Drop test program with half scale model CASTOR® HAW/TB2

Abstract

Federal Institute for Materials Research and Testing (BAM) is the competent authority for mechanical and thermal safety assessment of transport packages for spent fuel and high level waste in Germany. In context with package design approval of the new German high level waste cask CASTOR® HAW28M, BAM performed several drop tests with a half scale model of the CASTOR® HAW/TB2. The cask is manufactured by Gesellschaft für Nuklear Service mbH and was tested under accident transport conditions on the 200 tons BAM drop test facility at the BAM Test Site Technical Safety. For this comprehensive test program, the test specimen CASTOR® HAW/TB2 was instrumented at 21 measurement planes with altogether 23 piezo resistive accelerometers, five temperature sensors and 131 triaxial strain gauges in the container interior and exterior respectively. The strains of four representative lid bolts were recorded by four uniaxial strain gauges per each bolt. Helium leakage rate measurements were performed before and after each test in the above noted testing sequence. The paper presents some experimental results of the half scale CASTOR® HAW/TB2 prototype (14?500 kg) and measurement data logging. It illustrates the extensive instrumentation and analyses that are used by BAM for evaluating the cask performance to the mechanical tests required by regulations. Although some of the quantitative deceleration, velocity and strain values cannot be shown because of confidentially issues, they are provided qualitatively to illustrate the types of measurements and methodologies used at BAM.     

Finite element mesh design of a cylindrical cask under puncture drop test conditions

Abstract

Transport casks for radioactive materials have to withstand the 9 m drop test, 1 m puncture drop test and dynamic crush test with regard to the mechanical requirements according to the IAEA regulations. The safety assessment of the package can be carried out on the basis of experimental investigations with prototypes or models of appropriate scale, calculations, by reference to previous satisfactory safety demonstrations of a sufficiently similar nature or a combination of these methods. Computational methods are increasingly used for the assessment of mechanical test scenarios. However, it must be guaranteed that the calculation methods provide reliable results. Important quality assurance measures at the Federal Institute for Materials Research and Testing are given concerning the preparation, run and evaluation of a numerical analysis with reference to the appropriate guidelines. Hence, a successful application of the finite element (FE) method requires a suitable mesh. An analysis of the 1 m puncture drop test using successively refined FE meshes was performed to find an acceptable mesh size and to study the mesh convergence using explicit dynamic FE codes. The FE model of the cask structure and the puncture bar is described. At the beginning a coarse mesh was created. Then this mesh was refined in two steps. In each step the size of the elements was bisected. The deformation of the mesh and the stresses were evaluated dependent on the mesh size. Finally, the results were extrapolated to an infinite fine mesh or the continuous body, respectively. The uncertainty of the numerical solution due to the discretisation of the continuous problem is given. A safety factor is discussed to account for the uncertainty.     

Mechanical design assessment approaches of actual spent fuel and HLW transport package designs

Abstract

In recent years, BAM Federal Institute for Materials Research and Testing finalised the competent authority assessment of the mechanical and thermal package design in several German approval procedures of new spent fuel and high level waste package designs. The combination of computational methods and experimental investigations in conjunction with materials and cask components testing is the most common approach to mechanical safety assessment. The methodology in the field of safety analysis, including associated assessment criteria and procedures, has evolved rapidly over the last years. The design safety analysis must be based on a clear and comprehensive safety evaluation concept, including defined assessment criteria and constructional safety goals. In general, for new package designs, the implementation of experimental package drop tests in the approval process should be obligatory. Additionally, pre- and post-test calculations as well as components or material testing could be important. The extent to which drop tests are necessary depends on the individual package construction, the materials used and identified safety margins in the design.     

