Study of tearing behaviour of a PWR reactor pressure vessel lower head under severe accident loadings

In PWR severe accident scenarios, involving a relocation of corium (core melt) into the lower head, the possible failure mode of the reactor pressure vessel (RPV), the failure time, the failure location and the final size of the breach are regarded as key elements, since they play an important part in the ex-vessel phase of the accident.Both the LHF and OLHF experiments as well as the FOREVER experiments revealed that initiation of the failure is typically local. For the case of a uniform temperature distribution in the lower head, crack initiation occurs in the thinnest region and for the case of a non-uniform temperature distribution, it initiates at the highest temperature region. These experimental results can be modelled numerically (but more accurately with 3D finite element codes). The failure time predictions obtained using numerical modelling agree reasonably well with the experimental values.However, the final size of the failure is still an open issue. Analyses of both the LHF and OLHF experimental data (as well as of that from the FOREVER experiments) do not enable an assessment of the final size of the breach (in relation with the testing conditions and results).Indeed, the size of breach depends on the mode of crack propagation which is directly related to the metallurgical characteristics of the RPV steel. Small changes in the initial chemical composition of the vessel material can lead to different types of rupture behaviour at high temperatures. Different rupture behaviours were observed in the LHF and OLHF experiments using the SA533B1 steel. Similar observations were previously noticed during a CEA material characterization programme on the 16MND5 steel. To determine crack propagation and final failure size, 3D modelling would thus be needed with an adequate failure criterion taking into account the variability in behaviour of the RPV material at high temperatures.This paper presents an outline of the methodology being used in a current research programme of IRSN, in partnership with CEA and INSA Lyon. The aim is to model crack opening and crack propagation in French RPV lower head vessels under severe accidents conditions. This programme was initiated in 2003 and is made up of five main sections, namely an inventory of the different French PWR lower head materials, metallurgical investigations to better understand the cause of mechanical behaviour variability that is observed and related to material microstructure, Compact Tension (CT) testing of specimens to characterize the tear resistance of the material, validation of the modelling using experiments on tube specimens and the development of a new failure criterion for the 3D finite element models.     

小型压水堆严重事故下一回路承压管道蠕变预测分析模型开发

一回路承压管道蠕变是压水堆核电厂严重事故重要现象之一。针对小型压水堆,本文基于SCDAP/RELAP5程序开发了严重事故分析模型,利用实验拟合方法得到了一回路主管道(SA321)、自然循环式蒸汽发生器传热管(00Cr25Ni35Al Ti)两种材料蠕变预测分析模型,改进了SCDAP/RELAP5程序蠕变预测分析功能模块,并通过假想事故序列验证了SA321、00Cr25Ni35Al Ti蠕变预测分析模型的合理性。为后续开展小型压水堆严重事故下一回路承压管道蠕变规律研究提供基础参考。     

严重事故下大功率先进压水堆IVR-ERVC有效性分析

通过压力容器外部冷却(ERVC)以实现堆内熔融物滞留(IVR)作为反应堆严重事故缓解管理的一项重要举措一直以来广泛受到关注和研究。本文使用严重事故分析程序MELCOR,从瞬态角度对大型先进压水堆进行了IVR-ERVC相关研究。过程中重点关注了堆芯熔毁和重新定位,熔池形成、生长及其传热过程,并且对压力容器外部流动传热进行了分析。MELCOR计算所得下封头热流密度分布的瞬态结果与临界热流密度(CHF)比较和分析表明,1700 MWe大功率压水堆发生严重事故后在IVRERVC条件下能够保证压力容器的完整性,即,IVR-ERVC能够有效带出下封头熔融物的衰变热量,缓解严重事故后果。     

External cooling of a reactor vessel under severe accident conditions

The TMI-2 accident demonstrated that a significant quantity of molten core debris could drain into the lower plenum during a severe accident. For such conditions, the Individual Plant Examinations (IPEs) and severe accident management evaluations, consider the possibility that water could not be injected to the RCS. However, depending on the plant specific configuration and the accident sequence, water may be accumulated within the containment sufficient to submerge the lower head and part of the reactor vessel cylinder. This could provide external cooling of the RPV to prevent failure of the lower head and discharge of core debris into the containment.This paper evaluates the heat removal capabilities for external cooling of an insulated RPV in terms of (a) the water inflow through the insulation, (b) the two-phase heat removal in the gap between the insulation and the vessel and (c) the flow of steam through the insulation. These results show no significant limitation to heat removal from the bottom of the reactor vessel other than thermal conduction through the reactor vessel wall. Hence, external cooling is a possible means of preventing core debris from failing the reactor, which if successful, would eliminate the considerations of ex-vessel steam explosions, debris coolability, etc. and their uncertainties. Therefore, external cooling should be a major consideration in accident management evaluations and decision-making for current plants, as well as a possible design consideration for future plants.     

