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.     

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.     

Progress on PWR lower head failure predictive models

A good understanding of the mechanical behaviour of the reactor pressure vessel (RPV) lower head is necessary both for severe accident assessment and for the definition of appropriate accident mitigation strategies. Indeed, a well-characterized failure of the lower head leads to a better evaluation of the quantity and kinetics with which core material can escape into the containment. These are the initial conditions for several ex-vessel events such as direct heating of the containment or molten core-concrete interaction.In this context, the objectives of the joint on-going work of the WP10-2 group of SARNET are: (1) improvement of predictability of the time, mode and location of RPV failure; (2) development of adequate models with the ultimate aim of being included into integral codes; (3) interpretation/analysis of experiments with models/codes combined with sensitivity studies; and (4) better understanding of the breach opening process in order to better characterize the corium release into the containment.Different approaches are considered: a simplified but well predicting model recently implemented in the severe accident Astec and Icare-Cathare codes, and viscoplasticity models implemented in the Cast3m, Ansys and Code_Aster finite element codes. Several failure criteria are considered: stress criterion, strain criterion and damage evaluation (coupled way or post-evaluation).In this paper, the OLHF-1 experiment has been used to assess the models, to perform sensitivity studies and to evaluate failure criteria that could be applied in the case of reactors. All the partners performed 2D axisymmetric analyses, allowing the evaluation of time, mode and location of vessel failure. Nevertheless, CEA conducted further 3D calculations in order to study crack propagation and the corresponding results will be presented separately at the end of the paper. The numerical formulation of the different models used is given and a comparison of experimental and numerical results is presented. The paper also shows the progress made with the objective of defining failure criteria that can be used for reactor vessel applications.     

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.     

Evaluation of intentional depressurization strategy in Chinese 600 MWe PWR NPP

Intentional depressurization is one of the effective strategies in preventing high-pressure melt ejection (HPME) and direct containment heating (DCH), which is most feasible for the operating nuclear power plants (NPPs) in China. In order to evaluate this strategy of a Chinese 600 MWe PWR NPP, the plant model is built using SCDAP/RELAP5 code. ATWS, SBO, SGTR and SLOCA are selected as the base cases for analysis of intentional depressurization. The results show that opening safety valves of pressurizer manually when the core exit temperature exceeds 922 K can reduce the RCS pressure effectively and prevent the occurrence of HPME and DCH. Several uncertainties such as the operability of safety valves, ex-vessel failure and the transitory rise of RCS pressure are also analyzed subsequently. The results show that the opening of the safety valves can be initiated normally and that opening three safety valves is a more favorable strategy in the event of possible failure of one or more of the safety valves; the probability of ex-vessel failure is reduced after intentional depressurization is implemented; the transitory rising of reactor coolant system (RCS) pressure when the molten core materials relocate to the lower head of reactor pressure vessel (RPV) will not influence the effect of depressurization.     

严重事故条件下安全壳响应模拟研究

压水堆核电厂发生严重事故期间,从主系统释放的蒸汽、氢气以及下封头失效后进入安全壳的堆芯熔融物均对安全壳的完整性构成威胁。以国内典型二代加压水堆为研究对象,采用MAAP程序进行安全壳响应分析。选取了两种典型的严重事故序列：热管段中破口叠加设备冷却水失效和再循环高压安注失效,堆芯因冷却不足升温熔化导致压力容器失效,熔融物与混凝土发生反应（MCCI）,安全壳超压失效;冷管段大破口叠加再循环失效,安全壳内蒸汽不断聚集,发生超压失效。通过对两种事故工况的分析,证实了再循环高压安注、安全壳喷淋这两种缓解措施对保证安全壳完整性的重要作用。     

The design of the assembly tools for the ITER tokamak

The conceptual design of the purpose-built assembly tools required for ITER tokamak assembly is given. The ITER machine assembly is sub-divided into five major activities: lower cryostat, sector sub-assembly, sector assembly, ex-vessel, and in-vessel [1]. The core components, vacuum vessel (VV) and toroidal field coil (TFC), are assembled from nine 40° sub-assemblies, each comprising a 40° VV sector, two TFCs, and the associated VV thermal shield (VVTS). The lower cryostat activities must be completed prior to sector assembly in pit to prepare the foundations for the core components, and to locate the lower components to be trapped once the core components installation begins. In-vessel and ex-vessel activities follow completion of sector assembly. To perform these assembly activities requires both massive, purpose-built tools, and standard heavy handling and support tools. The tools have the capability of supporting and adjusting the largest of the ITER components; with maximum linear dimension 19 m and mass 1200 tonne, with a precision in the low mm range. Conceptual designs for these tools have been elaborated with the collaboration of the Korean Domestic Agency (KO DA). The structural analysis was performed as well using ANSYS code.     

