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DOE OSTI2014

Controlling O&M Costs of Advanced SMRs using Prognostics and Enhanced Risk Monitoring

Advanced small modular reactors (AdvSMRs) can contribute to safe, sustainable, and carbon-neutral energy production. The economics of small reactors (including AdvSMRs) will be impacted by the reduced economy-of-scale savings when compared to traditional light water reactors. The most significant controllable element of the day-to-day costs involves operations and maintenance (O&M). Enhancing affordability of AdvSMRs through technologies that help control O&M costs will be critical to ensuring their practicality for wider deployment.A significant component of O&M costs is the management and mitigation of degradation of components due to their impact on planning maintenance activities and staffing levels. Technologies that help characterize real-time risk of failure of key components are important in this context. Given the possibility of frequently changing AdvSMR plant configurations, approaches are needed to integrate three elements – advanced plant configuration information, equipment condition information, and risk monitors – to provide a measure of risk that is customized for each AdvSMR unit and support real-time decisions on O&M. This article describes an overview of ongoing research into diagnostics/prognostics and enhanced predictive risk monitors (ERM) for this purpose.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

SMR Containment Cable and Electrical Penetration Assembly System

GAIN Project CRADA Number NFE-21-08839, entitled “SMR Containment Cable and EPA System” was initiated by the partnership of Oak Ridge National Laboratory (ORNL) and Engineered Solutions Group (ESG) to test an ESG-designed Electrical Penetration Assembly and Containment Cabling System Qualified for not only SMR technologies, but also Advanced Reactors design. An Electrical Penetration Assembly (EPA) is a component used to allow electrical power and signal conductors as well as optical fiber through the nuclear reactor’s containment structure while maintaining a pressure barrier. The EPA ensures the containment's integrity both during the normal operation and also accident conditions by providing a sealed passage for power and signals. This project was undertaken to fill the equipment gap of EPA and Cabling Systems that require much more severe environmental requirements than legacy plant applications present due to their smaller containment volumes that result in high energy densities compared to legacy designs. This high energy density results in severe accident environments and also more severe normal operating conditions.This document describes cost effective approaches to qualify a unique EPA for Small Modular Reactor (SMR) technologies as legacy LWR EPA technologies will likely have inherent material performance insufficiencies. The DBA profiles for SMRs (and some Advanced Reactor Technologies) are more severe than the legacy qualification requirements making the design of the qualification testing system challenging as the temperatures and pressures can approach the limits permitted by ASME Pressure Vessel Code, as well as accident temperatures exceeding the capability of polymeric gaskets and dielectrics. Small Modular Reactors are designed to have, as the name suggests, modularity which implies sized for factory fabrication and subsequent assembly at the power plant site. SMR containment is much smaller than a legacy Light Water Reactor containment. The containment walls are likely to be comprised of stainless steel. Qualifying Electrical Penetration Assemblies (EPAs) through these steel vessels are of interest in this work. Methods are presented here that discuss critical safety and cost effectiveness for these SMR EPA’s test systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

TORCHE - Toolbox for Reactor Cross-Flow Heat Exchangers

As interest within the scientific community for the development of small modular reactors (SMRs) grows, utilizing compact and cross-flow heat exchangers present many design advantages. Cross-flow configurations of tube bundles allow water, liquid metal, or a molten salt to be contained within the tube side or shell side in an efficient spatial arrangement. The goal of this project is to provide the user with an easy-to-use set of tools for cross-flow heat exchanger design. The tools are intended to require little to no geometric set-up like meshing in a CFD code in order to enable rapid preliminary design and optimization. With this set of simple Python scripts, the user can determine the necessary quantities and correctional factors in order to assess the heat exchanger characteristics. The two characteristics used in designing novel and efficient heat exchangers incorporated into this work currently are pressure drop and heat transfer coefficients. In support of these efforts, the literature has been scoured for sources of experimental data and proposed methods for calculating pressure drop and heat transfer in cross-flow tube banks. Several empirical correlations and methodologies for calculating pressure drop and heat transfer incorporated into the Toolbox for Reactor Cross-Flow Heat Exchangers (TORCHE). TORCHE is an expansion on the cross-flow pressure drop scripts reported by Haefner et al.. Presented in this summary is a synopsis of the empirical correlations and methodologies of pressure drops and heat transfer coefficient. A validation effort of these models is also presented to provide confidence in the implementation. For this validation of TORCHE, experimental data has been gathered and extracted from graphs in the literature. Error bars were not reported in the experimental data used in this summary and therefore is not included in the analysis.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Baseload Hydrogen Production Using Nuclear and Renewable Energy: A Comparative Analysis

