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At least 73 records · Page 4

Review of ECCS Acceptance Criteria and Experimental Basis Evolution Toward Fuel Fragmentation, Relocation, and Dispersal Studies

The U.S. nuclear industry is pursuing extensions of light water reactor (LWR) fuel burnup and enrichment limits to approximately 75 GWd/t and 10 wt.% 235 U to achieve economic and operational benefits. A central safety consideration in this effort is the behavior of high burnup (HBu) fuel during loss-of-coolant accidents (LOCAs), particularly fuel fragmentation, relocation, and dispersal (FFRD). Here, this work provides a historical and technical review of U.S. LOCA regulation and experimentation, clarifying how the evolution of Emergency Core Cooling System (ECCS) acceptance criteria in 10 CFR 50.46 has shaped both testing approaches and interpretations of fuel safety. The study revisits the original intent of the ECCS criteria, showing that the peak cladding temperature and equivalent cladding reacted limits were developed as surrogates to preserve a coolable geometry. The explicit inclusion of the coolable geometry criterion in the regulation was intended to emphasize the underlying safety philosophy and as a safeguard against unforeseen failure modes, an intent that remains directly relevant to modern concerns regarding FFRD. The review traces the lineage of HBu LOCA experiments to the Argonne National Laboratory furnace tests, from which subsequent programs at Studsvik, Halden, and Oak Ridge National Laboratory were derived. These tests employed a 5 °C/s heating rate inherited from early embrittlement studies, a stylized temperature history that does not represent actual LWR LOCA thermal-hydraulics. Comparison of these test conditions to pressurized water reactor large break LOCAs and separate effects data indicates that the existing HBu LOCA database may not be fully applicable to all LWR LOCA scenarios, from which a qualitative framework for applicability is proposed.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Consensus DOE Advanced Fuels Campaign TREAT/SATS Test Plan [Slides]

This record is comprised of summary slides of the Combined TREAT-LOC & SATS Integral LOCA Experiment Plan. The experimental program has been developed to specifically address data gaps and opportunities identified through detailed review of the existing public knowledgebase on LOCA FFRD and specific experimental development for prototypic LOCA conditions for LWR systems. The test program relies on a unique combination of in-pile and out-of-pile experimental approaches to (1) provide clear tieback to the existing integral and semi-integral LOCA experiment database using state-of-the-art facilities. More importantly, this program will systematically investigate the impacts of: (2) prototypic HBu fuel and cladding thermomechanical behaviors under postulated LWR LOCA conditions never fully investigated before. These conditions correspond with prototypic decay-energy heat up (DEH) and stored-energy heat up (SEH) conditions. Unique TREAT capability will provide first evaluation of SEH conditions on HBu fuels. The test program includes an emphasis on developing improved mechanistic understanding of key phenomena through independent experimental systems, development of a database to support fuel performance modeling tools, world leading advanced materials characterization, and the most advanced approach to in-situ diagnostics ever deployed to evaluate FFRD. The results will represent a significant leap forward in the evaluation of prototypic conditions and novel data to support modeling development and validation, as well as to inform the technical basis of LOCA-induced FFRD.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Effect of spacer grids on high-burnup fuel fragmentation, relocation, and dispersal

