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DOE OSTI2025

Basis for Dose and Reactor Safety Design Criteria for Army Regulation AR 50–7 and DA Pamphlet

This report describes the basis used to develop the radiological dose acceptance and design criteria contained in the draft updates to Army Regulation 50–7 (AR 50–7) Army Reactor Program and its accompanying draft Department of the Army (DA) Pamphlet (PAM), Army Reactor Program Procedures. These criteria will apply to Army nuclear reactors that fall under AR 50–7 and its accompanying DA PAM and ensure alignment with the overall objectives of the Army Reactor Program. The development basis for the radiological dose and design criteria supports a modern, technology-neutral, risk-informed, and performance-based approach to Army regulation of reactors and the demonstration of “adequate protection of the public.” To establish these criteria that support the Army’s unique operational requirements, multiple well-known and well-established standards and their supporting documentation were reviewed to ensure consistency with existing regulatory safety levels, including guidance from U.S. and international sources. These include the U.S. Nuclear Regulatory Commission’s (NRC’s) regulations and policy, the Canadian Nuclear Safety Commission’s (CNSC’s) regulatory documents, the International Atomic Energy Agency’s (IAEA’s) safety standards, as well as industry input that is tailored specifically to advanced microreactors. This report walks through the key definitions and associated references used for these criteria, which are outlined in Section 2.0. Based on these definitions, the dose acceptance criteria were established for various receptors for routine reactor operations (Section 3.2), design basis accidents (Section 3.3), and beyond design basis accidents (Section 3.4). Comparisons of multiple national and international dose limits are provided in these sections. Lastly, Section 4.0 outlines the reactor safety design criteria contained in the draft DA PAM and their associated bases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Xe-100 Pebble Bed Small Modular Reactor: Solving Critical Challenges to Enable the Xe-100 Pebble Bed Advanced Reactor Concept (ARC) (Final Scientific and Technical Report)

This is the final progress report for the Department of Energy (DOE) – X Energy, LLC cooperative agreement DENE0008472. This report provides a high-level summary of the work performed during the entire period of performance, running from July 1, 2016 – June 30, 2022. This span of time covers the original 5-year award and a one year no-cost extension. There were four tasks within this project: (1) project management, (2) reactor design furtherance, (3) fuel development, and (4) Nuclear Regulatory Commission (NRC) engagement. Detailed reporting during execution of the project was provided by a total of 23 quarterly reports, 42 X-energy technical reports, and voluntary monthly update presentations. Other technical work products include 2 white papers and 2 Topical Report submitted to the Nuclear Regulatory Commission, 15 Potential Inventions documented, 4 patents issued, 3 patents pending, 8 peer reviewed journal articles, and 2 Oak Ridge National Laboratory Technical Manuscripts. All the X Energy milestones/deliverables were met early or on time and are archived in the DOE Office of Nuclear Energy’s Program Information Control System: Nuclear Energy under Fiscal Year 2016, Work Breakdown Structure 2.07 – X-Energy. All other work products are available to DOE upon request.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

The Monolithic Heat Pipe Microreactor Reference Plant Model Updates

This work presents the latest improvements to, and investigations performed with, the generic monolithic heat-pipe-cooled microreactor reference plant model for the United States Nuclear Regulatory Commission. This model serves as the foundation for the future detailed design evaluation models based on license applications. This model has been developed with the Comprehensive Reactor Analysis Bundle (BlueCRAB) and its specifications are based on open literature publications for the eVinci™ design . BlueCRAB is the U.S. Nuclear Regulatory Commission non-light-water reactor analysis system based on MOOSE, the Multiphysics Object-Oriented Simulation Environment framework, which can couple the Griffin, BISON, and Sockeye applications to resolve the various physics that are essential for the safety analysis of this type of reactor system. The core specifications include tristructural isotropic fuel, graphite monolith, graphite reflectors, and drums composed of graphite and B 4 C.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Development of a CRAB-MELCOR Framework for Utilization in Support of Estimating a Realistic Mechanistic Source Term for Microreactors

Research and development activities are being performed to link important advanced non-light-water microreactor technology research and development activities sponsored by the U.S. Department of Energy’s Office of Nuclear Energy with regulatory requirements and critical licensing needs likely to impact the deployment of a domestic commercial microreactor fleet. This report presents the progress of ongoing work to perform a gap analysis of the coupling of the Nuclear Regulatory Commission’s Comprehensive Reactor Analysis Bundle code suite and MELCOR code. This key Fiscal Year 2023 research reflects microreactor regulatory needs and challenges noted by industry, Department of Energy, and Nuclear Regulatory Commission stakeholders.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Human Factors Considerations for Automating Microreactors

