyses performed on the transportation package used in the NCT initial modeling and simulation demonstration [1]. The initial demonstration predicted the structural integrity of the fuel cladding by integrating models from the fuel rod/grid slot level, the single assembly-level, and the full cask-level. A number of sensitivity analyses were performed on the models at the different levels to determine how sensitive the results were to the parameters that were varied. The results are used to coarsely group the parameters investigated into four categories of sensitivity: No Sensitivity, Low Sensitivity; Moderate Sensitivity, and High Sensitivity. The High Sensitivity analyses are described in detail below. The Moderate, Low and No Sensitivity results are briefly described.

used nuclear fuel, UNF, normal conditions of trans↗

DOE OSTI2014

Fuel assembly shaker and truck test simulation

This study continues the modeling support of the SNL shaker table task from 2013 and includes analysis of the SNL 2014 truck test campaign. Detailed finite element models of the fuel assembly surrogate used by SNL during testing form the basis of the modeling effort. Additional analysis was performed to characterize and filter the accelerometer data collected during the SNL testing. The detailed fuel assembly finite element model was modified to improve the performance and accuracy of the original surrogate fuel assembly model in an attempt to achieve a closer agreement with the low strains measured during testing. The revised model was used to recalculate the shaker table load response from the 2013 test campaign. As it happened, the results remained comparable to the values calculated with the original fuel assembly model. From this it is concluded that the original model was suitable for the task and the improvements to the model were not able to bring the calculated strain values down to the extremely low level recorded during testing. The model needs more precision to calculate strains that are so close to zero. The truck test load case had an even lower magnitude than the shaker table case. Strain gage data from the test was compared directly to locations on the model. Truck test strains were lower than the shaker table case, but the model achieved a better relative agreement of 100-200 microstrains (or 0.0001-0.0002 mm/mm). The truck test data included a number of accelerometers at various locations on the truck bed, surrogate basket, and surrogate fuel assembly. This set of accelerometers allowed an evaluation of the dynamics of the conveyance system used in testing. It was discovered that the dynamic load transference through the conveyance has a strong frequency-range dependency. This suggests that different conveyance configurations could behave differently and transmit different magnitudes of loads to the fuel even when traveling down the same road at the same speed. It is recommended that the SNL conveyance system used in testing be characterized through modal analysis and frequency response analysis to provide context and assist in the interpretation of the strain data that was collected during the truck test campaign.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Predictive Engineering Tools for Injection-molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 Third Quarterly Report

This report describes the technical progresses made during the third quarter of FY 2014: 1) Autodesk introduced the options for fiber inlet condition to the 3D solver. These options are already available in the mid-plane/dual domain solver. 2) Autodesk improved the accuracy of 3D fiber orientation calculation around the gate. 3) Autodesk received consultant services from Prof. C.L. Tucker at the University of Illinois on the implementation of the reduced order model for fiber length, and discussed with Prof. Tucker the methods to reduce memory usage. 4) PlastiComp delivered to PNNL center-gated and edge-fan-gated 20-wt% to 30-wt% LCF/PP and LCF/PA66 (7”x7”x1/8”) plaques molded by the in-line direct injection molding (D-LFT) process. 5) PlastiComp molded ASTM tensile, flexural and impact bars under the same D-LFT processing conditions used for plaques for Certification of Assessment and ascertaining the resultant mechanical properties. 6) Purdue developed a new polishing routine, utilizing the automated polishing machine, to reduce fiber damage during surface preparation. 7) Purdue used a marker-based watershed segmentation routine, in conjunction with a hysteresis thresholding technique, for fiber segmentation during fiber orientation measurement. 8) Purdue validated Purdue’s fiber orientation measurement method using the previous fiber orientation data obtained from the Leeds machine and manually measured data by the University of Illinois. 9) PNNL conducted ASMI mid-plane analyses for a 30wt% LCF/PP plaque and compared the predicted fiber orientations with the measured data provided by Purdue University at the selected locations on this plaque. 10) PNNL put together the DOE 2014 Annual Merit Review (AMR) presentation with the team and presented it at the AMR meetings on June 17, 2014. 11) PNNL built ASMI dual domain models for the Toyota complex part and commenced mold filling analyses of the complex part with different wall thicknesses in order to support part molding. 12) Toyota and Magna discussed with PNNL on tool modification for molding the complex part. Toyota sent the CAD files of the complex part to PNNL to build ASMI models of the part for mold filling analysis to provide guidance to tooling and part molding.