A generic approach for steel containment vessel success criteria for severe accident loads

Safety has been defined as the foremost design criterion for the Heavy Water New Production Reactor (NPR-HWR) by the U.S. Department of Energy (DOE), Office of New Production Reactors (NP). The DOE-NP issued the Deterministic Severe Accident Criteria (DSAC) concept to guide the design of the NPR-HWR containment for resistance to severe accidents. The DSAC concept provides for a generic approach for containment vessel success criteria to predict the threshold of containment failure under severe accident loads. This concept consists of two parts: (1) Problem Statements and (2) Success Criteria. This paper is limited to a discussion of a generic approach for steel containment vessel success criteria. These criteria define acceptable containment response measures and limits for each problem statement. The criteria are based on the “best estimate” of failure with no conservatism. Rather, conservatism, if required, is to be provided in the problem statements prepared by the designer and/or the regulatory authorities. The success criteria are presented on a multi-tiered basis for static pressure and temperature loadings, dynamic loadings, and missiles that may impact the containment. Within the static pressure and temperature loadings and the dynamic loadings, the criteria are separated into elastic analysis success criteria and inelastic analysis success criteria. Each of these areas, in turn, defines limits on either the stress or strain measures as well as on measures for buckling and displacements. The rationale upon which these criteria are based is contained in referenced documents. Rigorous validation of the criteria by comparison with results from analytical or experimental programs and application of the criteria to a containment design remain as future tasks.     

严重事故条件下压力容器完整性评价的研究进展

堆芯熔融物堆内滞留(In-Vessel Retention,IVR)是以AP1000为代表的第三代轻水反应堆严重事故管理的重要策略之一,也是严重事故条件下保证压力容器完整性(Reactor Vessel Integrity,RVI)的典型方法之一.该文综述了国外在严重事故条件下压力容器完整性试验研究和理论分析的现状,总...     

Finite element analyses of a BWR vessel and penetration under severe accident conditions

This study assesses the two-dimensional thermal response of a BWR vessel and drain line penetration to three types of debris bed; primarily metallic, primarily ceramic and metallic and ceramic layered, with sensitivity studies for the most severe case. Structural finite element analysis evaluates vessel elastic, plastic and creep response for two cases which bound the thermal challenge to the vessel.Thermal analysis results indicate that drain line failure does not occur for the case when metallic debris relocates to the lower head; structural analysis predicts that the vessel also remains intact for this case. In cases where ceramic debris relocates to the lower head, drain line temperatures peak near values where failure may occur within several minutes; whereas vessel failure is not predicted for 3.5 to 4.0 hours. Sensitivity studies indicate that large porosity debris or high heat removal rates from the vessel and drain line outer surfaces can preclude failure temperatures from occurring.     

Bottom nozzle failure mechanism of water reactor pressure vessel under severe accident conditions

Most of past studies devoted to the creep rupture of a nuclear reactor pressure vessel (RPV) lower head under severe accident conditions, have focused on global deformation and rupture modes. Limited efforts were made on local failure modes associated with penetration nozzles as a part of TMI-2 vessel investigation project (TMI-2 VIP) in 1990s. However, it was based on an excessively simplified shear deformation model. In the present study, the mode of nozzle failure has been investigated using data and nozzle materials from Sandia National Laboratory's lower head failure experiment (SNL-LHF). Crack-like separations were revealed at the nozzle weld metal to RPV interfaces indicating the importance of normal stress component rather than the shear stress in the creep rupture. Creep rupture tests were conducted for nozzle and weld metal materials, respectively, at various temperature and stress levels. Stress distribution in the nozzle region is calculated using elastic–viscoplastic finite element analysis (FEA) using the measured properties. Calculation results are compared with earlier results based on the pure shear model of TMI-2 VIP. It is concluded from both LHF-4 nozzle examination and FEA that normal stress at the nozzle/lower head interface is the dominant driving force for the local failure. From the FEA for the nozzle weld attached in RPV, it is shown that nozzle welds failure occur by displacement controlled fracture of nozzle hole not by load controlled fracture of internal pressure. Considering these characteristics of nozzle weld failure, new concept of nozzle failure time prediction is proposed.     