The U.S. Nuclear Regulatory Commission (NRC) has interacted with vendors pursuing the commercialization of microreactors ( <10 MW th ). It is envisioned that microreactors could be assembled and fueled in a factory and shipped to a site. Many of the sites are expected to be remote locations requiring off-grid power or in some cases military bases. However, before this new class of nuclear reactor can be fully developed and implemented by designers, an effort must be made to explore the technical issues and provide reasonable assurance to the public regarding health and safety impacts centered on various technical issues. Prior works have examined many of these issues. One issue not yet fully explored is the possible change in role of the operations and support personnel. Due to the passive safety features of microreactors and their low level of nuclear material, the microreactor facilities may automate more functions and rely on inherent safety features more than its predecessor nuclear power plants. In some instances, human operators may not be located onsite and may instead be operating or monitoring the facility from a remote location. Some designs also call for operators to supervise and control multiple microreactors from the control room. This report explores the issues around reduced staffing of microreactors, highlights the historical safety functions associated with human operators, assesses current licensing requirements for appropriateness to varying levels of personnel support, and describes a recommended regulatory approach for reviewing the impact of reduced staff to the operation of microreactors. The report evaluates these issues through an extensive literature survey and Subject Matter Expert interviews. The literature covers research topics related to Human Factors Engineering as well as regulatory guidance given by the Nuclear Regulatory Commission.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

BISON Validation to In-Situ Cladding Burst Test and High Burnup LOCA Experiments

The process to develop and qualify nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and post irradiation examinations (PIEs); and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes approximately 20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long and drawn-out process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in-situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In general, the in-situ measurements provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the United States nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the Nuclear Regulatory Commission, through their research information letter, outlined a number of technical issues for the industry to address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heatup phase. Leveraging these advanced in-situ capabilities, this work intends to use insitu data generated from a simulated LOCA in the Severe Accident Test Station at Oak Ridge National Laboratory to better understand high-temperature creep and its impact on Zircaloy balloon and rupture performance. This work used the BISON fuel performance code to compare BISON’s high-temperature creep model predictions to in-situ data and identify limitations and gaps within the model. Additionally, BISON will subsequently be used to simulate relevant high-burnup LOCA tests. The results will be analyzed and compared to the available post-test data in a manner consistent with the approach outlined in the Nuclear Regulatory Commission research information letter.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

A High-Assay Low-Enriched Uranium Fuel Transportation Concept

The uranium 235U enrichment commonly used in fuel production for U.S. light water nuclear reactors typically does not exceed 5 wt%. In contrast, many of the currently investigated advanced reactor concepts demand fuel with higher enrichments. This includes high-assay low-enriched uranium (HALEU), characterized by a 235U enrichment of 5 to 20 wt%. The necessity of HALEU transportation in the fuel production cycle leads to new challenges caused by various technical and regulatory hurdles. Current U.S. Nuclear Regulatory Commission–approved transportation package designs for UF6 with enrichments above 5 wt% provide relatively small payloads [=116 kg (250 lb)]. Furthermore, in accordance with 10 CFR 71.55, package design activities for fissile material enriched above 5 wt% need to consider water infiltration in the containment as part of the criticality safety evaluations. This study presents a transportation package concept for HALEU advanced nuclear reactor fuel with a significantly higher payload of up to 376 kg (830 lb) of fissile material per package and up to 1881 kg (4149 lb) of HALEU per legal weight truck. The anticipated chemical form of the transported material is UO2 downblended from available highly enriched uranium. The concept utilizes a combination of existing transportation packaging, 18 inner canisters, and a novel basket design that includes a borated aluminum flux trap. Criticality and shielding evaluations; fundamental structural, confinement, and thermal assessments; and studies on package operations are presented. The results of this study build significant confidence in the technical feasibility of a high-capacity HALEU transportation package concept while demonstrating the concept’s potential to meet U.S. regulatory requirements.

Eidelpes, Elmar↗
DOE OSTI2025

Dose Exceedance Distance Sensitivity Based on Parametric Uncertainty

Sandia National Laboratories (SNL) collaborated with the US Nuclear Regulatory Commission's (NRC) Office of Nuclear Security and Incident Response (NSIR) and Office of Nuclear Regulatory Research (RES) to investigate the reasonable variability in the estimation of dose exceedance distances. SNL performed calculations using the MACCS code to elucidate the sensitivity of dose exceedance distances to variations in user input parameters.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2021