Injection molding, long-fiber thermoplastic, carbo↗

DOE OSTI2014

Assembly Level Modeling and Transportation Damage Prediction of Used Nuclear Fuel (UNF) Cladding

Under U.S. Nuclear Regulatory Commission (NRC) regulations, UNF must maintain its integrity in such a way that it can withstand the physical forces of handling and transportation associated with restaging the fuel and moving it to a different location such as an interim storage site, a geologic repository, or a treatment/recycling facility. Hence, understanding mechanical performance under cumulative loading stemming from normal conditions of storage (NCS), transfer from storage container to transport container if needed, and normal conditions of transport (NCT) is necessary as it establishes part of the safety basis via maintaining the fuel confining boundary (geometry), maintaining criticality safety, and is one of the critical components to the preservation of retrievability. An initial demonstration of modeling and simulation capabilities was performed as part of a collaborative effort between Pacific Northwest National Laboratory (PNNL), Sandia National Laboratory (SNL), Idaho National Laboratory (INL), Oak Ridge National Laboratory (ORNL), and the Transportation Technology Center Inc. (TTCI). This demonstration completed preliminary deterministic evaluations of moderate-to-high burnup UNF mechanical performance under NCS and NCT conditions. This paper focuses on work performed by PNNL on the assembly level modeling of a UNF assembly and fuel cladding damage predictions under NCT loads. The Finite Element (FE) model created for a 17 x 17 Pressurized Water Reactor (PWR) optimized fuel assembly (OFA) is discussed along with the communications to and from the fuel rod-level and cask-level models. Additionally, the methodology for determining cumulative damage is discussed including the 3000 mile damage prediction from a 10 second simulation. The damage results are shown for five shock and vibration broadened loading histories. It is found that predicted cladding strains were not large enough to cause structural failure, but cyclic strains roughly projected for the entire route were significant in some cases. The total damage from summation of the worst shock and vibration cases evaluated is approximately 18% of the expected fatigue limit. Therefore it is predicted that the fuel rods do not fail during NCT given the assumptions used throughout this initial demonstration.

used nuclear fuel, UNF, trasportation, damage, fue↗

DOE OSTI2014

Analytical Model Methodology Development and Demonstration of Approach on Used Fuel Performance Characterization for Condition of Normal Transportation

U.S. Nuclear Regulatory Commission (NRC) rules require that used nuclear fuel (UNF) rods maintain their integrity during handling, transportation, and storage to ensure maintenance of the fuel retaining boundary, safety against criticality, and long term fuel retrievability for processing and disposal. Consequently, understanding the mechanical performance of UNF rods under cumulative loading stemming from handling, normal conditions of transport (NCT), and normal conditions of storage (NCS) is necessary as their performance under these conditions establishes part of their safety basis. The U.S. Department of Energy (DOE) commissioned a multi-laboratory team consisting of subject matter experts at Pacific Northwest National Laboratory, Idaho National Laboratory, Sandia National Laboratory, and Oak Ridge National Laboratory to develop a methodology to examine the structural performance and potential for failure of UNF under NCT and to perform a demonstration of this methodology for a typical UNF transportation campaign. This team prepared a Research, Development, and Demonstration (RD&D) Plan that describes a methodology, including development and use of analytical models, to evaluate loading and associated mechanical responses of UNF rods and key structural components during NCT. The initial scope of this plan has now been fully executed. The demonstration of the methodology laid out in the RD&D plan is focused on structural performance evaluation of Westinghouse Electric 17×17 OFA pressurized water reactor fuel assemblies with a discharge burnup range of 30 58 GWd/MTU (assembly average), loaded in a representative high-capacity (=32 fuel rod assemblies) transportation package and transported on a 3000 mile rail journey. In general, the modeling and simulation approach consists of three levels; the cask level, the fuel assembly level, and the fuel rod level. This modeling approach utilized finite element analysis sub-modeling techniques to accurately model the complete spent nuclear fuel transport system on the railcar (cask restraint structure, cask, basket, assembly, and fuel rods). The sub-modeling approach allows for more detailed finite element models of individual system components, faster analysis run times for the individual sub-models, and flexibility when updating or modifying the sub-models to incorporate better excitation data, initial material properties, or other pertinent information. The final results of the initial demonstration are that cladding strains were not large enough to cause structural failure, but cyclic strains roughly projected for the entire route were significant in some cases. The number of cycles that the model hits certain strain "bins" are counted. These are extrapolated for a 3000 mile trip and the damage ratio is calculated which is the number of cycles the fuel rods hit certain strain bins over the 3000 mile journey divided by the number of cycles to failure. Under the final model and set of inputs, the total damage from summation of the worst shock and vibration cases is ~18% of the expected fatigue limit. Therefore the fuel rods are not expected to fail during NCT given the assumptions listed. Additionally, a number of sensitivity studies were performed. It was found that the areas of highest sensitivity were the cladding elastic modulus, the spacer grid stiffness, the spacer grid location, and gaps between the assembly and the cask; these findings can be used to guide future work.

