LWR fuel rod behavior during severe accidents

Chemical interactions between UO₂ fuel and Zircaloy cladding up to 2350°C are described. UO₂/Zircaloy single effects tests have been performed with short LWR fuel rod segments in inert gas and under oxidizing conditions. The reaction kinetics of molten Zircaloy cladding with solid UO₂ fuel has been investigated with UO₂ crucibles containing molten Zircaloy. The UO₂/Zircaloy reactions obey parabolic rate laws. The oxygen uptake by solid Zircaloy due to chemical interaction with UO₂ occurs nearly as quickly as that from the reaction with steam or oxygen.To study the competing effects of the external and internal cladding oxidation under realistic boundary conditions and the influence of the uncontrolled temperature escalation due to the exothermic steam/Zircaloy reaction on the maximum cladding temperature, single rod and bundle experiments have been performed. Electrically heated fuel rod simulators, including absorber rod material (Ag, In, Cd alloy), guide tubes and grid spacers are used. The maximum measured cladding temperature during the temperature escalation was about 2200°C. The failure temperature of the absorber rods and the extent of bundle damage depends on the guide tube material (Zircaloy or stainless steel) and varies between 1200 and 1350°C. The molten materials and liquid reaction products can relocate and form large coherent lumps on solidification, which may result in complete blockage of the fuel rod bundle cross section. In the future, 7 × 7 bundle experiments of 2 m overall length will be performed in the new CORA facility to study, in addition, the influence of quenching on fuel rod integrity.     

Enhancing the ABAQUS thermomechanics code to simulate multipellet steady and transient LWR fuel rod behavior

A powerful multidimensional fuels performance analysis capability, applicable to both steady and transient fuel behavior, is developed based on enhancements to the commercially available ABAQUS general-purpose thermomechanics code. Enhanced capabilities are described, including: UO₂ temperature and burnup dependent thermal properties, solid and gaseous fission product swelling, fuel densification, fission gas release, cladding thermal and irradiation creep, cladding irradiation growth, gap heat transfer, and gap/plenum gas behavior during irradiation. This new capability is demonstrated using a 2D axisymmetric analysis of the upper section of a simplified multipellet fuel rod, during both steady and transient operation. Comparisons are made between discrete and smeared-pellet simulations. Computational results demonstrate the importance of a multidimensional, multipellet, fully-coupled thermomechanical approach. Interestingly, many of the inherent deficiencies in existing fuel performance codes (e.g., 1D thermomechanics, loose thermomechanical coupling, separate steady and transient analysis, cumbersome pre- and post-processing) are, in fact, ABAQUS strengths.     

FEMAXI-IV: A computer code for the analysis of fuel rod behavior under transient conditions

A fuel rod behavior code FEMAXI-IV, presently under development, is an improved version of the FEMAXI-III code for the analysis of fuel rod behavior under transient conditions. To apply the FEMAXI-III code to transient conditions, the following additional models have been incorporated into the FEMAXI-III code: transient heat transfer model: axial gas mixing model; diffusion-type fission gas release model. This paper summarizes the above additional models, and the comparison of the FEMAXI-IV calculations with the experimental data.     

Validation of frey for the safety analysis of LWR fuel using transient fuel rod experiments

The analysis and comparison of severe light water reactor transient experiments are presented from the FREY verification and validation effort. The purpose of this study was to validate the predictive capabilities of the code for severe transient analysis. The FREY code, developed under the sponsorship of the Electric Power Research Institute, uses a two-dimensional finite-element computational method for the thermomechanical analysis of LWR fuel rods under steady state and transient conditions. A total of 10 test fuel rods from experimental programs conducted in both the Power Burst Facility and the Transient Reactor Test Facility have been used in this study. The fuel rods were selected from the following test programs: Power Coolant Mismatch Tests, PCM-2 and PCM-4: Reactivity Initiated Accident Test, RIA 1–2; Loss-of-Coolant Accident Test, LOC-3; First Fuel Rod Failure Test, FRF-1; and Irradiation Effects Test, IE-3. The test programs used in this study cover a large range of code applications for severe transient analysis. The methods used to model the fuel, cladding, and coolant geometry are discussed in addition to experimental data comparisons. The results of the PCM-2, RIA 1–2, and FRF-1 analyses are presented to highlight the full two-dimensional modeling capabilities of FREY and to compare the thermal and mechanical measurements with FREY's prediction. The comparisons show good general agreement, with a tendency for FREY to overpredict the peak cladding surface temperature for a few cases where strong three-dimensional effects have been identified.     