CCF Parameter Estimations, 2020 Update

This report documents the quantitative results of the common-cause failure (CCF) data collection effort (which included data through 2020) and summarizes the results of the parameter estimation quantification process performed on CCF data in the U.S. Nuclear Regulatory Commission (NRC) CCF database. This is the 2020 update to NUREG/CR-5497, updating data and parameter estimations for CCFs. This release, CCF Parameter Estimation 2020, reflects the CCF data contained within the CCF database, https://rads.inl.gov/Pages/CCF.aspx, by executing (in August 2021) the CCF query rules in the folder SPAR Rules 2020. The data covers the period from 1/1/2006 to 12/31/2020, the most recent 15-year period in which data are available. The use of the most recent rolling 15-year data in parameter estimation differs from previous updates, in which 1/1/1997 was used as the starting date (e.g., 1/1/1997 to 12/31/2015 for the 2015 update, 1/1/1997 to 12/31/2012 for the 2012 update). The new date range (i.e., the most recent 15-year period), was selected for this CCF update so as to be consistent with the date range chosen for the component reliability parameter estimation, and with the effort to include sufficient data for analysis while simultaneously reflecting the most recent industry performance. These results are appropriate for use in probabilistic risk assessment (PRA) studies, including the Standardized Plant Analysis Risk (SPAR) models of commercial nuclear power plants (NPPs) in the U.S. This update may be referred as: U.S. Nuclear Regulatory Commission, "CCF Parameter Estimations, 2020 Update," https://nrcoe.inl.gov/publicdocs/CCF/ccfparamest2020.pdf, November 2021.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

HAZARD ANALYSIS OF DIGITAL ENGINEERED SAFETY FEATURES ACTUATION SYSTEM IN ADVANCED NUCLEAR POWER PLANTS USING A REDUNDANCY-GUIDED APPROACH

Replacing the existing aging analog instrumentation and control (I&C) systems with modern safety control and protection digital technology offers one of the foremost means of performance improvements and cost reductions for the existing nuclear power plants (NPPs). However, the qualification of digital I&C systems remains a challenge, especially considering the issue of software common-cause failures (CCFs), which are difficult to address. With the application and upgrades of advanced digital I&C systems, software CCFs have become a potential threat to plant safety because most redundant designs use similar digital platforms or software in the operating and application systems. With complex designs of multilayer redundancy to meet the single-failure criterion, digital I&C safety systems (e.g., engineered safety-features actuation system [ESFAS]) are of a particular concern in the U.S. Nuclear Regulatory Commission (NRC) licensing procedures. This paper applies a modularized approach to conduct redundancy-guided systems-theoretic hazard analysis for an advanced digital ESFAS with multilevel redundancy designs. Systematic methods and risk-informed tools are incorporated to address both hardware and software CCFs, which provide guidance to eliminate the triggers of potential single points of failure in the design of digital safety systems in advanced plant designs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Phenomena Identification and Ranking Table (PIRT) for heat pipes

Heat pipes are advanced passive thermal management devices that utilize phase change and capillary action to achieve efficient heat transfer. However, due to the complexity of the phenomena coupled in heat pipes, including capillary, phase change, turbulence, and compressibility effects, there are high uncertainties in the predictability of their operational regimes and performance. This PIRT exercise, conducted as a collaborative effort involving the Department of Energy (DOE) Microreactor Program (MRP), the Nuclear Regulatory Commission (NRC), and university partners systematically identifies, reviews, and prioritizes critical phenomena affecting the operation of heat pipes based on their importance and knowledge levels. Additional analyses and discussion are provided for phenomena with high importance and low knowledge, such as wick de-wetting, critical heat flux, contact angles, and pressure dynamics. The discussions included the recognizing challenges and proposing future research directions for both modeling and simulation and experimental efforts. Additionally, the report addresses phenomena with medium importance and low knowledge that could impact heat pipe operation during non-normal or transient operation, including frozen startup, laminar to turbulent transition, geyser boiling, wick priming, underfilling conditions, surface roughness of the wick, NCGs trapped in the wick, and the timescales of startup and shutdown. In conclusion, this comprehensive evaluation serves as a valuable resource for guiding future research and development efforts, supporting the successful integration of heat pipes into critical applications such as nuclear reactors, and contributing to the advancement of heat pipe technologies in safety-critical industries.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2025

Human Factors Considerations for Anticipated Uses of Autonomy in Advanced Reactor Technologies

The objective of this report is examine anticipated advanced reactor designs that incorporate high levels of autonomy in operation of advanced reactor systems or facilities, and to begin identifying the human factors engineering (HFE) considerations relevant to those designs. The insights gained will help identify areas where U.S. Nuclear Regulatory Commission (NRC) may need to develop or update review guidance to adequately address HFE considerations essential for safe operation. The adequacy of existing guidance, along with recommendations for updates or new guidance, may be addressed in future reports. We use the term “landscape analysis” to describe the review, analysis, and characterization of publicly available information on the anticipated future state of the industry regarding particular technologies or operational concepts. This landscape analysis considers the potential range of advanced reactor automation concepts that may be used for monitoring and controlling nuclear systems and facilities, including the potential for highly automated, near autonomous, or fully autonomous operation of advanced nuclear reactors.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Preliminary Plan for Evaluation of Reactor Pressure Vessel Surveillance Materials from Palisades Nuclear Generating Station

