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DOE OSTI2023

Comparative Thermal Performance of Downdraft and Updraft Forced Convection in a Representative 3x3 PWR Fuel Assembly

A plethora of theoretical, numerical, and experimental investigations have relied on updraft forced convection of operating fuel assemblies for light water-cooled fuel assemblies. The inertial scales of turbulence in updraft flow through PWR fuel assemblies are primarily influenced by upstream mixing patterns within the lower plenum and consequent acceleration of flow through the lower core and support plates into the bottom nozzles. In secondary heat transfer applications such as steam generation, recuperation and economization, downdraft flow is utilized to retrieve maximal sensible heat from the primary coolant. Sub-channel volumes aligned vertically could also benefit from force of gravity in developing turbulent flows. A large reduction in pumping power, associated cost of operation and maintenance, and improved balance of plant is suggested to be possible through downdraft forced convection in PWR-type reactors. This article explores the impact of downdraft forced convection within the well-studied 3x3 sub-channel within a range of 20 hydraulic diameters across a representative intermediate flow mixing grid. A range of inflow Reynolds number from 10,000 to 60,000 is simulated over a range of equivalent heat loads of 20% to 100% spanning 20 hydraulic diameters. The fuel rods are represented in true geometric detail, and a constant-value heat profile is assumed for the investigation. At each inflow condition, the turbulence intensity, peak velocity, local heat transfer coefficient, peak wall heat flux, and peak wall temperature are collected across the sub-channel and compared with an updraft configuration evaluated at the same conditions.

Rao, Vivek↗

DOE OSTI2017

Characterization of local hydride re-orientation in high burn-up PWR fuel rods induced by high pressure at high temperatures

Hydride re-orientation in high burn-up PWR fuel rods was induced by high pressure at high temperatures. The high-burnup specimens were sectioned from PWR rods taken from a 15×15 assembly of the H.B. Robinson (HBR) Unit 2 reactor. Out-of cell benchmark tests performed on unirradiated hydrided Zircaloy-4 specimens were conducted to determine the appropriate temperature, pressure, cooling rate, and number of cooling cycles for the reorientation of the irradiated in-cell specimens. The in-cell hydride reorientation tests were performed using high-burnup fuel specimens under a hoop stress ≈145 MPa at 400°C. The specimens were heated to the target temperature of 400°C, held for 3 hours, cooled at 1°C/min to 170°C,and then heated at 1°C/min to the target temperature again for five cycles. Post test metallographic examinations showed that a significant amount of radial hydrides were induced in the HBR fuel rods. The length of radial hydride was up to 60 μm. For unirradiated materials, the ductility of the radial hydride treated specimens is significantly reduced as compared to the as-hydrided specimens having the same hydrogen concentration (≈300 wppm in this work). The mechanical testing on irradiated fueled samples with hydride reorientation experiments have been performed, and will be reported separately in the near future.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2014

Effects of Multiple Drying Cycles on High-Burnup PWR Cladding Alloys

The purpose of this research effort is to determine the effects of canister/cask vacuum drying and storage on radial hydride precipitation in high-burnup (HBU) pressurized water reactor (PWR) cladding alloys during cooling for a range of peak drying-storage temperatures, internal gas pressures, and hoop stresses. The HBU PWR cladding alloys have a wide range of hydrogen contents and varying hydride morphology after in-reactor service. Radial hydrides are a potential embrittlement mechanism for HBU cladding subjected to hoop-stress loading, which may be significant during normal cask transport. Ring compression tests (RCTs), which simulate pinch-type loading at grid spacers, are used to determine cladding ductility as a function of RCT temperature and the ductile-to-brittle transition temperature (DBTT). Previous tests were conducted with pressurized and sealed cladding rodlets heated to 400°C (the NRC ISG-11, Rev. 3, limit for all fuel burnups under normal conditions of storage and short-term loading operations) and cooled slowly at 5°C/h. Following this drying-storage simulation, the DBTT for HBU M5 ® decreased from 80°C to 70°C to <20°C as the peak hoop stress decreased from 140 MPa to 110 MPa to 90 MPa. Under similar drying-storage conditions, the DBTT for HBU ZIRLO™ decreased from 185°C to 125°C to 20°C to <20°C as the peak cladding hoop stress decreased from 140 MP to 110 MPa to 90 MPa to 80 MPa. These tests were conducted with a single heating-cooling cycle as simulation of the vacuum drying process with one drying cycle. (ISG-11, Rev. 3 allows <10 drying cycles, with cladding temperature variations that are less than 65°C each.)