Analysis of fuel rod behavior under normal operating conditions in Super Fast Reactor

A Super Fast Reactor is a pressure-vessel type, fast spectrum supercritical water-cooled reactor (SCWR) that is presently researched in a Japanese project. A preliminary core has been designed with 1.59E+06 W/m³ of power density [1]. In order to ensure the fuel rod integrity, the fuel rod behaviors under the normal operating conditions are analyzed using FEMAXI-6 code. Three types of the limiting fuel rods, with the maximum cladding surface temperature (MCST), maximum power peak (MPP) and maximum discharge burnup (MDB), are chosen to cover all the fuel rods in the core. The power histories of these fuel rods are taken from the neutronics calculation results in the core design. The available design range of the fuel rod design parameters, such as the initial gas plenum pressure, gas plenum length, grain size and pellet-cladding gap size, are found out in order to satisfy the following design criteria: (1) Maximum fuel centerline temperature should be less than 1900 °C. (2) Maximum cladding stress in circumstance direction should be less than 100 MPa. (3) Pressure difference on the cladding should be less than 1/3 of buckling collapse pressure. (4) Compressive stress to yield strength ratio should be less than 0.2. (5) Cumulative damage fraction (CDF) on the cladding should be less than 1.0. Finally the improved fuel rod design is proposed.     

FARST — A computer code for the evaluation of FBR fuel rod behavior under steady-state/transient conditions

FARST, a computer code for the evaluation of fuel rod thermal and mechanical behavior under steady-state/transient conditions has been developed. The code characteristics are summarized as follows:

1. (i) FARST evaluates the fuel rod behavior under the transient conditions. The code analyzes thermal and mechanical phenomena within a fuel rod, taking into account the temperature change in coolant surrounding the fuel rod.

2. (ii) Permanent strains such as plastic, creep and swelling strains as well as thermoelastic deformations can be analyzed by using the strain increment method.

3. (iii) Axial force and contact pressure which act on the fuel stack and cladding are analyzed based on the stick/slip conditions.

4. (iv) FARST used a pellet swelling model which depends on the contact pressure between pellet and cladding, and an empirical pellet relocation model, designated as “jump relocation model”.

The code was successfully applied to analyses of the fuel rod irradiation data from pulse reactor for nuclear safety research in Cadarache (CABRI) and pulse reactor for nuclear safety research in Japan Atomic Energy Research Institute (NSRR).The code was further applied to stress analysis of a 1000 MW class large FBR plant fuel rod during transient conditions. The steady-state model which was used so far gave the conservative results for cladding stress during overpower transient, but underestimated the results for cladding stress during a rapid temperature decrease of coolant.     

Matrix calculation of radiant heat transfer in LWR fuel bundles under accident conditions

A computer code was developed for calculating the radiant heat transfer in a LWR fuel bundle under accident conditions. The calculation method is a modular one: a fuel bundle or its part is divided into unit cells, each of which is composed of a coolant subchannel surrounded by several segments of solid or imaginary faces. The view factor matrix in each cell is expanded over the whole bundle using the concept of ‘boundary face’ between cells, and the resultant heat transfer equations are simultaneously solved for solid wall temperatures. The geometrical flexibility of this method is suitable for treating various simulation experiments for accidents. The method is also effective for repeated calculations of the radiant heat transfer reflecting state or material property changes when analyzing fuel rod behaviour under accident conditions.     