The Palisades Nuclear Generating Station (PNGS), located in Michigan, is owned and operated by Entergy. It is a Combustion Engineering 2-loop pressurized water reactor (PWR) producing 805 MWe (2,565 MWth). The PNGS was built between 1967 and 1970, with approval to operate at full power in 1973; the plant’s original license was due to expire on March 24, 2011. An application for 20-year extension was filed in 2005 with the Nuclear Regulatory Commission and was granted on January 18, 2007. Although the plant was scheduled for decommissioning by 2031, Entergy currently plans to close the PNGS in 2022. The PNGS included in its reactor pressure vessel (RPV) surveillance program a capsule, designated A-60, containing specimens of one of the vessel plates and a weld metal with nickel content of about 1.36 wt% and copper content of about 0.20 wt%. This capsule was irradiated to a fluence of 1.8 x 10 20 n/cm 2 . The capsule was removed from its surveillance position in 1995 and has been resident in the spent fuel pool since that time. The material is also of special interest because of its very high nickel content and because of the potential for development of NiMnSi (nickel-manganese-silicon) precipitates, dubbed “late blooming phases.” The surveillance program also includes a capsule, designated T-150, dedicated specifically for thermal aging, which would provide results for at least 33 effective full power years, which is beyond the current thermal-aging database for such materials. Given that license extensions to 60 years of operation have been approved by the US Nuclear Regulatory Commission for most of the currently operating light water reactors in the United States, and that the first extension to 80 years was recently approved, there exists the probability that some RPVs will reach and possibly exceed a fast neutron fluence (> 1 MeV) of 1 x 10 20 n/cm 2 . This is a fluence regime with no US surveillance data and very little test reactor data, except for the Light Water Reactor Sustainability Program–sponsored University of California Santa Barbara Advanced Test Reactor (ATR) ATR-2 project. Thus, the materials in the A-60 capsule represent a valuable resource for directly exploring the effects of commercial surveillance irradiation on a typical plate and a high-nickel weld with similar materials irradiated in the ATR-2 test reactor project. This report provides background information for the surveillance program, previous results of surveillance materials testing, the preliminary plan for capsule retrieval and disassembly, and the plan for testing and microstructural examination of the mechanical test specimens of these unique materials to assess the features induced by very high irradiation fluence or very long thermal aging time

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Pellet cladding mechanical interaction as a potential failure mechanism during a control rod drop accident in a boiling water reactor

Boiling water reactors (BWRs) represent approximately one-third of the operating fleet in the United States, contributing significantly towards the global effort in reducing carbon emissions. Even though most of the operating fleet has been in operation for quite some time, continued advancements in new nuclear fuel (such as accident tolerant fuel) or operating regimes (such as power up-rates and higher burnup operation) necessitates similar advancements in modeling and simulation capabilities. Bison, a component of the Virtual Environment for Reactor Applications (VERA), is a high-fidelity fuel performance code able to explore the fuel performance of a wide variety of fuel types in one-, two-, and three-dimensions. Until recently, the code had not been used for analyses of BWRs. Modeling capabilities have been added for Gd-bearing UO{sub 2} and pure zirconium liners. New models have been added based upon the U.S. Nuclear Regulatory Commission (NRC) guide-lines for hydrogen pickup in Zircaloy-2 claddings and pellet-clad mechanical interaction (PCMI) failure during a reactivity insertion accident (RIA), known as a rod drop accident (CRDA) in BWRs. Implementing and/or improving Bison modeling capabilities extended its analytical reach to areas beyond its original intended purpose. This paper demonstrates one of these capabilities as a proof of concept. Recently developed models enable Bison to provide an alternate approach for cladding integrity determination in CRDA evaluations, which currently use bounding conservative estimates. As part of this demonstration, NRC guidance on hydrogen-pickup and PCMI failure models were utilized in this research. Even though more research is needed in establishing right inputs and process in this area, this paper demonstrates Bison's ability to determine cladding integrity in a CRDA evaluation. This first of a kind demonstration is a proof of concept in this area, which could potentially be extended to a number of other areas where a more accurate cladding integrity determination would be needed. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Optimizing Transmission of Acoustic Signals to Monitor Internal Conditions of Canisters for Dry Storage of Commercial Spent Nuclear Fuel