Modelling of PWR lower head failure under severe accident loading using improved shells of revolution theory

In the study of severe pressurized water reactor accidents, the scenarios that describe the relocation of significant quantities of liquid corium at the bottom of the lower head are usually investigated from the mechanical point of view. In these scenarios, the risk of a breach and the possibility of a large quantity of corium being released from the lower head exists. This may lead to an out of vessel steam explosion or to direct heating of the containment; both which have the potential to lead to early containment failure.Within the framework of the OECD Lower Head Failure (OLHF) programme, a simplified model based on the theory of shells of revolution under symmetrical loading was developed by IRSN. After successfully interpreting some other representative experiments on lower head failures, the model was recently integrated into the European integral severe accident computer ASTEC code. The model was also used to obtain the thermo-mechanical behaviour of a 900-MWe pressurized water reactor lower head, subjected to transient heat fluxes under severe accident conditions.The main objective of this paper is to present: (1) the full mathematical formulations used in the development of the model, including their matrices and integrals defined by analytical expressions; (2) the two creep laws implemented, one for the American steel SA533B1 and one for the French steel 16MND5; and (3) the various numerical interpretations of experiments using the simplified model. This paper can be considered as a theoretical manual to aid users of the simplified model during modelling of lower head failures under severe accident conditions. One of the applications presented in this paper concerns the determination of a diagram representing the vessel time to failure as a function of the pressure level and the heat flux intensity. This information has been used by IRSN in probabilistic safety assessment and severe accident management analyses.     

Semi-analytical modeling of a PWR lower head failure under severe accident conditions using an axisymetrical shell theory

The USNRC/SNL OLHF program was carried out within the framework of an OECD project. This program consisted of four one-fifth scale experiments of a reactor pressure vessel (RPV) lower head failure (LHF) under well controlled internal pressure and large throughwall temperature differentials; the objectives were to characterize the mode, timing and size of a possible PWR lower head failure in the event of a core meltdown accident. These experiments should also lead to a better understanding of the mechanical behavior of the reactor vessel lower head, which is of importance both in severe accident assessment and the definition of accident mitigation strategies. A well-characterized failure of the lower head is of prime importance for the evaluation of the quantity of core material that can escape into the containment, since this defines the initial conditions for all ex-vessel events. A large quantity of escaping corium may lead to direct heating of the containment or ex-vessel steam explosion. These are important issues due to their potential to cause early containment failure. The experiments also provide data for model development and validation. For our part, as one of the program partners, a 2D semi-analytical model has been developed and used to simulate these experiments. The aim of this effort is to develop a simplified but well predicting code that can be then implemented in European integral severe accident computer codes (ASTEC, ICARE/CATHARE). This paper presents the detailed mathematical formulation of this simplified method which is used to interpret the experimental results. The axi-symmetric shell theory under internal pressure proposed by Timoshenko has been utilised. The solution to the equilibrium equations is presented, with particular attention to the Rabotnov analytical formula. The radius and the polar angle of the deformed structure have been written as analytical expressions in order to take the large displacements and large strains into account using our mathematical formulation. The Norton type creep law and the Kachanov damage law have been used. Several failure criteria were used in the calculations and their effect on the numerical results is discussed. This 2D semi-analytical model gives very satisfactory results when compared, with the experimental and numerical results that were presented recently in the Benchmark calculations based on the first test of the OLHF program. The performance of this model is also illustrated by its capacity to accurately simulate the deformation of the lower head, including the variation of wall thickness.     