As the global push towards net zero carbon gains momentum, the demand for clean hydrogen is expected to grow rapidly across various sectors, including transportation, industries and electrical grids. To meet this growing hydrogen demand, baseload hydrogen production facilities capable of providing a continuous and reliable supply of hydrogen will be necessary throughout the world. This paper explores the technoeconomic feasibility of establishing baseload electrolytic hydrogen production facilities in the United States, utilizing different clean generation resources. The key criteria include maintaining a consistent supply of clean hydrogen without putting baseload demand stress to already vulnerable power grid. In order to do that, the proposed facilities will host onsite clean power generation and energy storage technologies. The proposed facilities can capitalize on available investment and production incentives and have ability to export excess electricity to the utility at a bulk price. Several scenarios are considered based on the clean energy resources to support the electrolysis process including light water reactors (LWRs) currently evaluating retirement options, wind, solar PVs, and advanced small modular reactors (SMRs). For each scenario, a hypothetical hydrogen production facility is considered in a location in the US where the primary generation resource is at its peak strength. Comparative analysis in this paper reveal that the nuclear power plants are most economically viable for baseload hydrogen production facilities, outperforming renewable-based facilities with significantly lower levelized cost of hydrogen (LCOH). Even under best-case scenarios for resource availability, incentives and export prices, renewable-based facilities face challenges due to daily and seasonal generation variability, resulting in large installation sizes and lower capacity factors. Among renewable-based facilities, complementarity hybrids, providing more stable power supply, demonstrate superior economics compared to facilities based on a single renewable technology. While LWR-powered facility can achieve a negative LCOH with incentives, SMR-powered facilities can provide economic hydrogen supply with LCOH below $1/kg with high temperature electrolysis option. The analysis in this paper underscores the pivotal role of nuclear energy in the future hydrogen economy.

08 - HYDROGEN↗

DOE OSTI2015

Advanced Reactor Technology -- Regulatory Technology Development Plan (RTDP)

This DOE-NE Advanced Small Modular Reactor (AdvSMR) regulatory technology development plan (RTDP) will link critical DOE nuclear reactor technology development programs to important regulatory and policy-related issues likely to impact a “critical path” for establishing a viable commercial AdvSMR presence in the domestic energy market. Accordingly, the regulatory considerations that are set forth in the AdvSMR RTDP will not be limited to any one particular type or subset of advanced reactor technology(s) but rather broadly consider potential regulatory approaches and the licensing implications that accompany all DOE-sponsored research and technology development activity that deal with commercial non-light water reactors. However, it is also important to remember that certain “minimum” levels of design and safety approach knowledge concerning these technology(s) must be defined and available to an extent that supports appropriate pre-licensing regulatory analysis within the RTDP. Final resolution to advanced reactor licensing issues is most often predicated on the detailed design information and specific safety approach as documented in a facility license application and submitted for licensing review. Because the AdvSMR RTDP is focused on identifying and assessing the potential regulatory implications of DOE-sponsored reactor technology research very early in the pre-license application development phase, the information necessary to support a comprehensive regulatory analysis of a new reactor technology, and the resolution of resulting issues, will generally not be available. As such, the regulatory considerations documented in the RTDP should be considered an initial “first step” in the licensing process which will continue until a license is issued to build and operate the said nuclear facility. Because a facility license application relies heavily on the data and information generated by technology development studies, the anticipated regulatory importance of key DOE reactor research initiatives should be assessed early in the technology development process. Quality assurance requirements supportive of later licensing activities must also be attached to important research activities to ensure resulting data is usable in that context. Early regulatory analysis and licensing approach planning thus provides a significant benefit to the formulation of research plans and also enables the planning and development of a compatible AdvSMR licensing framework, should significant modification be required.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2014

Integration of Advanced Probabilistic Analysis Techniques with Multi-Physics Models