Safe storage of spent nuclear fuel (SNF) is critical to the nuclear fuel cycle and the future of nuclear energy. In the United States, SNF is stored primarily via two methods regulated by the U.S. Nuclear Regulatory Commission: wet storage in SNF pools and dry storage in dry cask storage systems (DCSSs). After about five years of cooling in spent fuel pools, the fuel assemblies are transferred into DCSSs, and the systems are filled with helium and sealed by welding. Deterioration of conditions inside of a DCSS is reflected in changes in the internal gas properties; this motivates the development of acoustic techniques to monitor internal gas properties, over extended storage periods, using sensors mounted on the exterior of the storage packages. However, a major challenge in collecting acoustic signals is the impedance mismatch between the steel canister shell and the gas. Only a small fraction of the ultrasonic signal can be transmitted through the gas medium. This paper documents experimental studies conducted on a full-scale canister mock-up to capture the gas-borne signals. Damping materials were pasted on the outside, and blocking and unblocking tests were conducted to identify the gas-borne signal. The results show that the excitation frequency plays an important role in maximizing the gas-borne signals. The gas-borne signal was successfully detected at around the theoretical time-of-flight. A high signal-to-noise ratio was achieved in the measurements. Next, the acoustic impedance matching layers were introduced, and the gas signal was drastically improved compared with that using no AIM layers.

Spent nuclear fuel (SNF), Canisters, Internal cond↗
DOE OSTI2022

Westinghouse Accident Tolerant Fuel Phase 2B with Higher Enriched and Higher Burnup Add-On Project Final Technical Report Deliverable Volume 1

The Westinghouse Electric Company LLC (Westinghouse) accident tolerant fuel (ATF) program funded by Westinghouse and the US Department of Energy (DOE) utilized chromium (Cr) coated zirconium alloy cladding with doped UO 2 (ADOPT(TM)) and uranium silicide (U 3 Si 2 ) high density/high thermal conductivity fuel for its lead test rod (LTR) program with irradiation beginning in 2019. ADOPT is a Cr 2 O 3 +Al 2 O 3 doped UO 2 pellet with increased oxidation resistance and density, and increased resistance to fission gas release. Due to the issues with U 3 Si 2 fuel reaction in pressurized water reactor (PWR) environments, uranium nitride (U 15 N) has been substituted for U 3 Si 2 as a long-term fuel option. Cr coated cladding with ADOPT fuel is the near-term Westinghouse EnCore fuel product. The long-term EnCore ® fuel product is SiGA ® SiC/SiC composite cladding with high density/high thermal conductivity UN fuel. In 2020, the higher burnup and higher enriched and (HBHE) program was integrated into the ATF program. The objective of this expanded program is to extend ATF burnups to at least 75 MWd/kgU to economically facilitate 24-month cycles in PWRs. The ATF program now includes ADOPT fuel with enrichments >5% 235 U. Over the past several years, Westinghouse has tested the Cr coated zirconium (Zr) and silicon carbide (SiC) claddings in Westinghouse Churchill autoclaves and the Massachusetts Institute of Technology (MIT) reactor. Additionally, the Cr coated cladding has been tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) and in LTR programs at the Doel 4 and Bryon 2 commercial reactors. High temperature tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried out to determine the time and temperature limits for the Cr coated zirconium claddings. These tests indicate that Cr coated Zr cladding can take temperatures up to about 1500°C for short periods of time without becoming totally oxidized. The main issue is the formation of the Cr-Zr eutectic at 1333°C resulting in the migration of this eutectic inward with the formation of ZrCr 2 which rapidly oxidizes to ZrO 2 on the outside of the tube. The Cr coated Zr cladding also delays the bursting of the tube, reduces the burst area, and reduces hydriding and embrittlement of the Zr which is a major benefit for reducing fuel fragmentation, redistribution, and dispersal (FFRD), the major licensing issue faced by HBHE. The manufacturing parameters for the SiC have been found to have a significant effect on the corrosion rate of the SiC in light water reactor (LWR) conditions and significant improvements have been made in the yield, quality, and oxidation resistance of the SiC cladding by identifying and tightening manufacturing process parameters. Current autoclave results for SiC composite claddings indicate that a corrosion rate of fewer than 2 micrometers per year can be achieved which meets corrosion requirements under normal operating conditions. High temperature steam oxidation tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried and determined that SiC cladding can withstand temperatures