Safety assessment aspects of type B(U) packages containing wet intermediate level waste

Abstract

In Germany, the mechanical and thermal safety assessment of approved packages for the transport of RAM is carried out by BAM as the competent authority according to the International Atomic Energy Agency regulations. BAM was involved in several approval procedures with ductile cast iron containers containing wet intermediate level waste. These contents, which are not dried, only drained, consist of saturated ion exchange resin and a small amount of free water. Compared to the safety assessment of packages with dry content, attention must be paid to some more specific points. The physical and chemical compatibility of the content itself and of the content with materials of the package must be shown. From the mechanical resistance point of view, the package has to withstand the forces resulting from the freezing liquid. The most interesting point, however, is the pressure build-up inside the package due to vapourisation. This could be caused by radiolysis of the liquid and must be taken into account for the storage period. The paper deals primarily with the pressure build-up inside the package caused by the regulatory thermal test (30 min at 800°C) as part of the cumulative test scenario under accident conditions of transport. To determine the pressure, the temperature distribution in the content must be calculated for the whole period from the beginning of the thermal test until cooling down. In this case, calculating the temperature distribution requires, besides the consideration of conduction and heat radiation, consideration of evaporation and condensation including the associated processes of transport.     

A study on the free drop impact of a cask using commercial FEA codes

The package used to transport radioactive materials, which is called a cask, must be designed to keep its contents safe under normal and hypothetical accident conditions. The design requirements of the cask are verified by test or finite element analysis (FEA). Comparing evaluation procedures for the safety of a new cask, the cost of FEA is generally much less than that test. Therefore, FEA is mainly used to verify safety of a cask under the considered conditions. However, one commercial FEA code may show different results from another FEA code for the same problem due to the modeler's several assumptions for simplifying actual states into the FE model and due to modeling technique. Materials of the components of a cask display elastic–plastic or elastic–perfectly plastic behavior under the considered conditions in which large deformation, impact and contact mechanism are included. The behavior is simulated with difficulty and may have different results depending on FEA codes. In this paper, finite element analysis is carried out for the 9-m free drop and the puncture condition under the hypothetical accident condition by using LS-DYNA3D and ABAQUS/Explicit. Energy and effective stress on each component are presented and compared between the two FEA codes, where the effective stress designates the maximum von Mises stress on inner and outer shells.     

Drop and fire testing of spent fuel and HLW transport casks at ‘BAM Test Site Technical Safety’

Abstract

BAM, as a competent German government institute for the mechanical and thermal testing of radioactive material transport and storage containers, operates unique drop and fire test facilities for experimental investigations on the open air BAM Test Site Technical Safety. To be able to perform even drop tests with full scale spent fuel or HAW casks (i.e. the German CASTOR cask designs), BAM constructed in 2004 a large drop test facility capable to handle 200 ton test objects, and to drop them onto a steel plate covered unyielding target with a mass of nearly 2600 ton. Drop test campaigns of the 181 ton GNS CONSTOR V/TC, the 129 ton MHI MSF-69BG and a 1∶2 scale model of the GNS CASTOR HAW28M (CASTOR HAW/TB2) have been performed since then. The experimental BAM drop testing activities can be supported also by drop testing of smaller packages (up to 2 ton) in an in-house test facility and by dynamic, guided impact testing of package components and material specimen inside a new drop test machine. In May 2008, a new modern fire test facility was put into operation. The facility provides two test stands fired with liquid propane. Testing in every case has to be completed by computational investigations, where BAM operates appropriate finite element modelling on appropriate computer codes, e.g. ABAQUS, LS-DYNA, ANSYS and other analytical tools.     

Mechanical safety analysis for high burn-up spent fuel assemblies under accident transport conditions