Increasing the fuel burnup limit in light-water reactors to improve fuel cycle economics requires a strong technical foundation. Experimental observations from the Halden and Studsvik programs have revealed severe fuel fragmentation during loss-of-coolant accident (LOCA) conditions, highlighting the need for additional technical evaluation. Consequently, further LOCA test data are needed to complement existing findings and improve the understanding of fuel fragmentation, relocation, and dispersal (FFRD) behavior. Oak Ridge National Laboratory’s Severe Accident Test Station has played a significant role in advancing the understanding of high-burnup fuel fragmentation, relocation, and dispersal phenomena. One remaining gap in the available experimental database is the effect of fuel assembly structural features on cladding deformation behavior during a LOCA, and more specifically, their impact on the fuel’s ability to fragment, relocate, and disperse. Recent analyses using the BISON fuel performance code suggest that cladding deformation near grid spacers will remain below the 3% threshold that has been reported in the NRC Research Information Letter, indicating that the cladding could remain mechanically constrained during the LOCA event. This paper builds upon the BISON analyses to design and conduct a series of out-of-cell tests aimed at further evaluating cladding deformation in and around grid spacers. In addition, these tests were used to assess local cladding temperature conditions and compare them against analytical predictions in order to better replicate expected in-reactor behavior. Finally, an in-cell high-burnup LOCA test was designed and performed to evaluate the effects of a grid spacer, or cladding restraint, on fuel fragmentation, relocation, and dispersal susceptibility. The high-burnup test results differed from those of historical LOCA experiments, with a recorded rupture temperature of 861°C. Two ballooned regions and corresponding rupture openings were observed, with rupture widths of approximately 0.64 mm for both ruptures and rupture lengths of 4.8 mm and 5.6 mm, respectively.

Capps, Nathan [ORNL]↗

MECHANISTIC MULTIPHYSICS MODELING OF CLADDING RUPTURE IN NUCLEAR FUEL RODS DURING LOSS-OF-COOLANT ACCIDENT CONDITIONS

The Loss of Coolant Accident (LOCA) is a design basis accident that is included as part of the safety analysis of nuclear power plants. As the nuclear industry desires to increase the cycle length and discharge burnup of existing nuclear power plants they must demonstrate safe operation during a LOCA on high burnup fuel. During a LOCA transient on high burnup fuel rods, the rods may undergo a process known as fuel fragmentation, relocation, and dispersal (FFRD). To permit dispersal, the cladding encapsulating the fuel must rupture with an opening size large enough to allow the fragmented fuel particles to release. Current licensing tools used by industry and the United States Nuclear Regulatory Commission are limited in geometric fidelity and materials that can be analyzed. These simulation tools generally employ a quasi-two-dimensional (1.5D or Layered1D) or 2D-RZ axisymmetric geometric representations exclusively. While a valid approach under some instances, there are times when important physics have an asymmetric behavior in the fuel rod. Examples include fuel fragmentation, thermal-hydraulic boundary conditions, and cladding rupture, all of which are important for LOCA analysis. As industry pursues burnup extensions it must be demonstrated that fuel dispersal can be mitigated or eliminated. To do this, an understanding of the rupture opening after cladding failure is required. This work presents the development of a model for predicting the size and location of the rupture opening in failed fuel rods during LOCA conditions using advanced modeling and simulation tools. In order to supply the rupture model with appropriate boundary conditions, improvements to fuel fragmentation, axial relocation and oxidation modeling were required. First, the eXtended Finite Element Method (XFEM) is used to mechanistically predict the number of fuel fragments that form due to material strength randomization, criteria for strength randomization, mesh density, power ramping rates and irradiation effects. These predictions with associated uncertainty were compared to empirical correlations developed for UO2 verifying that they can be used with increased confidence in subsequent axial relocation analyses. Secondly, a new first-of-its-kind Layered2D computational framework was developed that provides the ability to apply azimuthally varying boundary conditions while providing discrete layers to track fuel movement during the LOCA. An existing fuel axial relocation model developed for Layered1D was extended to work within the Layered2D framework. A large sensitivity study was performed on the initial version of the model to identify modeling parameters of particular importance, with the emissivity used for radiation after blowdown being the primary source of uncertainty. Then, a simplistic approach to incorporate mechanical degradation of the cladding due to oxidation was also developed to investigate the impact of reduced cladding thickness on predictions of the time to failure of cladding tubes. It was found that the cladding will typically rupture prior to a reduction in thickness that is sufficient to impact the rupture behavior. A model was then developed for predicting cladding rupture that transfers the cladding surface temperatures, rod internal and external pressures, fast neutron fluence, and fast neutron flux from a more detailed Layered1D, Layered2D, or 2D-RZ analysis to a 3D cladding only analysis. Comparisons of the rupture model to a few experiments indicate reasonable predictions. The rupture model was then applied to two accident tolerant fuel concepts (FeCrAl and Cr-coated Zircaloy) where it predicted that both ATF concepts would have smaller rupture openings and delayed rupture times than the standard Zircaloy-4 cladding material under identical loading conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Loss of Coolant High Burnup (LOC-HBu) Program