An integrated simulation platform that couples probabilistic analysis-based tools with model-based simulation tools can provide valuable insights for reactive and proactive responses to plant operating conditions. The objective of this work is to demonstrate the benefits of a partial implementation of the Small Modular Reactor (SMR) Probabilistic Risk Assessment (PRA) Detailed Framework Specification through the coupling of advanced PRA capabilities and accurate multi-physics plant models. Coupling a probabilistic model with a multi-physics model will aid in design, operations, and safety by providing a more accurate understanding of plant behavior. This represents the first attempt at actually integrating these two types of analyses for a control system used for operations, on a faster than real-time basis. This report documents the development of the basic communication capability to exchange data with the probabilistic model using Reliability Workbench (RWB) and the multi-physics model using Dymola. The communication pathways from injecting a fault (i.e., failing a component) to the probabilistic and multi-physics models were successfully completed. This first version was tested with prototypic models represented in both RWB and Modelica. First, a simple event tree/fault tree (ET/FT) model was created to develop the software code to implement the communication capabilities between the dynamic-link library (dll) and RWB. A program, written in C#, successfully communicates faults to the probabilistic model through the dll. A systems model of the Advanced Liquid-Metal Reactor–Power Reactor Inherently Safe Module (ALMR-PRISM) design developed under another DOE project was upgraded using Dymola to include proper interfaces to allow data exchange with the control application (ConApp). A program, written in C+, successfully communicates faults to the multi-physics model. The results of the example simulation were successfully plotted.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Neutronic analysis of a PWR-type SMR core using duplex ThO{sub 2}-UO{sub 2} in TRISO fuel particles

Currently, studies on small modular reactors (SMRs) present an important development due to the potential they represent in terms of safety, operational flexibility, economy, and non-energy applications. Furthermore, there is increasing interest in studying the use of thorium as fuel, as an effective way to solve problems such as the shortage of uranium reserves, reduction of nuclear waste and nuclear proliferation. Also, the use of thorium combined with highly enriched uranium TRISO particles has been studied, showing proper performance. In this work, the concept of ThO{sub 2}-UO{sub 2} duplex fuel is used, for the core configuration of a PWR type SMR that uses TRISO fuel, designed to achieve extended fuel cycles. Three distribution cases of ThO{sub 2} and UO{sub 2} in TRISO particles inside the fuel rods are compared. First, particles composed by a homogeneous mixture of ThO{sub 2} and UO{sub 2} are distributed inside of fuel elements. Second, the fuel zone of the fuel elements is divided into two radially, an internal one where the TRISO particles composed of ThO{sub 2} are distributed and the external one where the TRISO particles composed of UO{sub 2} are distributed. The third case is like the previous one, except that the particles that contain UO{sub 2} are distributed in the inner zone and those that contain ThO{sub 2} in the outer zone of the fuel elements. The comparison of the cases is carried out in terms of cycle main isotopes' mass transmutation, power distribution and temperature reactivity coefficients. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Phase 1 NuScale SMR FOAK Nuclear Demonstration Readiness Project (Final Scientific/Technical Report)

The overarching objective of the Phase 1 NuScale SMR First-of-a-Kind (FOAK) Nuclear Demonstration Readiness Project was to enhance competitiveness of the U.S. nuclear industry by enabling timely deployment of the NuScale small modular reactor (SMR). The scope of this Phase 1 project continued to advance the licensing and design maturity, particularly in those areas related to supporting customer readiness, supply chain integration, cost competitiveness, and cost confidence. This investment provided by the Government has accelerated development of these designs and technologies so that the existing domestic fleet of nuclear power plants remains viable and the most mature in the nuclear industry. The intent is to have the new, advanced U.S. designs be deployed as early 2026, and be globally competitive. As a part of the First-of-a-Kind Nuclear Demonstration Readiness Project, NuScale has been developing an advanced reactor design, leading the path for other development projects or complex technology advancements for existing plants that have significant technical and licensing risk. The NuScale Power team (NuScale) is advancing licensing, engineering, supply chain development, testing, and other required activities to enhance the innovation and competitiveness of the U.S. nuclear industry by enabling timely deployment of the NuScale SMR. Specifically, NuScale is performing the following activities in Phase 1. Fully supporting the NRC review of the NuScale DCA to ensure approval of a final safety evaluation report by the end of 2020. Improving plant cost confidence and cost competitiveness through design and supply chain advancement, incorporation of constructability best practices, and margin recovery to increase plant power output. Accelerating design maturity, technology development, and operational program readiness to support a customer commitment for plant deployment. The Department of Energy (DOE) Office of Scientific and Technical Information (OSTI), a unit of the Office of Science, fulfills agency-wide responsibilities to collect, preserve, and disseminate both unclassified and classified scientific and technical information (STI) emanating from DOE-funded research and development (R&D) activities at DOE national laboratories and facilities and at universities and other institutions nationwide. This scientific and technical report provides summaries of the analyses and research that was performed by NuScale under this project that achieves the objective of disseminating information to the nuclear industry to ensure the innovations realized are shared for the benefit of the industry at large.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2017