Abstract

Transport packages for spent fuel have to meet the requirements concerning containment, shielding and criticality as specified in the International Atomic Energy Agency regulations for different transport conditions. Physical state of spent fuel and fuel rod cladding as well as geometric configuration of fuel assemblies are, among others, important inputs for the evaluation of correspondent package capabilities under these conditions. The kind, accuracy and completeness of such information depend upon purpose of the specific problem. In this paper, the mechanical behaviour of spent fuel assemblies under accident conditions of transport will be analysed with regard to assumptions to be used in the criticality safety analysis. In particular the potential rearrangement of the fissile content within the package cavity, including the amount of the fuel released from broken rods has to be properly considered in these assumptions. In view of the complexity of interactions between the fuel rods of each fuel assembly among themselves as well as between fuel assemblies, basket, and cask body or cask lid, the exact mechanical analysis of such phenomena under drop test conditions is nearly impossible. The application of sophisticated numerical models requires extensive experimental data for model verification, which are in general not available. The gaps in information concerning the material properties of cladding and pellets, especially for the high burn-up fuel, make the analysis more complicated additionally. In this context a simplified analytical methodology for conservative estimation of fuel rod failures and spent fuel release is described. This methodology is based on experiences of BAM acting as the responsible German authority within safety assessment of packages for transport of spent fuel.     

German approach and feedback on experience of transportability of SNF packages after interim storage

In Germany, the concept of dry interim storage of spent fuel in dual purpose metal casks is implemented, currently for periods of up to 40 years. The casks being used have an approved package design in accordance with the international transport regulations. The license for dry storage is granted on the German Atomic Energy Act with respect to the recently revised ‘Guidelines for dry interim storage of irradiated fuel assemblies and heat-generating radioactive waste in casks’ by the German Waste management Commission. For transport on public routes between or after long term interim storage periods, it has to be ensured that the transport and storage casks fulfil the specifications of the transport approval or other sufficient properties, which satisfy the proofs for the compliance of the safety objectives at that time. In recent years, the validation period of transport approval certificates for manufactured, loaded and stored packages were discussed among authorities and applicants. A case dependent system of 3, 5 and 10 years was established. There are consequences for the safety cases in the Package Design Safety Report, including evaluation of long term behaviour of components and specific operating procedures of the package. The present research and knowledge concerning the long term behaviour of transport and storage cask components have to be consulted as well as experiences from interim cask storage operations. Challenges in the safety assessment are e.g. the behaviour of aged metal and elastomeric gaskets under IAEA test conditions to ensure that the results of drop tests can be transferred to the compliance of the safety objectives at the time of transport after the interim storage period. Assessment methods for the material compatibility, the behaviour of fuel assemblies and the aging behaviour of shielding parts are issues as well. This paper describes the state of the art technology in Germany, explains recent experience on transport preparation after interim storage and points out arising prospective challenges.     

CONSTOR® V/TC drop tests: pre-test analysis using the finite-element method

Abstract

CONSTOR^® is a family of steel–CONSTORIT–steel sandwich cask designs that have been developed with special consideration for an economical and effective method of manufacture by using conventional mechanical engineering technologies and common materials. The CONSTOR^® concept fulfils both the internationally valid IAEA criteria for transport and the requirements for long-term intermediate storage in the USA and various European countries. A full-scale prototype test cask, CONSTOR^® V/TC, of the latest CONSTOR^® design has been developed, with a heat removal capacity of up to 32 kW. A comprehensive drop testing programme consisting of five 9 m drops onto a flat unyielding target and seven 1 m drops onto a punch is to be carried out by BAM at the test facilities in Horstwalde during Autumn 2004, with the first 9 m side drop to be carried out during PATRAM 2004. The drop tests will form part of the application for a transport licence in both Germany and the USA. Extensive pre-test calculations have been performed using finite-element methods. The objectives of the analyses are as follows: (1) As an intermediate step in demonstrating the performance of the package in fulfilling the requirements of 10 CFR 71 and the IAEA transport regulations. (2) To justify the selection of drop tests. (3) To predict the performance of the V/TC in the drop tests. (4) To estimate the strain and acceleration–time history at measuring points to aid the setting up of the instrumentation. (5) To develop an analysis model that can be used in future safety analyses for transport and storage licence applications to confidently demonstrate the performance of the package. This paper will: present an overview of the analyses; discuss the methodology of the analysis, including the design and make-up of the models taking into account the behaviour of the package, the requirements of the licensing regimes and the present and future purposes of the model; discuss the modelling techniques used; present key results from the analyses; and discuss the behaviour of the package.     