Billone, M. C.↗

DOE OSTI2015

Bias Estimates Used in Lieu of Validation of Fission Products and Minor Actinides in MCNP K eff Calculations for PWR Burnup Credit Casks

The U.S. Nuclear Regulatory Commission (NRC) Division of Spent Fuel Storage and Transportation recently issued Interim Staff Guidance (ISG) 8, Revision 3. This ISG provides guidance for burnup credit (BUC) analyses supporting transport and storage of PWR pressurized water reactor (PWR) fuel in casks. Revision 3 includes guidance for addressing validation of criticality (k eff ) calculations crediting the presence of a limited set of fission products and minor actinides (FP&MA). Based on previous work documented in NUREG/CR-7109, recommendation 4 of ISG-8, Rev. 3, includes a recommendation to use 1.5 or 3% of the FP&MA worth to conservatively cover the bias due to the specified FP&MAs. This bias is supplementary to the bias and bias uncertainty resulting from validation of k eff calculations for the major actinides in SNF and does not address extension to actinides and fission products beyond those identified herein. The work described in this report involves comparison of FP&MA worths calculated using SCALE and MCNP with ENDF/B-V, -VI, and -VII based nuclear data and supports use of the 1.5% FP&MA worth bias when either SCALE or MCNP codes are used for criticality calculations, provided the other conditions of the recommendation 4 are met. The method used in this report may also be applied to demonstrate the applicability of the 1.5% FP&MA worth bias to other codes using ENDF/B V, VI or VII based nuclear data. The method involves use of the applicant s computational method to generate FP&MA worths for a reference SNF cask model using specified spent fuel compositions. The applicant s FP&MA worths are then compared to reference values provided in this report. The applicants FP&MA worths should not exceed the reference results by more than 1.5% of the reference FP&MA worths.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Isotopic and Fuel Lattice Parameter Trends in Extended Enrichment and Higher Burnup LWR Fuel Vol I: PWR fuel

Commercial light water reactor (LWR) operators and fuel vendors in the United States are pursuing changes to nuclear fuel that include extended enrichment (EE) and accident-tolerant fuel (ATF) designs. The term EE (8% > 235 U > 5%) is used in this report to refer to a subset of high assay low-enriched uranium (HALEU) that is considered usable in commercial US LWRs in the near term. ATF features are designed to improve fuel system performance under accident conditions. One goal of EE is to improve fuel cycle economy by enabling fuel to be depleted to higher burnup than the typical current maximum pin burnup limits (62 gigawatt-days per metric ton of uranium [GWd/MTU]). Adoption of EE, ATF, and high burnup (HBU) fuels in the US commercial fleet requires a clear understanding of the effects on core physics parameters and used fuel isotopic content, as well as confidence in the accuracy of computer code predictions over an expanded range of materials, enrichment, and burnup. A thorough understanding of the applicability and adequacy of benchmark data (e.g., criticality, decay heat, isotopic content) for computer code validation is necessary to ensure that appropriate safety margins are maintained. To prepare for and support these potential changes, the effects of EE, ATF, and HBU are being assessed for selected representative LWR fuel designs. The project is divided into phases: this report summarizes the findings of Phase 1, which focuses on the lattice physics parameter and used fuel isotopic changes for a conventional Westinghouse 17×17 pressurized water reactor (PWR) design. The primary investigation tool is the SCALE Polaris code using the SCALE 56-group Evaluated Nuclear Data File (ENDF)/B-VII.1 cross sections. The goal of the current work is to (1) identify and explain important effects of EE and HBU (reactivity, lattice physics, and isotopic effects) assuming that PWR fuel design and usage remain similar to those for current enrichment fuel, (2) provide limited code-to-code comparisons with higher order cross section libraries and/or codes, and (3) identify any apparent anomalous trends in the results for further investigation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Review of Experimental Assay Data for PWR Spent Fuel