Operating displays - new concept: high performance displays - 118

New control rooms in Nuclear Power Plants using digital Distributed Control System (DCS) operated with software displays, are providing thousands of signals to the operating crew. When an event happens, the Flood of information provided to operators could obscure the initiator event increasing the operator response time, work load and complicating the selection of the actions to be performed. There are some initiatives that are trying to minimize the 'avalanche effect' as the alarm engineering filtering and prioritization or diagnostic displays. Likewise, new control rooms are lost the availability to know the plant status just with a quick glance to the panel indicators. Regarding Small Modular Reactors, where in some cases four operators should monitor and control twelve reactors, these problems are even more significant. The challenge is to find a solution, based on current digital systems, that supply information to operators in order to prevent events and take early actions to minimize or avoid any unexpected incident. In order to minimize human errors, Tecnatom has developed a specific set of displays, called 'High Performance Displays' (HPD) based on objectives, work environment limitation, and non-anticipated events. These displays are being design following the HFE standards: applying the NUREG-0711 elements to identify the information that they have to content and the NUREG-0700 to design the interface. The function of these displays is monitoring the plant situation in a way that the operators are able to recognize any potential event at a simple glance but controlling thousands of signals through pattern recognition, symmetries, regular polygons and colors. The objective of the HPD is to provide an integrated function minimizing the tunnel effect and reduce the workload during the diagnosis phase. Moreover, HPD enhance operators to take the right actions to anticipate the response to any event, even avoiding it, if possible This paper analyzes how HPD's have been design as well as presents the results of a preliminary validation of their capabilities. The preliminary validation is a reduce validation in a full scope simulator running two representative scenarios of abnormal and emergency operation. The analysis is focused on the first stage of the event, i.e. the detection phase, HPD's have been installed in a generic full scope simulator of a nuclear power plant, digital controlled. Both scenarios have been performed by two different operator crews. The first operator shift has worked with the conventional human machine interface, that is, displays similar to the ones currently installed in existing nuclear power plant with digital control. The second crew, reproduce the same scenarios but with HPD available. The studio collects preliminary data in order to compare results, draw lesson learned from the experience to improve HPD design, and find solutions in terms of reducing human errors, human workload, and increase the availability of the plant. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Validation of RELAP-7 for Forced Convective and Natural Circulation Reactor Flows