Effect of water injection on hydrogen generation during severe accident in PWR

Effect of water injection on hydrogen generation during severe accident in a 1000 MWe pressurized water reactor was studied.The analyses were carried out with different water injection rates at different core damage stages.The core can be quenched and accident progression can be terminated by water injection at the time before cohesive core debris is formed at lower core region.Hydrogen generation rate decreases with water injection into the core at the peak core temperature of 1700 K,because the core is quenched and reflooded quickly.The water injection at the peak core temperature of 1900 K,the hydrogen generation rate increases at low injection rates of the water,as the core is quenched slowly and the core remains in uncovered condition at high temperatures for a longer time than the situation of high injection rate.At peak core temperature of 2100-2300 K,the Hydrogen generation rate increases by water injection because of the steam serving to the high temperature steam-starved core.Hydrogen generation rate increases significantly after water injection into the core at peak core temperature of 2500 K because of the steam serving to the relocating Zr-U-O mixture.Almost no hydrogen generation can be seen in base case after formation of the molten pool at the lower core region.However,hydrogen is generated if water is injected into the molten pool,because steam serves to the crust supporting the molten pool.Reactor coolant system (RCS) depressurization by opening power operated relief valves has important effect on hydrogen generation.Special attention should be paid to hydrogen generation enhancement caused by RCS depressurization.     

Study on severe accident mitigation measures for the development of PWR SAMG

In the development of the Severe Accident Management Guidelines （SAMG）, it is very important to choose the main severe accident sequences and verify their mitigation measures. In this article, Loss-of-Coolant Accident （LOCA）, Steam Generator Tube Rupture （SGTR）, Station Blackout （SBO）, and Anticipated Transients without Scram （ATWS） in PWR with 300 MWe are selected as the main severe accident sequences. The core damage progressions induced by the above-mentioned sequences are analyzed using SCDAP/RELAP5. To arrest the core damage progression and mitigate the consequences of severe accidents, the measures for the severe accident management （SAM） such as feed and bleed, and depressurizations are verified using the calculation. The results suggest that implementing feed and bleed and depressurization could be an effective way to arrest the severe accident sequences in PWR.     

On the prediction of the reactor vessel integrity under severe accident loadings (RPVSA)

In order to allow more reliable predictions on the lower head response under core melt-down conditions, the temperature distribution has been analysed including the natural convection in the corium pool. Furthermore, the mechanical models and the failure criteria have been improved based on the RUPTHER and FASTHER experiments where typical temperature gradients are simulated. Lower head local melting as well as corium crust development has been addressed in the CORVIS experiments studying the contact between an alumina/iron thermite and a thick steel plate. The upper head loading by corium impact due to a postulated in-vessel steam explosion has been investigated by the BERDA experiments. Similarity rules were considered such that the results can be directly converted to reactor conditions. Based on these investigations admissible steam explosion energy releases are determined which the upper head can carry. If these limits are not exceeded the reactor containment cannot be endangered by broken head fragments. To provide the necessary basic data, mechanical material tests have been performed.     

Failure strains and proposed limit strains for an reactor pressure vessel under severe accident conditions

The local failure strains of essential design elements of a reactor vessel are investigated. The size influence of the structure is of special interest. Typical severe accident conditions including elevated temperatures and dynamic loads are considered.The main part of work consists of test families with specimens under uniaxial and biaxial load. Within one test family the specimen geometry and the load conditions are similar, but the size is varied up to reactor dimensions. Special attention is given to geometries with a hole or a notch causing non-uniform stress and strain distributions typical for the reactor vessel. A key problem is to determine the local failure strain. Here suitable methods had to be developed including the so-called “vanishing gap method”, and the “forging die method”. They are based on post-test geometrical measurements of the fracture surfaces and reconstructions of the related strain fields using finite element models.The results indicate that stresses versus dimensionless deformations are approximately size independent up to failure for specimens of similar geometry under similar load conditions. Local failure strains could be determined. The values are rather high and size dependent. Statistical evaluation allow the proposal of limit strains which are also size dependent. If these limit strains are not exceeded, the structures will not fracture.     