up to about 1800°C to 1900°C before excessive corrosion reactions begin, and that the SiC will not balloon and burst. ADOPT fuel pellets were incorporated into the Westinghouse ATF program because of their increased density and oxidation resistance. A topical report supporting the use of ADOPT pellets has been submitted to the NRC and will be approved shortly. ADOPT pellets have been a product in Europe for over 15 years. The additives work to make larger grain sizes which appear to reduce fission gas release during transients as well as increase the density of the pellet. Fuel rod and assembly design in preparation for the lead test rod (LTR) and lead test assembly (LTA) programs is underway as well as licensing efforts with the Nuclear Regulatory Commission (NRC). Finally, accident analyses coupled with economic evaluations for both operating savings as well as fuel savings have been initiated. Modular Accident Analysis Program 5 (MAAP5) calculations indicate that both Cr coated cladding and SiC composite cladding can increase the time to fuel rod loss of geometry for up to two hours longer than current Zr based cladding in a station blackout scenario. This additional time is due to the much higher oxidation resistance of the SiC and Cr coated cladding. These two hours can be used to implement additional response options instituted through the Diverse and Flexible Mitigation Capability (FLEX) program by reactor operators. Both ATF cladding options also reduce hydrogen production which dramatically reduces primary system and containment pressure and the risk of fission product release beyond containment in the unlikely event of an accident. The lower pressure in the system allows more time to feed cooling water to the core, resulting in the avoidance of fuel melting. The coping time is extended indefinitely if the modest water flow provided by FLEX continues. Experimental work on methods to rapidly fabricate SiC composite structures with high density and reduce the fabrication price of SiC fibers while maintaining a high level of performance is needed. Methods for mitigating or stopping the Cr-Zr eutectic are also needed to further improve the oxidation resistance of Cr coated Zr. Minimal (<1%) swelling of U 3 Si 2 and subsequent fission gas release has been demonstrated up to 20 MWd/kgU. Irradiation experiments with U 3 Si 2 fuel in ATR to determine these properties at 40 MWd/kgU were completed but post irradiation examinations were not done since U 3 Si 2 has been replaced by UN. UN has three issues that are being addressed. The first is increasing the oxidation resistance so that there is not excessive reaction up to ~1500°C. While UN increases the pellet density and additives to the UN postponed the temperature at which rapid oxidation occurred by ~100°C to 200°C, this is not enough, and pellet coating options are now being pursued. The second is developing a method to manufacture that does not require the multi-step process of UF 6 to UO 2 to UC to UN. Efforts are underway looking at UF 6 to UN 2 to UN and UF 6 to UF 4 to UN 2 to UN reactions. Finally, an economically acceptable process for potentially enriching the 15 N content of the nitrogen used to make UN to >95% 15N was identified though not experimentally validated. In addition to the work supported by the DOE, research and testing activities are being carried on in a world-wide effort funded by many countries such as Sweden, United Kingdom, Belgium, Netherlands, Spain, Germany, Japan, and France. This work is being facilitated through the Westinghouse led Collaboration for Advanced Research on Accident Tolerant Fuel (CARAT) program. Annual meetings were organized in 2018 and 2019 by Westinghouse as a venue for presentation of this work and to provide for the cross-fertilization of ideas among the many outstanding researchers in the ATF area. No meetings were held in 2020 and 2021 due to the COVID-19 related restrictions on traveling and gatherings. Since SiC, coated cladding, and high-density fuel options are not currently used in the nuclear industry; support from the government and industry members is needed to further the significant effort of setting new standards. The same is true for the Nuclear Regulatory Commission (NRC) which must review and approve the commercial use of these new fuels since all current regulations are oriented toward Zr/UO 2 fuel. Several meetings have been held with the NRC to generate a fast-track approach to licensing ATF using a combination of atomic modeling, in-rod sensors, and in-reactor testing. This approach was memorialized in an “Accelerated Fuel Qualification White Paper” prepared by the Accelerated Fuel Qualification Working Group lead by General Atomics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Westinghouse Accident Tolerant Fuel Phase 2B with Higher Enriched and Higher Burnup Add-On Project Final Technical Report Deliverable Volume 2