New reactor designs such as small modular reactors and newly proposed passive safety systems rely on natural circulation two-phase flow cooling of the reactor core under accident conditions. Without a pump to drive the flow, the circulation rate is a strong function of void fraction. Under these conditions where the flow rate, pressure drop, and heat transfer are all closely coupled through the mixture density, the accurate prediction of void fraction is pivotal. Furthermore, while these passive systems boast a more reliable cooling option, the sensitivity of the system to two-phase flow instabilities is more likely than in forced convective cooling and can result in dangerous density wave or flow excursion conditions. Improvement of one-dimensional system codes and further development of three-dimensional code capability are all important efforts in addressing these issues. The proposed work is a critical step towards providing confidence through validation of the capability of thermal-hydraulic tools to meet the emerging challenges in reactor simulation. Historically, system analysis codes develop a stiffness over time due to fine-tuning of adjustable code parameters that result in a reluctance or inability to adopt improved models. Therefore, a rigorous effort should be invested in preparation for RELAP-7 to identify required modeling improvements of constitutive relations and validation of the code applicability to the wide range of possible reactor flow conditions. Part of this validation involves the uncertainty quantification which is a critical step in the Code Scaling, Applicability, and Uncertainty (CSAU) methodology and Best-Estimate Plus Uncertainty (BEPU) licensing method. BEPU allows recovery of safety margins and potentially optimizing plant performance, resulting in economic benefit for the reactor operators. Beginning with the collection of past experimental data covering prototypic LWR conditions, this document reviews three critical datasets available for the validation of system codes. The experimental methods, procedures, facilities, instrumentation, and supplementary information are consolidated to aid the validation efforts of this work and future projects. These three datasets (824 conditions) are chosen due to their wide acceptance and demonstrated application for code validation. Two experimental datasets from the Nuclear Power Engineering Corporation (NUPEC) span prototypic conditions of Boiling Water Reactors (BWR) and Pressurized Water Reactors (PWR). These datasets are labeled as the BFBT (BWR Full-size Fine-mesh Bundle Test) and the PSBT (PWR Subchannel and Bundle Test) datasets respectively. The third dataset is taken in an internally heated annulus that is scaled based on a BWR subassembly and includes two-phase flows important to post-blowdown analysis. Together, the datasets consider the full range of pressure and mass flux expected in LWR forced convective flows from steady-state to long term cooling conditions. Recognizing the deficiency of available data under low-pressure, low-flow, a new natural circulation dataset consisting of 107 conditions is obtained. With system pressures ranging between 145 and 950 kPa, natural circulation is driven by a heat flux up to 275 kW/m2 in a 3 m long heated region of the annulus test section which is followed by a 2 m long unheated region before entering a condenser. Stable natural circulation flow rates in this facility were measured to be between 182 and 590 kg/m2-s. Pressure and temperature are measured at ten locations in the facility. In addition, measurements of void fraction, interfacial area concentration, and gas velocity are obtained at five axial locations in the annulus test section. The RELAP5-3D code demonstrates good accuracy for void fraction predictions in BFBT and PSBT benchmarks, but shows relatively large discrepancy in the annulus experiments at lower pressures. In two-phase natural circulation, large oscillations are observed in many system parameters during the simulation of 19 experiment cases which were conducted at low pressures, and the model shows good predictive performance with the remaining 88 experiment cases. However, some discrepancies in void fraction and temperature predictions are found which may require improved constitutive modeling under these low-pressure, low-flow condition. The quantified uncertainty in void fraction predictions in three forced convection benchmarks due to uncertainties in boundary conditions and geometries are relatively small, except for a few cases in the annulus experiment. The output uncertainty of the natural circulation model is quantified by considering the measurement error in boundary conditions, and it is shown that the output uncertainty ranges are relatively small for the range of conditions considered. Through this work, a clear pathway is provided for validation of RELAP7 once the code is available.

42 ENGINEERING↗

DOE OSTI2026

Irradiation of UC1+x kernels using the MiniFuel vehicle: Microstructure, phase analysis, and initial post-irradiation examination

Uranium carbide is a candidate fuel form for a wide range of advanced reactors, including larger Generation IV reactors as well as small modular reactors and microreactors. However, its commercial deployment timeline faces challenges via traditional qualification approaches. To address this issue, an accelerated fission rate irradiation test was performed to collect basic fuel performance data to inform fuel performance models and potential future integral tests. Hyperstoichiometric UC (UC1+x) kernels were irradiated in the High Flux Isotope Reactor using the MiniFuel irradiation vehicle. The test matrix spanned two temperature regimes (700 °C and 800 °C) and burnup levels (1.8 % FIMA and 2.8 % FIMA). Between 21 and 63 kernels were tested at each unique temperature and burnup condition. As-fabricated microstructural analysis revealed a multiphase composition with UC, UC2, UC2−y, and U-C-O bearing phases for the irradiated kernels. Following irradiation, fission gas release, swelling, and microstructures were analyzed. Measured fission gas release was below 5 % for all irradiation conditions, reaching a maximum at the highest temperature and burnup condition. A binary swelling response was observed; the lower burnup and temperature conditions resulted in negligible swelling, but the higher burnup and temperature conditions produced significant anisotropic swelling and densification in a subset of kernels. The basic microstructural exams of kernels following irradiation were not capable of showing a correlation between kernels that exhibited excessive swelling and those that did not. Characterization of a subset of samples using the Advanced Photon Source and more detailed microstructural examination of unirradiated kernels revealed that a subset of kernels contained very high UC2 phase fractions. The anomalous swelling response is hypothesized to have been driven by this chemical variation. The results of this irradiation highlight the potential of accelerated fission rate irradiation testing to explore such behaviors and inform the development of fuel specifications.