增强IVR有效性的堆内注水策略研究

熔融物堆内滞留（IVR）是一项核电厂重要的严重事故管理措施,通过将熔融物滞留在压力容器内,以保证压力容器完整性,并防止某些可能危及安全壳完整性的堆外现象。对于高功率和熔池中金属量相对不足的反应堆,若下封头形成3层熔池结构,则其顶部薄金属层导致的聚焦效应可能对压力容器完整性带来更大的威胁。本文考虑通过破口倒灌及其他工程措施实现严重事故下熔池顶部水冷却,建立熔池传热模型,分析顶部注水的带热能力,建立事件树,分析顶部注水措施的成功概率及IVR的有效性。结果表明,通过压力容器内外同时水冷熔融物,能显著增强IVR措施的有效性。     

Recursively coupled thermal and mechanical FEM-analysis of lower plenum creep failure experiments

Postulating an unlikely core melt down accident for a light water reactor (LWR), the possible failure mode of the reactor pressure vessel (RPV) and its failure time have to be investigated for a determination of the load conditions for subsequent containment analyses. Worldwide several experiments have been performed in this field accompanied with material properties evaluation, theoretical, and numerical work.     

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.     

Demonstration of the heat removing capabilities of the EPR core catcher

The EPR implements an additional, fourth level of defense-in-depth that aims at limiting and restricting the consequences of a postulated severe accident with core melting to the immediate vicinity of the plant. As this requires an intact confinement, it is necessary, among others, to avoid an attack of the molten core on the basemat. For that purpose, the EPR includes a large ex-vessel core catcher. It increases the surface-to-volume ratio of the melt after its release from the reactor pressure vessel (RPV) and allows the effective quenching and stabilization of the melt before it can attack the structural concrete.The bottom and sides of the core catcher are cooled by a system of horizontal water-filled channels. The water is provided either passively, by overflow from an internal reservoir, or actively by the containment heat removal system (CHRS).To quantify the heat removing capability of the horizontal part of the proposed cooling structure, a set of experiments in a full-scale, horizontal, 5 m long cooling channel have been performed. To simulate decay heat, the channel was electrically heated from the top. The experiment was integrated in the BENSON test rig, a highly flexible, separate-effect test facility operated by Framatome ANP. In accordance with the potential later modes of operation, both co-current and counter-current flow of the water/steam mixture have been investigated.The tests demonstrated the good-natured behavior of the system, even for induced heat fluxes that significantly exceed realistically expectable maximum values. Although, at high heat fluxes, a local dry-out occurred at the top of the channel, structural temperatures remained in a safe range. This excellent performance is attributed to the fact that heat can enter the water through both the horizontal and vertical surfaces of the cooling channel. As a result a high, effective critical heat flux (CHF) level is achieved. The performed tests yield a valuable contribution to the validation of the function of the EPR core catcher concept.     

Ex-vessel core melt stabilization research (ECOSTAR)

The project on ex-vessel core melt stabilization research (ECOSTAR) started in January 2000 to be concluded by end of 2003. The project is performed by 14 partner institutions from five European countries and involves a large number of experiments with low- and high-temperature simulant melts and real corium at different scales. Model development and scaling analysis allows application of the research results to existing and to future LWRs in the area of reactor design and accident mitigation. The project is oriented toward the analysis and mitigation of severe accident sequences that could occur in the ex-vessel phase of a postulated core melt accident. The issues are: (1) the release of melt form the pressure vessel, (2) the transfer and spreading of the melt on the basement, (3) the analysis of the physical–chemical processes that are important for corium behavior especially during concrete erosion with onset of solidification, and (4) stabilization of the melt by cooling through direct water contact. The results achieved so far resolve a number of important issues: the amount of melt that could be transferred at RPV failure from the RPV into the containment can be substantially reduced by lowering the residual pressure in the primary circuit. It is found that melt dispersion also strongly depends on the location of the RPV failure, and that lateral failure results in substantially less melt dispersion. During melt release, the impinging melt jet could erode parts of the upper basement surface. Jet experiments and a derived heat transfer relation allow estimation of its contribution to concrete erosion. Spreading of the corium melt on the available basement surface is an important process, which defines the initial conditions for concrete attack or for the efficiency of cooling in case of water contact, respectively. Validation of the spreading codes based on a large-scale benchmark experiment is underway and will allow determination of the initial conditions, for which a corium melt can be assumed to spread homogeneously over the available surface. Experiments with UO₂-based corium melts highlight the role of phase segregation during onset of melt solidification and during concrete erosion. To cool the spread corium melt, the efficacy of top flooding and bottom flooding is investigated in small-scale and in large-scale experiments, supported by model developments. Project assessment is continuing to apply the results to present and future reactors.     