The primary objective of this study is to review existing experimental assay data for pressurized water reactor (PWR) spent fuel, identify gaps in existing data, and asses the potential value of new isotopic measurements for nuclides relevant to burnup credit, shielding, and decay heat validation. The impact of adding new, high-quality experimental assay data on uncertainties associated with PWR depletion validation is discussed. In particular, the discussion focuses on potential benefits of additional isotopic measurements for spent fuel rods available at Oak Ridge National Laboratory. Selected measurements for these spent fuel rods are ongoing in Fiscal Year 2019 (FY19) as funded by the US Department of Energy (DOE) under the Spent Fuel and Waste Science and Technology (SFWST) Program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Fracture Toughness and Fatigue Crack Growth Rate Testing of Baffle-Former Bolts Harvested from a Westinghouse Two-Loop Downflow Type PWR

As one of the pressurized water reactor (PWR) internal components, baffle-former bolts (BFBs) are subjected to significant mechanical stress and neutron irradiation from the reactor core during the plant operation. Over the long operation period, these conditions lead to potential degradation and reduced load-carrying capacity of the bolts. In support of evaluating long-term operational performance of materials used in core internal components, the Oak Ridge National Laboratory (ORNL), through the Department of Energy (DOE), Light Water Reactor Sustainability (LWRS) Program, Materials Research Pathway (MRP) has harvested two high fluence BFBs from a commercial Westinghouse two-loop downflow type PWR. The two bolts of interest, i.e. bolts # 4412 and 4416, were withdrawn from service in 2011 as part of a preventative replacement plan. No identification of cracking or potential damage was found for these bolts during their removal in 2011. However, the bolts required a lower torque for removal from the baffle structure than the original torque specified during installation. Irradiation displacement damage levels in the bolts range from 15 to 41 displacements per atom. The goal of this project is to perform detailed microstructural and mechanical property characterization of BFBs following in-service exposures. The information from these bolts will be integral to the LWRS program initiatives in evaluating end of life microstructure and properties. Furthermore, valuable data will be obtained that can be incorporated into model predictions of long-term irradiation behavior and compared to results obtained in high flux experimental reactor conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Microstructural Characterizations of Two High Fluence Baffle-Former Bolts Retrieved from a Westinghouse Two-loop Downflow Type PWR

As one of the pressurized water reactor (PWR) internal components, baffle-former bolts (BFBs) are subjected to significant mechanical stress and neutron irradiation from the reactor core during the plant operation. Over the long operation period, these conditions lead to potential degradation and reduced load-carrying capacity of the bolts. In support of evaluating long-term operational performance of materials used in core internal components, the Oak Ridge National Laboratory (ORNL), through the Department of Energy (DOE), Office of Nuclear Energy, Light Water Reactor Sustainability (LWRS) Program, Materials Research Pathway (MRP), has harvested two high fluence BFBs from a commercial Westinghouse two-loop downflow type PWR. The two bolts of interest, i.e. bolts # 4412 and 4416, were withdrawn from service in 2011 as part of a preventative replacement plan. No identification of cracking or potential damage was found for these bolts during their removal in 2011. However, the bolts required a lower torque for removal from the baffle structure than the original torque specified during installation. Irradiation damage levels in the bolts range from 15 to 41 displacements per atom. The goal of this project is to perform detailed microstructural and mechanical property characterization of BFBs following in-service exposures. The information from these bolts will be integral to the LWRS program initiatives in evaluating end of life microstructure and properties. Furthermore, valuable data will be obtained that can be incorporated into model predictions of long term irradiation behavior and compared to results obtained from experimental reactor conditions