Adorno Lopes, Denise [ORNL] (ORCID:000900023705987↗

DOE OSTI2016

Study for requirement of advanced long life small modular fast reactor

To develop an advanced long-life SMR core concept, the feasibility of the long-life breed-and-burn core concept has been assessed and the preliminary selection on the reactor design requirement such as fuel form, coolant material has been performed. With the simplified cigar-type geometry of 8m-tall CANDLE reactor concept, it has demonstrated the strengths of breed-and-burn strategy. There is a saturation region in the graph for the multiplication factors, which means that a steady breeding is being proceeded along the axial direction. The propagation behavior of the CANDLE core can be also confirmed through the evolution of the axial power profile. Coolant material is expected to have low melting point, density, viscosity and absorption cross section and a high boiling point, specific heat, and thermal conductivity. In this respect, sodium is preferable material for a coolant of this nuclear power plant system. The metallic fuel has harder spectrum compared to the oxide and carbide fuel, which is favorable to increase the breeding and extend the cycle length.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Methodology for Risk-informed O&M decision making in power plants

Incorporation of real-time component information using equipment condition assessment (ECA) through the development of enhanced risk monitors (ERM) for active components in advanced reactor (AR) and advanced small modular reactor (SMR) designs. We incorporate time-dependent failure probabilities from prognostic health management (PHM) systems to dynamically update the risk metric of interest. This information is used to augment data used for supervisory control and plant-wide coordination of multiple modules by providing the incremental risk incurred due to aging and demands placed on components that support mission requirements.

Source record↗

DOE OSTI2015

Preliminary Framework for Human-Automation Collaboration

The Department of Energy’s Advanced Reactor Technologies Program sponsors research, development and deployment activities through its Next Generation Nuclear Plant, Advanced Reactor Concepts, and Advanced Small Modular Reactor (aSMR) Programs to promote safety, technical, economical, and environmental advancements of innovative Generation IV nuclear energy technologies. The Human Automation Collaboration (HAC) Research Project is located under the aSMR Program, which identifies developing advanced instrumentation and controls and human-machine interfaces as one of four key research areas. It is expected that the new nuclear power plant designs will employ technology significantly more advanced than the analog systems in the existing reactor fleet as well as utilizing automation to a greater extent. Moving towards more advanced technology and more automation does not necessary imply more efficient and safer operation of the plant. Instead, a number of concerns about how these technologies will affect human performance and the overall safety of the plant need to be addressed. More specifically, it is important to investigate how the operator and the automation work as a team to ensure effective and safe plant operation, also known as the human-automation collaboration (HAC). The focus of the HAC research is to understand how various characteristics of automation (such as its reliability, processes, and modes) effect an operator’s use and awareness of plant conditions. In other words, the research team investigates how to best design the collaboration between the operators and the automated systems in a manner that has the greatest positive impact on overall plant performance and reliability. This report addresses the Department of Energy milestone M4AT-15IN2302054, Complete Preliminary Framework for Human-Automation Collaboration, by discussing the two phased development of a preliminary HAC framework. The framework developed in the first phase was used as the basis for selecting topics to be investigated in more detail. The results and insights gained from the in-depth studies conducted during the second phase were used to revise the framework. This report describes the basis for the framework developed in phase 1, the changes made to the framework in phase 2, and the basis for the changes. Additional research needs are identified and presented in the last section of the report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Coupled Calculations in Helical Steam Generator: Validation on Legacy Data