Stress biaxiality in high-burnup PWR fuel cladding under reactivity-initiated accident conditions

In order to promote a better understanding of failure mechanisms of high-burnup pressurized water reactor (PWR) fuels under reactivity-initiated accident (RIA) conditions, stress biaxiality in cladding has been estimated for the pellet-cladding (PC) mechanical interaction (PCMI) phase. The estimation was based on an analysis of the transient elongations of a pellet stack and a cladding tube measured in RIA-simulating experiments in the nuclear safety research reactor (NSRR) using the RANNS code. Stress biaxiality in the high-burnup PWR fuel cladding during the PCMI phase has been estimated to be 0.7–0.8, on average, at the mid-wall of the cladding. A comparison with fresh fuel test results and a sensitivity analysis showed that the effects of burnup and pulse width on cladding stress biaxiality are less than 10% for the investigated range. The present analysis also indicated that PC friction is strong, and that the cladding constraint on pellet stack elongation is significant irrespective of burnup. Therefore, it is recommended that strong PC friction be assumed, which is similar to the mechanical bonding condition, and that fuel pellets be treated as deformable materials in models of fuel behavior during the PCMI phase.     

蒸汽发生器完全丧失给水引发的压水堆严重事故研究

采用严重事故最佳估算程序SCDAP/RELAP5/MOD3.4,建立了美国Surry核电站的详细计算模型,对完全丧失给水(TLFW)引发的堆芯熔化事故进行了研究分析.为准确预测压力容器内堆芯熔化的进程,给二级PSA提供可信的初始条件,计算中考虑了一回路压力边界的蠕变破裂失效,并评价了人为干预对堆芯熔化进程及事故后果的影响.     

Behaviour of fission products under severe PWR accident conditions VERCORS experimental programme—Part 1: General description of the programme

VERCORS is an analytical experimental programme focusing on the release of fission products (FP) and actinides from an irradiated fuel rod, under conditions representative of those encountered during a severe PWR accident. The 17 tests - financed jointly by EDF and IRSN - were conducted by the CEA on its Grenoble site in a specific high-activity cell at the Laboratory for Active Materials (LAMA) over a 14-year period (1989-2002), in accordance with three test phases. A first series of six tests (VERCORS 1-VERCORS 6) was conducted between 1989 and 1994 on UO₂ fuel close to the relocation. Next, two different test series - VERCORS HT (three tests) and RT (eight tests) - were alternately performed between 1996 and 2002 at higher temperature up to the fuel sample collapse. These tests focused on UO₂ and MOX fuels with a variety of initial configurations (intact or debris beds). This programme made it possible to precisely quantify fission product releases in all the situations explored, as well as to identify similar behavioural patterns between some of these fission products, thus making it possible to classify them schematically into four groups with decreasing volatility: (1) volatile FP including fission gases, iodine, caesium, antimony, tellurium, cadmium, rubidium and silver with very high releases (practically total release) at temperatures of around 2350 °C; (2) semi-volatile FP, a category composed of molybdenum, rhodium, barium, palladium and technetium with releases of 50-100%, but very sensitive to oxygen potential and with marked redeposits nearby the emission point; (3) FP that are low volatile, such as ruthenium, cerium, strontium, yttrium, europium, niobium and lanthanum, with significant releases of around 3-10% on average, but capable (for some elements and under particular conditions) of reaching 20-40%; (4) non-volatile FP composed of zirconium, neodymium and praseodymium, for which no release can be measured by gamma spectrometry for the envelope conditions of the VERCORS test grids. Actinides each have their own type of behaviour. They can nevertheless be subdivided into two categories, the first including U and Np, with releases of up to 10% and behaviour similar to that of the low volatile FP, and the second (Pu) with very low releases, typically less than 1%.     

Influence of temperature on tearing resistance of welds for PWR vessels

The effect of temperature on ductile fracture toughness of three narrow gap SAW welds and one MMAW weld (SA 508 Cl.3 base metal) was investigated using 25 mm thick CT specimens. Chemical analyses, tensile and Charpy V tests were also performed. Two methods of toughness characterization (partial unloadings or interrupted tests) were used at 20–43°C and service temperature (293°C). Values of J at initiation, and after a moderate propagation were considered and compared. At a given temperature, properties of the four welds were fairly similar. A conservative estimate of the toughness reduction factor, associated with a temperature increase from 43°C to 293°C, is $\text{J}{}^{293}\text{?}\text{J}{}^{43}\text{1.6}$. Fracture surfaces were examined, showing a pattern of patches with dimples separated by areas of smoother surfaces. This fracture surface appearance can be related to the weld microstructure. Two models were tried for predicting the change of fracture toughness with temperature through the effect of this latter parameter on tensile properties. The characteristic distance model of ductile fracture provides a satisfactory estimate of the temperature effect on toughness.