LOC-HBu is a joint experimental program (JEEP) operating within the Nuclear Energy Agency’s (NEA’s) framework for irradiation experiments II (FIDES-II). LOC-HBu is dedicated to the understanding of light water reactor (LWR) fuel performance at high burnup under loss of coolant accident (LOCA) conditions. LOC-HBu aims to support burnup extension needs by addressing identified R&D priorities to achieve an improved understanding of fuel fragmentation, relocation, and dispersal (FFRD) of HBu fuel during LOCA events. The need for such experiments was identified in the United States by the Fuel Performance Testing Technical Expert Group (FPTTEG) under the Electric Power Research Institute (EPRI)’s Collaborative Research on Advanced Fuel Technologies (CRAFT) framework. A combined in-pile and furnace testing program plan was developed by researchers at Idaho National Laboratory (INL) and Oak Ridge National Laboratory (ORNL) which was reviewed and approved by the FPTTEG Combined TREAT-LOC and SATS LOCA Experiment Plan. The first 4 tests identified in this plan are being put forward by the U.S. Department of Energy (U.S. DOE) and INL for inclusion in the FIDES-II second triannual work period. The data produced under this plan will be used to further validate and confirm existing models and inform future R&D and model development. The experimental program was specifically developed to address data gaps and opportunities identified via detailed review of the existing public knowledge base on LOCA FFRD, as well as reviewing specific experimental development activities regarding prototypic LOCA conditions for light-water reactor (LWR) systems. The program will systematically investigate the impacts of prototypic HBu fuel/cladding thermomechanical behaviors under postulated LWR LOCA conditions not yet fully investigated. These conditions correspond with prototypic decay-energy heatup (DEH) and stored-energy heatup (SEH) conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Burst characteristics of advanced accident-tolerant FeCrAl cladding under temperature transient testing

Here assessment of burst characteristics of accident-tolerant fuel (ATF) claddings is essential to evaluate the safety margins of nuclear reactors, and better understanding can enable accelerated licensing for reactor concepts that include the new materials. Therefore, this study investigated the burst behavior of an ATF candidate of C26M, which is an iron–chromium–aluminum alloy (FeCrAl) under transient testing like the simulated loss-of-coolant accident (LOCA) conditions, except the water-quenching phase, in light-water reactors (LWRs). The effect of LOCA specimen length was assessed in terms of post-burst tube parameters. No critical length effect was determined on the burst pressure, burst location, and burst size measurements. Burst temperature showed larger variation likely due to its measurement approach used in this study. The post-test diametral strain was identified as the critical parameter to reduce the specimen length as compared to tube burst length or width. Postmortem optical metrology and digital image correlation were employed to determine the local strain-state during the simulated LOCA, which showed the loading path was close to equibiaxial conditions in regions away from the burst location, rather than internally pressurized conditions (or “plane-strain” tension). Pst-test microstructural characterizations of the FeCrAl revealed that ductile damage was present at the edge of the outer radial surface while the rest of the material was ruptured via cleavage at LOCA burst temperatures. Furthermore, internal grain boundary cracks were observed at locations away from the tube burst region. This behavior was considered to occur during the cooling down period of the simulated LOCA test. Overall, this study aimed to provide essential data for fuel performance code development by considering micromechanics of the deformation and failure.