Scale model impact limiter in type assessment of radioactive material transport packages

Abstract

In Germany, the Federal Institute for Materials Research and Testing (BAM) is the competent authority for the mechanical and thermal design safety assessment of transport packages for radioactive material according to IAEA regulations. The combination of experimental and numerical safety proof forms the basis for a state of the art evaluation concept. Reduced scale models are often used in experimental investigation for design assessment of transport packages corresponding to IAEA regulations. This approach is limited by the fact that a reduced scale model cask can show different behaviours from a full scale cask. The paper focuses on the peculiarities of wood filled impact limiter of reduced scale models. General comments on drop testing with reduced scale models are given, and the relevant paragraphs of the IAEA regulations and Advisory Material are analysed. Possible factors likely to influence the energy absorbing capacity of wood filled impact limiting devices are identified on the basis of similarity mechanics. Among possible significant influence factors on the applicability of small scale models are strain rate and size effects, failure mechanisms, underground compliance, gravitational and friction effects. While it was possible to derive quantitative estimations for the influence of strain rate, size effects and target compliance, it was not possible to evaluate the influence of compression mechanisms and gravitation. In general, if reduced scale models are used in proof of safety, uncertainties increase in comparison with full scale models. Additional safety factors to exclusively cover the uncertainties of reduced scale model testing have to be demanded. The possible application of reduced scale models in regard to crucial aspects for proof of safety has to be analysed critically.     

Results of full scale CONSTOR® V/TC prototype 9 m horizontal drop test

Abstract

In the context of the research on the mechanical safety of packages for radioactive material, full scale drop tests with spent fuel and high activity waste transport and storage casks have been performed by the Federal Institute for Materials Research and Testing (BAM). The research reflects national and international interest in acquiring comparative knowledge of full and reduced scale model drop tests as well as in finite element calculations. This paper presents the experimental, analytical and first numerical results of the full scale drop test with the full scale CONSTOR^® V/TC prototype, manufactured by GNS, Gesellschaft für Nuklear-Service mbH, Germany. The prototype was tested by BAM in a 9 m horizontal drop test onto the unyielding target of the BAM drop test facility in Horstwalde, Germany.     

Extended Drop Tests Of DCI Casks with Artificial Flaws Demonstrating the Existing Safety Margins

Abstract

The use of spent fuel shipping and storage casks made of ductile cast iron (DCI) has been common practice for about 15 years when the development of such casks started in Germany where qualified foundries are able to produce these heavy section castings at the high quality level needed for this kind of application. To promote the discussion on safety against brittle failure a lot of research had been carried out in different countries. The two test programmes in Germany on casks with big artificial flaws under severe impact conditions is summarised in this paper. The first test object was a thick walled DCI ‘pipe’ (150 mm wall thickness) with dimensions equivalent to a 1:2.5 scale cask model. It was dropped with a 40 mm deep laser sharpended flaw from heights of up to 9 m onto rails. As a second test object a full scale CASTOR VHLW cask was used. This specimen had a flaw with a depth of 120 mm in a 260 mm thick wall. With increasing drop heights (up to 14 m) and stress intensity factors (up to material fracture toughness) this object was also dropped onto rails. For both cases the measured data (decelerations, crack opening displacement, strains, material properties) are presented. No brittle failure occurred, although in the 14 m drop of the CASTOR VHLW Cask the impact was 6.5 times higher than the impact measured in the mechanical test of the type B package design. The results demonstrate that DCI casks have significantly high safety margins even in the hypothetical case of an impact beyond type B package design requirements.     