The NEAMS program aims to develop an integrated multi-physics simulation capability “pellet-to-plant” for the design and analysis of future generations of nuclear power plants. In particular, the Reactor Product Line code suite's multi-resolution hierarchy is being designed to ultimately span the full range of length and time scales present in relevant reactor design and safety analyses, as well as scale from desktop to petaflop computing platforms. Flow-induced vibration (FIV) is widespread problem in energy systems because they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occurs. Given the importance of reliable components in the nuclear industry, flow-induced vibration has long been a major concern in safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from flow-induced vibration and related failures. Advanced reactors, such as integral Pressurized Water Reactors (PWRs) considered for Small Modular Reactors (SMR), often rely on innovative component designs to meet cost and safety targets. One component that is the subject of advanced designs is the steam generator, some designs of which forego the usual shell-and-tube architecture in order to fit within the primary vessel. In addition to being more cost- and space-efficient, such steam generators need to be more reliable, since failure of the primary vessel represents a potential loss of coolant and a safety concern. A significant amount of data exists on flow-induced vibration in shell-and-tube heat exchangers, and heuristic methods are available to predict their occurrence based on a set of given assumptions. In contrast, advanced designs have far less data available. Advanced modeling and simulation based on coupled structural and fluid simulations have the potential to predict flow-induced vibration in a variety of designs, reducing the need for expensive experimental programs, especially at the design stage. Over the past five years, the Reactor Product Line has developed the integrated multi-physics code suite SHARP. The goal of developing such a tool is to perform multi-physics neutronics, thermal/fluid, and structural mechanics modeling of the components inside the full reactor core or portions of it with a user-specified fidelity. In particular SHARP contains high-fidelity single-physics codes Diablo for structural mechanics and Nek5000 for fluid mechanics calculations. Both codes are state-of-the-art, highly scalable tools that have been extensively validated. These tools form a strong basis on which to build a flow-induced vibration modeling capability. In this report we discuss one-way coupled calculations performed with Nek5000 and Diablo aimed at simulating available FIV experiments in helical steam generators in the turbulent buffeting regime. In this regime one-way coupling is judged sufficient because the pressure loads do not cause substantial displacements. It is also the most common source of vibration in helical steam generators at the low flows expected in integral PWRs. The legacy data is obtained from two datasets developed at Argonne and B&W.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2015

Enabling Situation Awareness Under High Levels of Automation: Results From An Experimental Study

The Department of Energy’s Advanced Reactor Technologies (ART) program sponsors research, development and deployment activities through its Next Generation Nuclear Plant, Advanced Reactor Concepts, and Advanced Small Modular Reactor (aSMR) programs to promote safety, technical, economical, and environmental advancements of innovative Generation IV nuclear energy technologies. The Human Automation Collaboration (HAC) research project is located under the aSMR program, which identifies developing advanced instrumentation and controls and human-machine interfaces as one of four key research areas. New nuclear plants are expected to employ significantly more advanced technology than the systems in the current reactor fleet as well as utilize automation to a greater extent. However, advancing technology and increasing automation does not necessarily imply improved efficiency and safety of the plant. Instead, a number of concerns about how these technologies will affect human performance and the overall safety of the plant need to be addressed. More specifically, it is important to investigate how the operator and the automation work as a team to ensure effective and safe plant operation, also known as the human-automation collaboration (HAC). The HAC project at INL, investigates collaboration methods between a system’s automation and human operators and how that collaboration impacts the performance and reliability of overall system performance. Some well documented human performance issues associated with typical human automation collaboration methods include reduced operator situation awareness (SA), complacency, and over reliance on the system automation (Endsley, 1995, 1996, 1997; Endsley & Kaber, 1999; Kaber & Endsley, 1997, 2004; Parasuraman et al., 2000; Sheridan, 2002; Wickens & Hollands, 2000; Wright & Kaber, 2005). The HAC research effort addresses how to best design the collaboration between the operators and the automated systems in a manner that has the greatest positive impact on overall plant performance and reliability, hence addressing many of the documented issues. The ultimate goal of the HAC research effort is to develop design guidance that supports optimal interaction between humans and automated systems.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2018

Demonstration of Fully Coupled Calculations in Helical Steam Generator: Toward Predictions of Fluid Elastic Instability