36 MATERIALS SCIENCE↗

Characterization of modeling and experimental data inconsistencies from burst testing for high-burnup commercial fuel rod applications

Fuel fragmentation, relocation, and dispersal are some of the largest issues remaining in the nuclear industry before rod-average burnup can be increased beyond 62 GWd/tU. The issue is primarily related to the potential for fuel to be dispersed into the reactor primary system, which may increase public risk. One way to prevent dispersal is to avoid cladding burst. The objective of this work is to support the high burnup safety case by evaluating cladding burst under high-burnup, full-length fuel rods and to identify uncertainties that could improve model predictions. The results of this analysis will evaluate realistic, prototypic loss-of-coolant accident (LOCA) conditions; support future cladding burst test designs; and inform the development of mechanistic material models. Realistic high-burnup operating conditions were implemented in the BISON fuel performance code to simulate steady-state and LOCA transient fuel rod evolution to the point at which cladding burst occurred. Parametric studies are performed to assess code response to changes in rod internal pressures and heating rates. Results were compared with simulated LOCA experiments to identify inconsistencies between commercial fuel rod analysis and experimental validation. The representative full-length fuel rod LOCA simulation results did not agree with cladding burst tests. Cladding burst tests indicated burst occurring well below (100–150 °C) those calculated in the full-length fuel rod LOCA analysis. Further investigation indicated that the cladding burst tests do not appear to be representative for full-length fuel rods. The inconsistency investigated in this work showed that the differences between the BISON simulation and the experiment's cladding burst conditions arise from an incomplete characterization of the cladding surface temperature, detailed rodlet characterization, lack of cladding strain measurements, and uncertainty in the cladding creep and failure models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

3D probabilistic fracture mechanics / computational fluid dynamics simulation of a reactor pressure vessel under transient conditions

Reactor pressure vessels (RPVs) are safety-critical light-water-reactor components that, under irradiation, experience long-term material degradation in the form of embrittlement. This can increase their susceptibility to fracture under thermal-shock conditions, which could occur during off-normal transients such as loss-of-coolant accidents (LOCAs). During a LOCA, the most severe conditions for the RPV occur when emergency core cooling water is injected through the cold legs into the water-and-steam-filled RPV. The rapid cooling of the downcomer and internal RPV surface causes decreased temperature and elevated thermally driven tensile stresses in the RPV wall. This, combined with long-term material embrittlement, may cause fracture initiation at pre-existing flaws, challenging the integrity of the RPV. Assessing RPV integrity during transients with a large spatial variation in the coolant temperature requires a modeling approach that considers the effects of spatially varying coolant temperature on the fracture probability of a population of flaws distributed throughout the RPV, accounting for spatially varying embrittlement. Here, the present study addresses this need by demonstrating first-of-its-kind coupling of a high-fidelity 3D computational fluid dynamics code with 3D probabilistic fracture mechanics This was accomplished using representative models of a pressurized-water reactor subjected to small- and medium-break LOCA conditions, both of which can result in large spatial temperature variations. While the observed impact of accounting for 3D effects was minimal under the small-break LOCA this study indicates a significant increase in the probability of fracture initiation under the medium-break LOCA when 3D effects are considered, relative to a spatially uniform cooling scenario.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Modeling and Simulation of Fuel Dispersal During the Loss-of-Coolant Accident