The Westinghouse Electric Company LLC (Westinghouse) accident tolerant fuel (ATF) program funded by Westinghouse and the US Department of Energy (DOE) utilized chromium (Cr) coated zirconium alloy cladding with doped UO 2 (ADOPT(TM)) and uranium silicide (U 3 Si 2 ) high density/high thermal conductivity fuel for its lead test rod (LTR) program with irradiation beginning in 2019. ADOPT is a Cr 2 O 3 +Al 2 O 3 doped UO 2 pellet with increased oxidation resistance and density, and increased resistance to fission gas release. Due to the issues with U 3 Si 2 fuel reaction in pressurized water reactor (PWR) environments, uranium nitride (U 15 N) has been substituted for U 3 Si 2 as a long-term fuel option. Cr coated cladding with ADOPT fuel is the near-term Westinghouse EnCore ® fuel product. The long-term EnCore fuel product is SiGA ® SiC/SiC composite cladding with high density/high thermal conductivity UN fuel. In 2020, the higher burnup and higher enriched and (HBHE) program was integrated into the ATF program. The objective of this expanded program is to extend ATF burnups to at least 75 MWd/kgU to economically facilitate 24-month cycles in PWRs. The ATF program now includes ADOPT fuel with enrichments >5% 235 U. Over the past several years, Westinghouse has tested the Cr coated zirconium (Zr) and silicon carbide (SiC) claddings in Westinghouse Churchill autoclaves and the Massachusetts Institute of Technology (MIT) reactor. Additionally, the Cr coated cladding has been tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) and in LTR programs at the Doel 4 and Bryon 2 commercial reactors. High temperature tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried out to determine the time and temperature limits for the Cr coated zirconium claddings. These tests indicate that Cr coated Zr cladding can take temperatures up to about 1500°C for short periods of time without becoming totally oxidized. The main issue is the formation of the Cr-Zr eutectic at 1333°C resulting in the migration of this eutectic inward with the formation of ZrCr 2 which rapidly oxidizes to ZrO 2 on the outside of the tube. The Cr coated Zr cladding also delays the bursting of the tube, reduces the burst area, and reduces hydriding and embrittlement of the Zr which is a major benefit for reducing fuel fragmentation, redistribution, and dispersal (FFRD), the major licensing issue faced by HBHE. The manufacturing parameters for the SiC have been found to have a significant effect on the corrosion rate of the SiC in light water reactor (LWR) conditions and significant improvements have been made in the yield, quality, and oxidation resistance of the SiC cladding by identifying and tightening manufacturing process parameters. Current autoclave results for SiC composite claddings indicate that a corrosion rate of fewer than 2 micrometers per year can be achieved which meets corrosion requirements under normal operating conditions. High temperature steam oxidation tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried and determined that SiC cladding can withstand temperatures up to about 1800°C to 1900°C before excessive corrosion reactions begin, and that the SiC will not balloon and burst. ADOPT fuel pellets were incorporated into the Westinghouse ATF program because of their increased density and oxidation resistance. A topical report supporting the use of ADOPT pellets has been submitted to the NRC and will be approved shortly. ADOPT pellets have been a product in Europe for over 15 years. The additives work to make larger grain sizes which appear to reduce fission gas release during transients as well as increase the density of the pellet. Fuel rod and assembly design in preparation for the lead test rod (LTR) and lead test assembly (LTA) programs is underway as well as licensing efforts with the Nuclear Regulatory Commission (NRC). Finally, accident analyses coupled with economic evaluations for both operating savings as well as fuel savings have been initiated. Modular Accident Analysis Program 5 (MAAP5) calculations indicate that both Cr coated cladding and SiC composite cladding can increase the time to fuel rod loss of geometry for up to two hours longer than current Zr based cladding in a station blackout scenario. This additional time is due to the much higher oxidation resistance of the SiC and Cr coated cladding. These two hours can be used to implement additional response options instituted through the Diverse and Flexible Mitigation Capability (FLEX) program by reactor operators. Both ATF cladding options also reduce hydrogen production which dramatically reduces primary system and containment pressure and the risk of fission product release beyond containment in the unlikely event of an accident. The lower pressure in the system allows more time to feed cooling water to the core, resulting in the avoidance of fuel melting. The coping time is extended indefinitely if the modest water flow provided by FLEX continues. Experimental work on methods to rapidly fabricate SiC composite structures with high density and reduce the fabrication price of SiC fibers while maintaining a high level of performance is needed. Methods for mitigating or stopping the Cr-Zr eutectic are also needed to further improve the oxidation resistance of Cr coated Zr. Minimal (<1%) swelling of U 3 Si 2 and subsequent fission gas release has been demonstrated up to 20 MWd/kgU. Irradiation experiments with U 3 Si 2 fuel in ATR to determine these properties at 40 MWd/kgU were completed but post irradiation examinations were not done since U 3 Si 2 has been replaced by UN. UN has three issues that are being addressed. The first is increasing the oxidation resistance so that there is not excessive reaction up to ~1500°C. While UN increases the pellet density and additives to the UN postponed the temperature at which rapid oxidation occurred by ~100°C to 200°C, this is not enough, and pellet coating options are now being pursued. The second is developing a method to manufacture that does not require the multi-step process of UF 6 to UO 2 to UC to UN. Efforts are underway looking at UF 6 to UN 2 to UN and UF 6 to UF 4 to UN 2 to UN reactions. Finally, an economically acceptable process for potentially enriching the 15 N content of the nitrogen used to make UN to >95% 15 N was identified though not experimentally validated. In addition to the work supported by the DOE, research and testing activities are being carried on in a world-wide effort funded by many countries such as Sweden, United Kingdom, Belgium, Netherlands, Spain, Germany, Japan, and France. This work is being facilitated through the Westinghouse led Collaboration for Advanced Research on Accident Tolerant Fuel (CARAT) program. Annual meetings were organized in 2018 and 2019 by Westinghouse as a venue for presentation of this work and to provide for the cross-fertilization of ideas among the many outstanding researchers in the ATF area. No meetings were held in 2020 and 2021 due to the COVID-19 related restrictions on traveling and gatherings. Since SiC, coated cladding, and high-density fuel options are not currently used in the nuclear industry; support from the government and industry members is needed to further the significant effort of setting new standards. The same is true for the Nuclear Regulatory Commission (NRC) which must review and approve the commercial use of these new fuels since all current regulations are oriented toward Zr/UO 2 fuel. Several meetings have been held with the NRC to generate a fast-track approach to licensing ATF using a combination of atomic modeling, in-rod sensors, and in-reactor testing. This approach was memorialized in an “Accelerated Fuel Qualification White Paper” prepared by the Accelerated Fuel Qualification Working Group lead by General Atomics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Risk Importance Ranking of Fire Data Parameters to Enhance Fire PRA Model Realism