Topical BAM cask design evaluation using drop tests and numerical calculations: accidental cask drop without impact limiters onto storage building foundation

Abstract

Cask impacts without impact limiters onto unyielding targets result in totally different mechanical reactions from those of relatively smooth impacts using impact limiters. During the licensing procedure of the new GNS CASTOR HAW 28M design for vitrified high activity waste, BAM therefore decided to perform an additional drop test with a 1 : 2 scale test cask (CASTOR HAW/TB2). In spite of a small drop height of only 0˙3 m onto the unyielding target of the BAM drop test facility, which conservatively covers any storage building foundation, the impact caused considerable stresses to the cask structure with high stress and strain rates. This paper presents the evaluation strategy of BAM including the drop test results and the development and qualification of appropriate finite element modelling to achieve sufficient agreement between test and calculation results. Further steps include mechanical analyses of reduced and full scale cask designs to determine the most critically stressed areas of the structure, verify scaling factors and demonstrate safety with respect to cask integrity and tightness.     

Methodological aspects for finite element modelling of lid systems for Type B(U) transport packages

Abstract

The regulatory compliance of the containment system is of essential importance for the assessment process of Type B(U) transport packages. The requirements of the International Atomic Energy Agency safety standards for transport conditions imply high loading on the containment system. The integrity of the containment system has to be ensured in mechanical and thermal tests. The containment system of German spent nuclear fuel and high level waste transport packages usually includes bolted lids with metal gaskets. The finite element (FE) method is recommended for the analysis of lid systems according to the guideline BAM-GGR 012 for the assessment of bolted lid and trunnion systems. The FE analyses provide more accurate and detailed information about loading and deformation of such kind of structures. The results allow the strength assessment of the lid and bolts as well as the evaluation of relative displacements between the lid and the cask body in the area of the gasket groove. This paper discusses aspects concerning FE simulation of lid systems for type B(U) packages for the transport of spent nuclear fuel and high level waste. The work is based on the experiences of the BAM Federal Institute for Materials Research and Testing as the German competent authority for the mechanical design assessment of such kind of packages. The issues considered include modelling strategies, analysis techniques and interpretation of results. A particular focus of this paper is on the evaluation of the results with regard to FE accuracy, influence of the FE contact formulation and FE modelling techniques to take the metallic gasket into account.     

Impact target characterisation of BAM drop test facility

Abstract

BAM safety related research of containers for radioactive material focuses on advanced mechanical safety assessment methods for verification of the structural integrity and leak tightness under normal conditions of transport and hypothetical accident conditions during transport and storage. An essentially unyielding target with a rigid surface is required for impact tests performed for package approval according to IAEA regulations. In addition to specification of a target, e.g. with a combined mass more than 10 times that of the specimen for drop tests, unyielding target characteristics have been investigated with various package designs and different impact tests. The unyielding target of the BAM drop test facility, a reinforced concrete block together with an embedded and anchored mild steel plate, provides relatively large mass and stiffness with respect to the packages being tested. For monitoring reasons accelerometers and strain gauges are embedded in the concrete block of the foundation at several positions. Additionally, dynamic impact responses like vibrations and rigid body motion can be measured by seismic accelerometers. The mechanical characterisation of the target's rigidity is based on experimental results from various drop tests. Test containers with weights of 181 000 kg, 127 000 kg and 8010 kg hit the target with velocities up to 13˙5 m s^–1 in the horizontal and vertical drop positions. The rigidity of the impact target can be demonstrated with experimental results confirmed by analytical approaches. Some conclusions can be drawn about experimental testing as well as analytical calculations in order to compare impact effects.     

German Competent Authority Guidance in Finite-element Methods Applications for Package Design Assessment

Abstract

The development of new methods in analysing package designs using the finite-element method is of increasing importance. Package designers are increasingly applying the growing opportunities afforded by numerical methods to perform safety assessments for their products; this also requires suitable methods for competent authorities like BAM to verify applicants' results. This paper gives a topical overview of experiences and trends within the complex field of finite-element design testing. First some general and more formal aspects are described concerning the selection of the correct finite-element program and documentation of modelling, material properties, boundaries and calculation results, including their interpretation. To give a reliable basis for applicants in Germany BAM has recently drawn up and published a Finite Element Guideline. Secondly, actual technical questions are discussed: these are of wide interest and range from mechanical reflections on cask drop and extreme impact scenarios to thermal reflections on the removal of decay heat and fire scenarios. Examples from BAM's work on finite-element development activities are given to demonstrate the great opportunities as well as the difficulties of using finite-element methods for package safety analysis and design testing.     