This document is the compilation of the milestone portion to a larger end of project NEUP report. The executive summary of the modeling portion is provided below: In the event of cladding rupture during a postulated LOCA in a pressurized water reactor, fuel particles, along with fission gases, can be expelled into the reactor core from the fractured fuel rod, a phenomenon referred to as fuel dispersal. The initial stage of fuel dispersal is strongly influenced by the high-pressure ejection of fuel fragments, the size and geometry of the ruptured cladding, and the depressurization history of the fuel rod during the postulated LOCA transient. Depending on the location of the burst orifice relative to the quench front, the dispersal event represents an intricate three-phase flow and heat transfer phenomenon, where high-temperature fuel particles carried by the fission gases interact with the coolant within the narrow subchannels of the fuel assemblies, inducing localized phase change. Given the unique multiphysics nature of this phenomena, the current study develops a dedicated computational framework to predict the mass distribution and cooling of dispersing fuel particles, facilitating post-accident assessment and management of the fuel assemblies. Considering the scale of nuclear reactor applications, a continuum three-fluid model is proposed for simulating the transport of solids within the reactor core. With high-temperature fuel fragments within the liquid media, nucleation sites inducing phase changes are dispersed within the flow domain. Coupled with the fact that the transient dispersal event occurs on different time scales than other three-phase flow applications, this study derives a time-averaged three-fluid flow model without losing generality. The assumptions regarding the continuum treatment of the solid phase and the modeling of fuel dispersal behavior are incorporated to simplify the governing equations and derive applicable closure relations. The computational validation of the model was conducted using adiabatic experimental results obtained from ongoing research at Oregon State University, focusing on characterizing fuel dispersal behavior during simulated LOCA conditions. Settlement characteristics of the solids, quantified by the probability distribution of equivalent particles, closely matched the probability density functions reported in experimental studies. The transport of fuel particles within a scaled 5 × 5 lattice of a pressurized-water reactor rod bundle geometry was modeled through a two-fluid Eulerian framework. The required boundary conditions were evaluated from the fuel performance code BISON in a postulated large-break LOCA scenario. The modeling framework considered solid fuel particles as granular matter, interacting with the gaseous dry steam phase and fission gases through the governing interfacial momentum exchange between the participating fluids. The simulation results provided the volume fraction of the solids obtained at the bottom surface of the enclosing tank geometry. Postulated LOCA leading to fuel dispersal phenomena involves the strong coupling between fuel thermomechanics, cladding deformation, thermal-hydraulics, and fuel particle transport. Incorporation of such a strong coupling in numerical simulation is performed by coupling the multiphysics solvers. In the case of fuel dispersal, a strong coupled simulation can be performed by coupling the BISON code for fuel performance, the TRACE code for system-level thermal hydraulics, and fuel particle transport in Multiphysics Object-Oriented Simulation Environment (MOOSE). For such intricate infrastructure, the MOOSE Framework eases the data transfer between codes. The recent version of MOOSE has incorporated the Navier-Stokes module for the fluid flow. An exploratory exercise was done to gain familiarity with finite volume capabilities in the MOOSE framework to incorporate the Spalart-Allmaras (SA) turbulence model. New finite-volume and auxiliary kernels were introduced to assemble the SA transport equation, compute turbulent viscosity, and evaluate wall distance and diagnostic turbulence terms, fully integrated with existing Navier-Stokes modules. A turbulent lid-driven cavity at a Reynolds number of approximately 10,000 is used for verification. MOOSE shows the robust solver convergence and produces the turbulent features. But it underpredicts the velocity profile and turbulent quantities, emphasizing the need to develop improved SA near-wall treatments (e.g., low-Re corrections or wall functions) as a key direction for future work.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DEVELOPMENT OF TRANSIENT FISSION GAS RELEASE CAPABILITIES TO STUDY HIGH BURNUP COMMERCIAL FUEL PERFORMANCE UNDER LOSS OF COOLANT ACCIDENT CONDITIONS

The contribution of transient fission gas release to the burst behaviour of high burnup fuel during a loss of coolant accident (LOCA) for commercial light water reactors is a complex phenomenon that is not fully understood. During the temperature ramp associated with a LOCA, there is significant, additional transient fission gas release in excess of steady state fission gas release from normal operation. The timing of this release and the various conditions that impact this release warrant further study. To better characterize this phenomenon, a system was developed to capture and characterize fission gas released from irradiated fuel during simulated LOCAs. This system is an upgrade to the existing Oak Ridge National Laboratory Severe Accident Test Station LOCA test apparatus and detects fission gas by gamma counting cryogenically cooled cold traps and by using an online gas mass spectrometer. The examined fuel can be pressurized or open to the furnace atmosphere. The design and operation of this new capability are discussed. Results from the first tests on high burnup fuel are presented. In the initial test, the LOCA relevant transient fission gas release was 5.3% for an unpressurized segment. Post-test microscopy on the tested samples is presented to demonstrate the likely radial source of transient fission gas release.