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Assessment of the Analysis Capability for Core-wide PWR Pellet-Clad Interaction (PCI) Screening

The Level 1 Milestone, L1:CASL.P13.03, “Assess the analysis capability for core-wide PWR Pellet-Clad Interaction (PCI) screening and demonstrate detailed 3-D analysis on selected sub-region.”, has been completed by the Fuels, Materials and Chemistry and Physics Integration focus areas of CASL. This report illustrates the application of VERA simulation to PWR core-wide PCI screening, with emphasis on the multi-dimensional analysis capabilities of BISON fuel performance code. The VERA codes utilized in this effort are: the fuel performance code BISON and the VERA-CS sub-element, which combines the neutron transport code MPACT and the thermal-hydraulics code COBRA-TF (CTF). The target reactor for this work is Watts Bar Unit 1, Cycles 6 and 7, selected on the basis that PCI failures had occurred during power start-up in both cycles, despite the moderate power levels, which offered an interesting test of the code’s veracity and a particularly challenging condition for this Milestone’s assessment. The analysis began by performing BISON-IN-VERA, i.e. VERA-CS + BISON, quarter-core depletion calculations, from which limiting assemblies and limiting fuel rods were selected using a four-parameter selection criterion: high power, high temperature, small gap thickness and high cladding hoop stress. The cladding material being Westinghouse Zirlo, the analysis utilized a new material model developed for this cladding by CASL’s FMC team using open literature sources. The VERA-CS + BISON analysis resulted in identifying 51 limiting rods as candidates for more detailed PCI analysis using stand-alone BISON, employing local 2D and 3D geometric models. This local-effects BISON analysis provided detailed PCI failure assessment, considering the impact of power histories on the two potential sources of PCI failure: the classical SCC-PCI and the missing pellet surface geometry MPS-PCI. The 51-rod analyses of Watts Bar Unit 1 cycle 6 and 7 revealed that the classical SCC-PCI stress levels were well below the failure threshold determined in a previous CASL study, which implicated the other mode of failure, namely MPS-PCI. Considering MPS defects to be the root cause for the failure, the local-effects calculations was repeated using MPS defect sizes equal to and larger than Westinghouse quality assurance standards. Initial results of this new analysis showed a significant increase in the cladding stress, indicating that an MPS may have been present in cycle 6 and 7 for the failure to occur. In order to determine the size of MPS needed for cycle 6 and 7 rods to fail, a sensitivity study using 2-D and 3-D models was performed. The results showed cladding hoop stresses, while remaining below the failure level for an MPS of equal size to the acceptance standard, continued to increase as the size of the MPS increased. This report has demonstrated the use of BISON, in consort with VERA’s simulation methodology, for core-wide PCI failure screening capability. Utilizing this demonstration, and emulating the PCI margin analysis methodology developed in the EPRI PCI guidelines, BISON-IN-VERA simulation can be used very effectively to develop core power histories to minimize PCI failure potential.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Precursor Evolution and Stress Corrosion Cracking Initiation of Cold-Worked Alloy 690 in Simulated Pressurized Water Reactor Primary Water