Used Nuclear Fuel, Storage, Transportation, Normal↗

DOE OSTI2014

Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 First Quarterly Report

The CRADA between PNNL, Autodesk, Toyota and Magna has been effective since October 28th, 2013. The whole team including CRADA and subcontract partners kicked off the project technically on November 1st, 2013. This report describes work performed during the first quarter of FY 2014. The following technical progresses have been made toward project milestones: 1) The project kickoff meeting was organized at PlastiComp, Inc. in Winona on November 13th, 2013 involving all the project partners. During this meeting the research plan and Gantt chart were discussed and refined. The coordination of the research activities among the partners was also discussed to ensure that the deliverables and timeline will be met. 2) Autodesk delivered a research version of ASMI to PNNL for process modeling using this tool under the project. PNNL installed this research version on a PNNL computer and tested it. Currently, PNNL is using ASMI to prepare the models for PlastiComp plaques. 3) PlastiComp has compounded long carbon-fiber reinforced polypropylene and polyamide 6,6 compounds for rheological and thermal characterization tests by the Autodesk laboratories in Melbourne, Australia. 4) Initial mold flow analysis was carried out by PlastiComp to confirm that the 3D complex part selected by Toyota as a representative automotive part is moldable. 5) Toyota, Magna, PlastiComp and PNNL finalized the planning for molding the Toyota 3D complex part. 6) Purdue University worked with PNNL to update and specify the test matrix for characterization of fiber length/orientation. 7) Purdue University developed tools to automate the data collection and analysis of fiber length and orientation measurements. 8) Purdue University designed and specified equipment to replace the need for equipment using the technology established by the University of Leeds at General Motors.

42 ENGINEERING↗

DOE OSTI2013

Fuel Assembly Shaker Test Simulation

This report describes the modeling of a PWR fuel assembly under dynamic shock loading in support of the Sandia National Laboratories (SNL) shaker test campaign. The focus of the test campaign is on evaluating the response of used fuel to shock and vibration loads that a can occur during highway transport. Modeling began in 2012 using an LS-DYNA fuel assembly model that was first created for modeling impact scenarios. SNL’s proposed test scenario was simulated through analysis and the calculated results helped guide the instrumentation and other aspects of the testing. During FY 2013, the fuel assembly model was refined to better represent the test surrogate. Analysis of the proposed loads suggested the frequency band needed to be lowered to attempt to excite the lower natural frequencies of the fuel assembly. Despite SNL’s expansion of lower frequency components in their five shock realizations, pretest predictions suggested a very mild dynamic response to the test loading. After testing was completed, one specific shock case was modeled, using recorded accelerometer data to excite the model. Direct comparison of predicted strain in the cladding was made to the recorded strain gauge data. The magnitude of both sets of strain (calculated and recorded) are very low, compared to the expected yield strength of the Zircaloy-4 material. The model was accurate enough to predict that no yielding of the cladding was expected, but its precision at predicting micro strains is questionable. The SNL test data offers some opportunity for validation of the finite element model, but the specific loading conditions of the testing only excite the fuel assembly to respond in a limited manner. For example, the test accelerations were not strong enough to substantially drive the fuel assembly out of contact with the basket. Under this test scenario, the fuel assembly model does a reasonable job of approximating actual fuel assembly response, a claim that can be verified through direct comparison of model results to recorded test results. This does not offer validation for the fuel assembly model in all conceivable cases, such as high kinetic energy shock cases where the fuel assembly might lift off the basket floor to strike to basket ceiling. This type of nonlinear behavior was not witnessed in testing, so the model does not have test data to be validated against.a basis for validation in cases that substantially alter the fuel assembly response range. This leads to a gap in knowledge that is identified through this modeling study. The SNL shaker testing loaded a surrogate fuel assembly with a certain set of artificially-generated time histories. One thing all the shock cases had in common was an elimination of low frequency components, which reduces the rigid body dynamic response of the system. It is not known if the SNL test cases effectively bound all highway transportation scenarios, or if significantly greater rigid body motion than was tested is credible. This knowledge gap could be filled through modeling the vehicle dynamics of a used fuel conveyance, or by collecting acceleration time history data from an actual conveyance under highway conditions.

Klymyshyn, Nicholas A.↗