Harp, Jason↗

Evaluating transient fission gas release in high burnup light water reactor fuel during loss of coolant accident conditions via new capabilities

In this work, the role of transient fission gas release (tFGR) in the cladding burst behavior of high burnup fuel during a loss-of-coolant accident (LOCA) in commercial light water reactors was further investigated via the use of a new apparatus. During the LOCA-related temperature ramps of high burnup fuel, the release of fission gases exceeds the steady-state release observed under normal operating conditions. An enhancement was made to the Oak Ridge National Laboratory Severe Accident Test Station (SATS) to probe the various factors influencing tFGR. Experiments were performed on commercially irradiated, zirconium-clad uranium dioxide fuel, and this paper details the design of the experimental setup, the initial test results, and the subsequent post-test analyses. Notably, the first test on high burnup fuel demonstrated a LOCA-relevant tFGR of 5.3% from an unpressurized fuel segment. The ultimate tFGR was 10.7% for beyond LOCA conditions. A follow-up test on similar fuel revealed a tFGR of 12.6% under comparable conditions. Microstructural analysis and an analysis of the released gas provide some insight regarding the source of tFGR in the fuel. Finally, a grain boundary bubble model may aid in the interpretation of the results and offer a guide for future work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Mesoscale simulations of High Burnup Fuel Fragmentation: Applying phase-field modeling to understand high burnup fuel fragmentation during loss of coolant accident conditions

During a loss-of-coolant accident (LOCA) in a nuclear power plant, a rapid increase in temperature is experienced in the fuel. In commercial light water reactors (LWRs), the high burnup structure (HBS) forms in regions of the UO 2 fuel where local burnup is high, characterized by smaller grain sizes and large, overpressurized bubbles. During a LOCA transient, fuel in the HBS region is susceptible to fine fragmentation, where the fuel breaks up into micron-size fragments (sometimes referred to as pulverization). To better understand the mechanisms behind this phenomenon, mesoscale computational modeling using the Idaho National Laboratory code Marmot has been employed to simulate the process of HBS formation and response to a LOCA transient. The process of complete and partial HBS formation was demonstrated in prototypical LWR conditions. The simulated HBS microstructures from these simulations were passed to a phase-field model of fracture. To provide a more direct comparison with experiments, a set of experiments conducted by Studsvik on fine fragmentation/pulverization during LOCA conditions was simulated using the BISON fuel performance code. The temperature profiles from the BISON simulations were passed to a phase-field model to determine the gas bubble pressure as a function of time. These pressure histories were used in a phase-field model of fracture to determine under what conditions and in which types of bubbles fine fragmentation was likely to occur.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Out-of-Pile Testing and Instrumentation Transient Water Irradiation System

Current initiatives to increase the burnup of conventional nuclear fuels past the approximate 62 GWd/t limit have been spurred on by direct savings to refueling and waste storage. The technical justification for a new license limit requires extensive qualification through experimental testing. Unlike beginning-of-life fuels, high-burnup fuels are more susceptible to fuel fragmentation, relocation, and dispersal (FFRD), therefore more data is needed to characterize fuels under key accident scenarios. The Transient Reactor Test Facility (TREAT) located at the Idaho National Laboratory has developed a testing apparatus architecture to test fuels and claddings at prototypic conditions. The Transient Water Irradiation System (TWIST) is the latest iteration of a testing device capable of conducting loss of coolant accidents (LOCAs) in TREAT. The Out-of-Pile Testing and Instrumentation TWIST (OPTI-TWIST) is an electrically heated device that is analogous to TWIST. OPTI-TWIST allows for detailed instrumentation and thermal-hydraulic characterization. TWIST ultimately aims to conduct the most advanced in-situ diagnostics to evaluate FFRD in a prototypic LOCA. Moreover, it will explore the phenomenological bifurcation of a decay-energy heat up driven LOCA and a stored-energy heat up driven LOCA. The instrumentation suite includes conventional thermocouples and pressure transducers in addition to an electro impedance sensor, an acoustic emission sensor, an optical pressure sensor, and an optical pyrometer. Characterizing these instruments in OPTI-TWIST eliminates complications of irradiation effects while preserving extreme thermal-hydraulic conditions. Finally, benchmarking both devices to a thermal-hydraulic code like the Reactor Excursion and Leak Analysis Program (RELAP)5-3D provides a unique opportunity for iteration. Pre-test predictions and post-test interpretations inform the physical designs, operational procedures, test conditions, and instrumentation types and positions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