Stress corrosion crack initiation of two thermally-treated, cold-worked (CW) alloy 690 (UNS N06690) materials was investigated in 360oC simulated PWR primary water using constant load tensile (CLT) tests and blunt notch compact tension (BNCT) tests equipped with direct current potential drop (DCPD) for in-situ detection of cracking. SCC initiation was not detected by DCPD for either the 21% or 31%CW CLT specimens loaded at their yield stress after ~9,220 hours, however intergranular (IG) precursor damage and isolated surface cracks were observed on the specimens. The two 31%CW BNCT specimens loaded at moderate stress intensity after several cyclic loading ramps showed DCPD-indicated crack initiation after 10,400 hours of exposure at constant stress intensity, which was resulted from significant growth of IG cracks. The 21%CW BNCT specimens only exhibited isolated small IG surface cracks and showed no apparent DCPD change throughout the test. Post-test cross-section examinations revealed many grain boundary (GB) nano-cavities in the bulk of all the CLT and BNCT specimens particularly for the 31%CW materials. Cavities were also found along GBs extending to the surface suggesting an important role in crack nucleation. This paper provides an overview of the evolution of GB cavities and discusses their effects on crack initiation in CW alloy 690.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2012

Regeneratively Cooled Liquid Oxygen/Methane Technology Development Between NASA MSFC and PWR

The National Aeronautics & Space Administration (NASA) has identified Liquid Oxygen (LOX)/Liquid Methane (LCH4) as a potential propellant combination for future space vehicles based upon exploration studies. The technology is estimated to have higher performance and lower overall systems mass compared to existing hypergolic propulsion systems. NASA-Marshall Space Flight Center (MSFC) in concert with industry partner Pratt & Whitney Rocketdyne (PWR) utilized a Space Act Agreement to test an oxygen/methane engine system in the Summer of 2010. PWR provided a 5,500 lbf (24,465 N) LOX/LCH4 regenerative cycle engine to demonstrate advanced thrust chamber assembly hardware and to evaluate the performance characteristics of the system. The chamber designs offered alternatives to traditional regenerative engine designs with improvements in cost and/or performance. MSFC provided the test stand, consumables and test personnel. The hot fire testing explored the effective cooling of one of the thrust chamber designs along with determining the combustion efficiency with variations of pressure and mixture ratio. The paper will summarize the status of these efforts.

Robinson, Joel W.↗

DOE OSTI2015

VERA Core Simulator Methodology for PWR Cycle Depletion

This paper describes the methodology developed and implemented in MPACT for performing high-fidelity pressurized water reactor (PWR) multi-cycle core physics calculations. MPACT is being developed primarily for application within the Consortium for the Advanced Simulation of Light Water Reactors (CASL) as one of the main components of the VERA Core Simulator, the others being COBRA-TF and ORIGEN. The methods summarized in this paper include a methodology for performing resonance self-shielding and computing macroscopic cross sections, 2-D/1-D transport, nuclide depletion, thermal-hydraulic feedback, and other supporting methods. These methods represent a minimal set needed to simulate high-fidelity models of a realistic nuclear reactor. Results demonstrating this are presented from the simulation of a realistic model of the first cycle of Watts Bar Unit 1. The simulation, which approximates the cycle operation, is observed to be within 50 ppm boron (ppmB) reactivity for all simulated points in the cycle and approximately 15 ppmB for a consistent statepoint. The verification and validation of the PWR cycle depletion capability in MPACT is the focus of two companion papers.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