An interpretation of Fukushima-Daiichi Unit 3 plant data covering the two-week accident-progression phase based on correction for pressure data

Water columns were adopted in the pressure measurement system of Fukushima-Daiichi Unit 3 to compensate for evaporation/condensation during normal operation. Some of these water columns evaporated partially during the accident condition jeopardizing correct understanding on actual pressure. Through inter-comparison of reactor pressure vessel (RPV) and suppression chamber (S/C) pressures with drywell (D/W) pressure, such water-column-change effect was evaluated. From this evaluation, correction for the specific effect was developed for RPV and S/C pressure data. With this corrected pressure, slight pressure difference among RPV, S/C, and D/W during the accident transient was evaluated. This information of pressure difference was then integrated with other available data, such as water level, containment atmosphere monitoring system, and environmental dose rate in the Fukushima-Daiichi site, into an interpretation of accident progression behavior focusing on RPV and primary containment vessel pressurization/depressurization and radioactive material release to environment. It is suggested that dryout of in-vessel and ex-vessel debris was likely causing pressure decrease on one hand, and S/C water poured into pedestal heated by relocated debris was a likely cause of pressurization on the other hand. Cyclic reflooding of pedestal debris and its dryout was likely leading to the cyclic pressure change lasting several times until the final debris reflooding.     

Estimation of ex-vessel steam explosion pressure loads

An ex-vessel steam explosion may occur when, during a severe reactor accident, the reactor vessel fails and the molten core pours into the water in the reactor cavity. A steam explosion is a fuel coolant interaction process where the heat transfer from the melt to water is so intense and rapid that the timescale for heat transfer is shorter than the timescale for pressure relief. This can lead to the formation of shock waves and production of missiles that may endanger surrounding structures. A strong enough steam explosion in a nuclear power plant could jeopardize the containment integrity and so lead to a direct release of radioactive material to the environment.In this article, different scenarios of ex-vessel steam explosions in a typical pressurized water reactor cavity are analyzed with the code MC3D, which is being developed for the simulation of fuel–coolant interactions. A parametric study was performed varying the location of the melt release (central, right and left side melt pour), the cavity water subcooling, the primary system overpressure at vessel failure and the triggering time for explosion calculations. The main purpose of the study was to establish the influence of the varied parameters on the fuel–coolant interaction behaviour, to determine the most challenging cases and to estimate the expected pressure loadings on the cavity walls. For the most explosive central, right side and left side melt pour scenarios a detailed analysis of the explosion simulation results was performed. The study shows that for some ex-vessel steam explosion scenarios higher pressure loads are predicted than obtained in the OECD programme SERENA phase 1.     

Structural integrity assessment of the reactor pressure vessel under the external reactor vessel cooling condition

Since the suggestion of external reactor vessel cooling (ERVC), the effects of melting and cooling on the response of structural integrity of the reactor pressure vessel (RPV) under core melting accident conditions have been investigated. To investigate the initial behavior of RPV lower head and the effects of analysis conditions on the structural integrity of RPV, the transient analysis is utilized considering the transient state. To obtain an analogy with real phenomena, the material properties were determined by combining and modifying the existing results considering phase transformation and temperature dependency. The temperature and stress analyses are performed for core melting accident by using ABAQUS. Finally, the potential for vessel damage is discussed using the Larson-Miller curve and damage rule. In addition, the results by transient analysis are compared with those by steady state analysis and the effects of analysis conditions on structural integrity are reviewed.     