Revised guidelines for the procedure for approval of package designs in Germany

Abstract

The IAEA Regulations for the Safe Transport of Radioactive Material TS-R-1 are applied in Germany through the implementation of the Dangerous Goods Transport Regulations for Class 7 of the International Modal Organisations (ADR, RID, IMDG-Code, ICAO-TI). Based on this the procedures for the approval of package designs used in Germany are in compliance with the provisions of TS-R-1. BfS is the competent authority for the approval of Type B(U), Type B(M) and Type C packages and all packages containing fissile material, and BAM is the competent authority for approval of H(U)/H(M) packages for UF6, special form and low-dispersible radioactive material. The basis for the procedure for approval of package design in Germany are the R 003 guidelines, first issued by the Ministry of Transport, Building and Housing (BMVBW) in 1991. These guidelines have been reviewed and revised to reflect the latest developments in the regulations as well as in regulatory practice. In particular they have been extended to the procedures for approval of Type C packages and packages subject to transitional arrangements, special form and low-dispersible radioactive material, and provide more detailed information to the applicant about the requested documentation. This paper gives an overview of the main parts and provisions of the revised R 003 guidelines issued in December 2004 including scope, responsibilities, application, documentation, evaluation and certification for the various approval procedures.     

Competent Authority Approval of Package Designs in the United Kingdom

Abstract

Type B packages and all packages containing fissile material, as well as special form radioactive materials, special arrangements and certain shipments, are required to be approved by the competent authority. In the United Kingdom competent authority approval is carried out on behalf of the Secretary of State by the Radioactive Materials Transport Division (RMTD) of the Depatment of the Environment, Transport and the Regions (DETR). Competent authority approval of a package design is given only after a detailed assessment of the design by the specialist staff of RMTD. There are three facets to the assessment procedure, namely engineering, criticality and radiation protection, and quality assurance. The engineering assessor ensures that the designer has demonstrated the integrity of the containment and shielding systems under the regulatory conditions. The criticality assessor examines criticality safety and radiation protection measures, and together with the engineering assessor, decides whether this is maintained under regulatory conditions. The quality assurance assessor verifies that the applicant has established the necessary controls to ensure that the design requirements are met. The applicant is responsible for making the case for approval, but the assessment is facilitated if the competent authority is involved with the designer at an early stage in development and during the construction of any test prototype. When a regulatory test programme is required, it is designed and carried out by the applicant, but agreed and witnessed by representatives of RMTD. Following the test programme, the applicant submits a formal application, supported by a design safety report (DSR). The DSR provides a full analysis of the design and the test results, including the behaviour of the package under normal and accident conditions of transport, the manufacturing and maintenance procedures, quality assurance and the emergency provisions for the operation of the package. RMTD produces a comprehensive Guide to Applications, which details the information required in all types of application for competent authority approval in the United Kingdom.     

Numerical simulation of impact problems applied to development of spent fuel transport cask for research reactors

Abstract

With the support of the International Atomic Energy Agency, a packaging to transport research reactor irradiated fuel was designed by a trinational team from Argentina, Brazil and Chile. A half-scale model for materials test reactor fuel was constructed and tested according to specifications of regional regulations. Numerical modelling of impact problems played a key role in the cask development. During the design process, it was necessary to improve the performance of the shock absorbers and the containment system. This process was carried out using numerical simulations to predict the behaviour of different shock absorber materials, to consider design improvements and to select the drop orientations. The finite element method was used to simulate the impact problem, and a particular effort was undertaken to model all of the geometrical features with high detail, constitutive equations of different materials and multiple contact problems.