Post-irradiation Examinations of High Burnup PWR Rods

The High Burnup Spent Fuel Data Project (herein referred to as the “project”), sponsored by the US Department of Energy (DOE) Office of Nuclear Energy (NE), is focused on experimentally evaluating the effects of long-term storage and transportation on high burnup (HBU) (defined as >45 gigawatt days per metric ton uranium) pressurized water reactor (PWR) spent nuclear fuel (SNF) [1]. To support this project, in the fall of 2017, an instrumented bolted-lid cask (project cask) at the North Anna reactor site was loaded with intact, HBU PWR fuel assemblies (project assemblies) having four different kinds of cladding and will be reopened in approximately 10-years for inspection. To support pre- and post-storage SNF rod characterization, 25 “sister rods” that are similar to the rods being stored in the project cask were extracted from seven different fuel assemblies at the North Anna nuclear power plant for post-irradiation examination (PIE).The sister rod testing program has multiple objectives, including: 1) Baseline testing to provide essential information on the physical condition and properties of the cladding and the fuel in the cladding prior to the loading, drying, and long-term dry storage process (analogous to an experiment control group). Similar tests are expected to be performed at the end of the 10-year storage period on rods extracted from the cask to identify any changes in the properties of the fuel rods that may have occurred during the dry storage period; and 2) Tests to provide material property and physical data using accelerated separate effects tests (SETs) and small-scale tests (SSTs) to explore a wide range of conditions that may occur for other dry storage systems and/or while the fuel is being transported after aging.Testing will be focused on understanding overall SNF rod strength and durability, and be comprised of both composite fuel and defueled clad testing with a focus on measuring cladding material and mechanical properties. Nondestructive testing is currently underway and plans are being updated to support the initial set of destructive tests that are expected to begin by early 2018. While the data generated can be used for multiple purposes, a primary goal of the sister rod PIE data and associated measured mechanical properties are expected to support existing fuel storage licensing and relicensing activities by addressing identified knowledge gaps, and enhance the technical bases for post-storage transportation, handling, and consolidation activities [1]. This paper presents results obtained from the sister rod testing to date, and describes some of the planned measurements, equipment, and procedures that will be implemented for the initial set of destructive examinations.

Montgomery, Rose↗

DOE OSTI2018

Bison Fuel Performance Modeling on RIA in a PWR

This report is prepared to fulfill a Level 2 milestone for CASL on “deliver and document RIA fuel performance modeling using Bison fuel performance code.” The work performed is focused on modeling the full length commercial fuel rod response under a design basis Reactivity Initiated Accident (RIA), in particular, a hypothetical Control Rod Ejection Accident (CREA) in a Pressurized Water Reactor (PWR). Fuel rods with different burnups, 0 (fresh fuel), 20, 40, and 60 GWd/tU have been modeled with a reactivity worth insertion of $1.24 at Hot Zero Power (HZP) condition. Bison failure modeling method, and a brief summary of validations on selected RIA cases from CABRI and NSRR testing facilities are also described. The work performed has demonstrated the successful application of Bison code in the modeling of thermal and mechanical responses in RIAs for PWRs. In particular, Bison code has a more mature capability in the modeling of the frictional contact between pellet and cladding of the high burnup fuels, which is critical for modeling the Pellet Clad Mechanical Interaction (PCMI). The modeling of RIA using Bison code shows fuels in PWR environment could have different responses than in the simulated RIA tests, and results indicate that a transition from PCMI to Departure from Nucleate Boiling (DNB) could happen at relatively lower enthalpies: a better heat transfer from the fuel to coolant could increase cladding temperature and ductility, but at the same time also reduces the margin to DNB, which could cause high temperature oxidation and ballooning type of failures. The precise determination of the transition into DNB may rely on a more accurate input of the power histories in the simulated RIAs from VERA, the core simulator of CASL. The limiting conditions in PWRs could be quite different than those tests with non-typical testing conditions, and the improvement of the modeling of thermal responses, such as, clad coolant heat transfer, gap heat transfer, clad thermal inertia, and radial power profiles could be important considerations of the RIAs. In modeling the fuel responses in a fast transient, a number of variables could affect the initial burnup states, and some material models, e.g., fuel mechanical models, fission gas release, and corrosion models, and parameters can affect modeling results as well. Those uncertainties and advanced modeling capabilities need to be investigated in the future study of RIAs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