堆芯熔化严重事故下反应堆压力容器下封头高温蠕变分析

核电厂在发生堆芯熔化严重事故时,采用堆内熔融物滞留（IVR）策略将熔融物包容在反应堆压力容器（RPV）内是一项重要缓解措施。在IVR策略期间,RPV下封头在熔融物的极高温度载荷和力学载荷的共同作用下很有可能因过度蠕变变形而失效。因此,有必要对熔融物滞留条件下RPV下封头进行蠕变变形分析,以保证RPV结构完整性。该文在假定IVR条件下,采用有限元方法对RPV下封头进行热-结构耦合分析,通过计算得到容器壁的温度场和应力场,以及下封头的塑性和蠕变变形,并结合塑性和蠕变断裂判据对下封头进行失效分析。结果表明,考虑蠕变影响后,结构的变形将大大增加;严重事故下采取熔融物滞留策略期间,RPV下封头的主要失效模式为蠕变失效而非塑性失效;内压对蠕变变形量和蠕变失效时间有较大影响。该文为严重事故下RPV下封头的蠕变和失效研究提供了分析方法。      

国产反应堆压力容器用16MND5钢的蠕变损伤本构模型研究

为了获得反应堆压力容器（RPV）材料在高温下的蠕变行为,保证RPV在严重事故工况下的完整性,本研究对国产RPV用16MND5钢的高温蠕变性能进行了测试,获得了600~900℃下材料的蠕变性能,并基于应变强化的基本蠕变本构模型与基于延性耗竭理论的蠕变损伤模型,建立了适用于16MND5钢的蠕变损伤本构模型,给出了材料的蠕变损伤模型参数。结果表明,本文提出的蠕变损伤本构模型的有限元模拟数据与试验数据符合性较好,验证了此蠕变损伤模型的正确性。该方法可用于严重事故情况下RPV的蠕变损伤分析,为RPV的完整性分析提供支持。      

Interaction of a screw dislocation with Cu-precipitates,nanovoids and Cu–vacancy clusters in BCC iron

In a previous work we studied the interaction of a ½〈1 1 1〉{1 1 0} edge dislocation with Cu-rich precipitates containing also vacancies and Ni, thereby mimicking precipitates known to form in RPV steels [1]. Here, we extend the study and consider the interaction of the Cu-rich precipitates with ½〈1 1 1〉 screw dislocations, known to govern the slip in BCC metals and alloys below room temperature. The results show that three different mechanisms take place upon interaction of a screw dislocation with pure Cu precipitates, nanovoids and Cu–vacancy clusters. Pure Cu precipitates are always sheared, while in the reaction with nanovoids local climb, especially at high temperature, is also observed. The interaction mechanisms studied at various temperatures reveal that the penetration of the screw dislocation into Cu–vacancy clusters leads to absorption of the majority of the vacancies on the dislocation line, with the consequent formation of a helical turn. The removal of the helical turn, even a very small one, from the dislocation line requires as high stress as for the passage through a row of nanovoids of comparable size.     

Evaluation of ductile–brittle transition temperature before and after neutron irradiation for RPV steels using small punch tests

Small punch (SP) tests were performed to evaluate the ductile–brittle transition temperature before and after a neutron irradiation of reactor pressure vessel (RPV) steels produced by different manufacturing (refining) processes. The results were compared to the standard transition temperature shifts from the conventional Charpy tests and the Master Curve fracture toughness tests in accordance with the American Society for Testing and Materials (ASTM) standard E1921. Small punch specimens were taken from a 1/4t location of the vessel thickness and machined into a 10 mm × 10 mm × 0.5 mm dimension. The specimens were irradiated in the research reactors at Korea Atomic Energy Research Institute Nuclear Research Institute in the Czech Republic at the different fluence levels of about 290 °C. Small punch tests were performed in the temperature range of RT to −196 °C using a 2.4 mm diameter ball. For the materials before and after irradiation, the small punch transition temperatures (T_SP), which are determined at the middle of the upper small punch energies, showed a linear correlation with the Charpy index temperature, T_41 J. T_SP from the irradiated samples was increased with the fluence levels and was well within the deviation range of the unirradiated data. However, the transition temperature shift from the Charpy test (ΔT_41 J) shows a better correlation with the transition temperature shift (ΔT_SP(E)) when a specific small punch energy level rather than the middle energy level of the small punch curve is used to determine the transition temperature. T_SP also had a correlation with the reference temperature (T₀) from the Master Curve method using a pre-cracked Charpy V-notched (PCVN) specimen.