The NEAMS program aims to develop an integrated multi-physics simulation capability “pellet-to-plant” for the design and analysis of future generations of nuclear power plants. In particular, the Reactor Product Line code suite's multi-resolution hierarchy is being designed to ultimately span the full range of length and time scales present in relevant reactor design and safety analyses, as well as scale from desktop to petaflop computing platforms. Flow-induced vibration (FIV) is widespread problem in energy systems because they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occurs. Given the importance of reliable components in the nuclear industry, flow-induced vibration has long been a major concern in safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from flow-induced vibration and related failures. Advanced reactors, such as integral Pressurized Water Reactors (PWRs) considered for Small Modular Reactors (SMR), often rely on innovative component designs to meet cost and safety targets. One component that is the subject of advanced designs is the steam generator, some designs of which forego the usual shell-and-tube architecture in order to fit within the primary vessel. In addition to being more cost- and space-efficient, such steam generators need to be more reliable, since failure of the primary vessel represents a potential loss of coolant and a safety concern. A significant amount of data exists on flow-induced vibration in shell-and-tube heat exchangers, and heuristic methods are available to predict their occurrence based on a set of given assumptions. In contrast, advanced designs have far less data available. Advanced modeling and simulation based on coupled structural and fluid simulations have the potential to predict flow-induced vibration in a variety of designs, reducing the need for expensive experimental programs, especially at the design stage. Over the past seven years, the Reactor Product Line has developed the integrated multi-physics code suite SHARP. The goal of developing such a tool is to perform multi-physics neutronics, thermal/fluid, and structural mechanics modeling of the components inside the full reactor core or portions of it with a user-specified fidelity. In particular SHARP contains high-fidelity single-physics codes Diablo for structural mechanics and Nek5000 for fluid mechanics calculations. Both codes are state-of-the-art, highly scalable tools that have been extensively validated. These tools form a strong basis on which to build a flow-induced vibration modeling capability. In the last two years a significant effort was devoted to 1) develop and validate a fully coupled capability in SHARP for Fluid-Structure calculations (FSI) and 2) validate the use of SHARP for one-way coupled calculations in helical steam generators on legacy data available as well as novel experiments. In this report we discuss an extension of previous one-way coupled calculations performed with Nek5000 and Diablo aimed at simulating available FIV experiments in helical steam generators in the turbulent buffeting regime. It was demonstrated that in the buffeting regime one-way coupling was judged sufficient because the pressure loads do not cause substantial displacements. However, higher speeds led to a reduction in accuracy and the need for a fully coupled capability for velocity or approaching the critical velocity and fluid elastic instability. In this report we demonstrate such fully coupled capability on the Argonne test case discussed in previous reports.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Coupled Calculations of the NuScale FIV Tests – Pre-test Simulations and Sensitivity Analysis

The NEAMS program aims to develop an integrated multi-physics simulation capability “pellet-to-plant” for the design and analysis of future generations of nuclear power plants. In particular, the Reactor Product Line code suite's multi-resolution hierarchy is being designed to ultimately span the full range of length and time scales present in relevant reactor design and safety analyses, as well as scale from desktop to petaflop computing platforms. Flow-induced vibration (FIV) is widespread problem in energy systems because they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occurs. Given the importance of reliable components in the nuclear industry, flow-induced vibration has long been a major concern in safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from flow-induced vibration and related failures. Advanced reactors, such as integral Pressurized Water Reactors (PWRs) considered for Small Modular Reactors (SMR), often rely on innovative component designs to meet cost and safety targets. One component that is the subject of advanced designs is the steam generator, some designs of which forego the usual shell-and-tube architecture in order to fit within the primary vessel. A significant amount of data exists on flow-induced vibration in shell-and-tube heat exchangers, and heuristic methods are available to predict FIV based on a set of given assumptions. In contrast, advanced designs have far less data available. Advanced modeling and simulation based on coupled structural and fluid simulations have the potential to predict flow-induced vibration in a variety of designs, reducing the need for expensive experimental programs, especially at the conceptual design stage. Over the past several years, the Reactor Product Line has developed a FIV capability in SHARP. SHARP contains high-fidelity single-physics codes Diablo for structural mechanics and Nek5000 for fluid mechanics calculations. Both codes are state-of-the-art, highly scalable tools that have been extensively validated. In previous reports we have discussed the implementation and validation of an FIV capability for helical steam generators and fuel assemblies. In this report we discuss one-way coupled calculations performed with Nek5000 and Diablo for the NuScale FIV tests. In the turbulent fretting regime one-way coupling is judged to be sufficient because the pressure loads do not cause substantial displacements. It is also the most common source of vibration in helical steam generators per the low flows expected in integral PWRs. The simulations precede the tests, as experimental data was not available at the delivery of this report. Several assumptions had to be made on the support-tube interaction and multiple tests and sensitivity analysis have been performed. Additional work remains to be done and it is discussed in the future work section.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