POST-TEST EXAMINATIONS OF A LOCA SAMPLE FROM AN IRRADIATED HIGH-BURNUP PWR M5 FUEL ROD

A LOCA integral test with high burnup PWR M5 fuel rod was conducted in the Irradiated Fuel Examination Laboratory through the complete LOCA sequence: heating the LOCA sample to 300ºC and pressurizing the internal pressure to 8.27 MPa, heating at 5ºC/s from 300 to 1200ºC, holding in steam for 90s at 1200ºC, cooling at 3ºC/s to 800ºC, followed by water quench and rapid cooling to 100ºC. After LOCA testing, examinations, such as the fuel fragmentation analysis, burst and ballooning characterization, axial strain measurement, and microstructural examinations were performed. Metallographic examinations of an as-irradiated high burnup sample adjacent to the LOCA test sample revealed a bonding layer between the fuel and cladding. The posttest LOCA examinations indicates the corrosion layer formed during normal operations in the commercial reactor might provide a protection against the steam oxidation at high temperatures for test times performed in this work. The microstructure of the as-irradiated fuel is compared to the microstructure of the post-LOCA test fuel. Posttest LOCA examination on unirradiated post-tests Zr cladding samples was conducted, which served as baseline data for in cell testing with irradiated samples. The results obtained with irradiated PWR high burnup M5 fuel rad were compared to the LOCA test data obtained with irradiated BWR high burnup Zircaloy-2 fuel rod at Argonne national Laboratory.

Yan, Yong↗

DOE OSTI2018

Post-Irradiation Examinations of High Burnup PWR Fuel Rods - Initial Results

Bevard, Bruce Balkcom↗

DOE OSTI2013

ALLOY 690 SURFACE NANOSTRUCTURES DURING EXPOSURE TO PWR PRIMARY WATER AND POTENTIAL INFLUENCE ON STRESS CORROSION CRACKING INITIATION

Alloy 690 (30 wt% Cr) is currently being used to replace lower Cr alloy 600 (16 wt% Cr) in critical pressurized water reactor (PWR) components due to its superior protection against stress corrosion cracking (SCC). The increased Cr content is believed to assist in forming a protective chromia film on the surface that inhibits corrosion and intergranular attack (IGA) in particular. A key objective for this work is to understand how surface microstructural features act as precursor sites for SCC nucleation. Unstressed alloy 690 specimens have been exposed to simulated PWR water conditions at 360°C including cold-worked materials shown to susceptible to SCC in crack-growth tests. Detailed surface and near-surface characterizations were performed on cross-section samples starting with low kV backscatter scanning electron microscopy (SEM) imaging to document the extent of general and localized corrosion. Selected surface and local corrosion regions were then prepared by focused ion beam milling for transmission electron microscopy (TEM) and atom probe tomography (APT) analyses. TEM is used to determine the oxidation microstructures as well as compositional gradients associated with the degradation, while APT is conducted to investigate the atomistic redistribution of alloying and impurity elements in the oxides and surrounding metal.

Olszta, Matthew J.↗

DOE OSTI2016

Finite element analysis of the PWR control rod absorber thermal evaluation

The RCCAs (Rod Cluster Control Assembly) are part of the reactor control systems and are designed to adjust the reactivity by neutron absorption. In PWR, a RCCA is composed of a spider holding 24 control rods. During operation, the absorber stacks are heated up by neutron and γ-ray radiation. This paper describes the PWR control rod absorber temperature analysis model in details, derives the theoretical equations, and presents a FEA model for control rod absorber thermal evaluation. The FEA model is based on finite element analysis and on 3 major assumptions: 1) steady-state condition, 2) the thermal conductivities of absorber, cladding and gas are assumed to be constant, and 3) thermal expansion and radiation are neglected. The control rod of an AFA 3G fuel assembly in Ningde NPP unit 1 and 2 in steady state on condition I operation was used as a case to qualify the FEA method. A special software named CRABE, designed and qualified by AREVA, was used to do the same analysis for comparison. Several conclusions can be drawn. First, compared with traditional methods, FEA is more convenient with higher accuracy and can greatly simplify the calculation process. In addition, the FEA software is always ease to use, with a friendly interface and a more intuitive display of results. Secondly, the FEA model was qualified though a practical case calculated in different ways. Thirdly, when it comes to a special structure such as an eccentric absorber or an oval cladding, the FEA model has a great applicability, while traditional methods are difficult to use.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