Fire is historically and analytically a significant contributor to nuclear power plant risk. The level of fire risk and the methods, tools and data for modeling this risk is highly debated by experts. One area of debate is the input data used in fire modeling and how to deal with this data’s high uncertainty. This report outlines initial work performed for determining the key parameters causing this uncertainty and how it propagates into nuclear power plant models. This research paves the way for the development of methods to reduce fire data uncertainty used in modeling. The Nuclear Regulatory Commission has mandated that nuclear power plants perform fire risk modeling. However, there are several issues with the current risk modeling implementation that affect the results. Approved modeling methods can be overly conservative and often do not match plant experience. Also, the data used in the modeling can have high uncertainties and is influenced by expert judgement. To evaluate input data uncertainty, researchers performed an initial review of several fire experiments done at Sandia National Laboratories. Uncertainties for fire data can come from many sources, such as experiment design constraints, environmental conditions, or other plant-specific aspects. There are many different significant and insignificant parameters driving the uncertainty. Additionally, the uncertainty of the different input data used in the fire modeling could have a significant or insignificant effect on the entire plant risk. A four-step methodology was developed to perform Integrated Probabilistic Risk Assessment Importance Ranking. A demonstration case using these steps was set up and three of the four steps were completed in fiscal year (FY) 2019 and the fourth step done FY 2020. These steps are: 1. The qualitative analysis of potential sources was conducted with the following items identified for the demonstration. • Maximum heat release rate • Time to maximum heat release rate • Duration of max heat release rate • Time to decay • Thermal conductivity of concrete • Specific heat of concrete • Density of concrete • Cable jacket thickness 2. A quantitative characterization of dominant sources of uncertainty was performed. A list of distributions and determined values of the dominant sources is shown in Appendix A. 3. A quantitative screening of the potential sources of uncertainty using Morris Elementary Effects Analysis was completed. An experimental model using the physics-based fire modeling tool Fire Dynamics Simulator was developed and coupled with the Risk Analysis Virtual Environment. The Morris analysis identified at least two parameters that can be eliminated as significant contributors (specific heat of concrete and cable jacket thickness). 4. Global importance measure (Global IM) analysis to generate a comprehensive ranking based on their influence on the plant risk. In this research, a moment-independent Global IM is used since it can address (a) uncertainty in the input parameters of the fire model, (b) uncertainty in the risk outputs, and (c) non-linearity and interactions among input parameters in the fire model, more accurately than the correlation-based and variance-based global methods. The observations from the research showed that, depending on the initial and boundary conditions of the fire scenarios, fire-induced damage could have a very small probability and could be dominated by the tail of the uncertainty distribution; hence, the accuracy of the correlation-based and variance-based methods is questionable. The moment-independent Global IM analysis in this research provides a better understanding of how experimental uncertainty data affects industry’s plant models and where improvements in that data will have the largest benefit for improving fire modeling accuracy in causing core damage. Among the five unscreened parameters obtained from the Morris EE analysis, the Global IM analysis results for the case study indicated that max heat release rate and fire location are the most important parameters. The report also outlines benefits of using a unified computational platform that integrates the underlying simulations (e.g., a fire progression model), quantitative screening (using the Morris EE method), and the Global IM analysis. A unified platform can (i) facilitate the ranking of input parameters considering multiple key fire scenarios simultaneously, rather than considering one scenario at a time, (ii) contribute to more explicit and accurate treatment of dependencies at multiple levels of Fire PRA, (iii) facilitate the sampling-based uncertainty quantification for Fire PRA, and (iv) help generating both “industry-wide” and "plant-specific" ranking of uncertainty sources in Fire PRA. Future research should be done to include additional parameters such as detection/suppression or cable fire spread. Adding a PRA software such as SAPHIRE to the RAVEN platform would help with plant model integration and improve treatment of fire-induced dependency. The I-PRA risk importance ranking methodology offered in this report can provide valuable information for efficiently (a) enhancing the realism of Fire PRA for existing plants and (b) supporting the development of Dynamic Fire PRA for advanced reactors and new plants.

97 MATHEMATICS AND COMPUTING↗