The mechanistic prediction of transient fission-gas release from LWR fuel

The steady-state and transient gas release and swelling subroutine (GRASS-SST) is a mechanistic computer code for the prediction of fission-gas behavior in UO₂-base fuels. GRASS-SST treats fission-gas release and fuel swelling on an equal basis and simultaneously treats all major mechanisms that influence fission-gas behavior. The GRASS-SST transient analysis has evolved through comparisons of code predictions with the fission-gas release and physical phenomena that occur during reactor operation and transient direct-electrical heating (DEH) testing of irradiated light-water reactor fuel. The GRASS-SST steady-state analysis has undergone verification for end-of-life fission-gas release and intragranular bubble-size distributions. The results of GRASS-SST predictions for transient fission-gas release during DEH tests are in good agreement with experimental data. Comparisons of GRASS-SST predictions of gas release and bubble-size distributions with the results of DEH transient tests indicate that (1) coalescing bubbles do not have sufficient time to grow to equilibrium size during most transient conditions, (2) mobilities of fission-gas bubbles in UO₂ are enhanced during nonequilibrium conditions if the excess pressure in the bubble is sufficient to generate an equivalent stress greater or equal to the yield stress of the surrounding matrix, and (3) channel formation on grain surfaces and coalescence of the channels with each other and with the tunnels of gas along the grain edges can contribute to grain-boundary separation and/or the rapid, long-range interconnection of porosity. The phenomena of grain-boundary separation and/or long-range interconnection of porosity provides an important release mechanism for fission gas that has moved out of the grains of irradiated fuel.     

Stress corrosion cracking of Zircaloy-4 cladding at elevated temperatures and its relevance to transient LWR fuel rod behaviour

In extensive out-of-pile experiments from 500 to 900° C it has been shown that, of all the volatile fission products in a LWR fuel rod, only iodine can cause low ductility failure of Zircaloy-4 tubing due to stress corrosion cracking up to about 800° C. The critical iodine concentration above which brittle cladding failure occurs was determined as a function of temperature in the absence and presence of UO₂ fuel. A comparison of these values with the amount expected in the fuel cladding gap during a LOCA transient shows that a clear influence of iodine on burst strain can be expected only up to 700° C. This is in agreement with the results of in-pile LOCA tests performed in the FR-2 reactor with high burnup fuel rods. Since the burst temperatures during a LOCA transient would generally be above 700° C, an influence of iodine on burst strain is not very probable in a LOCA. However, with respect to ATWS transients where the maximum cladding temperatures would be below 700° C, an influence of iodine on the mechanical properties of zircaloy can be expected.     

A new mechanistic code SFPR for modeling of single fuel rod performance under various regimes of LWR operation

A new mechanistic code SFPR for modeling of single fuel rod behavior under various regimes of LWR reactor operation (normal and off-normal, including severe accidents) is under development at IBRAE. The code is designed by coupling of two stand-alone mechanistic codes MFPR (for modeling of irradiated UO₂ fuel behavior and fission product release) and SVECHA/QUENCH, or S/Q (for modeling of Zr cladding thermo-mechanical and physico-chemical behavior). Both codes were initially designed for accident conditions (and for this reason, are rather mechanistic) and later extended to various normal operation conditions. On the base of thorough validation against various out-of-pile and in-pile experiments, development of an advanced fuel performance code for best estimate code calculations for both normal and off-normal LWR operation regimes is foreseen.     

Probabilistic models for fuel rod puncturing in an LWR core during a LOCA

The number of fuel rods which puncture during an LWR loss-of-coolant accident (LOCA) must be estimated as part of the plant radioactivity release analysis. Due to the great number of fuel rods in the core and the great number of contributing parameters, many of them associated with wide uncertainty and/or truly random variability limits, probabilistic methods are well applicable. A succession of computer models developed for this purpose is described together with applications to a WWER-440 PWR. Deterministic models are shown to be seriously inadequate and even misleading under certain circumstances. A simple analytical probabilistic model appears to be suitable for many applications. Monte Carlo techniques allow the development of such sophisticated models that errors in the input data presently available for practical problems probably become dominant in the residual uncertainty of the core-wide fuel rod puncture analysis.     

A methodology for the evaluation of fuel rod failures under accident conditions

Abstract

Recent studies on the long-term behaviour of high-burnup spent fuel have shown that, under normal conditions of storage, challenges to cladding integrity from various postulated damage mechanisms, such as delayed hydride cracking, stress-corrosion cracking and long-term creep, would not lead to any significant safety concerns during dry storage, and regulatory rules have subsequently been established to ensure that a compatible level of safety is maintained. However, similar regulatory rules have not yet been developed to address failures of fuel rod cladding that could potentially lead to reconfigured fuel geometry under hypothetical transport accidents. At issue is the effect on cladding ductility of potential changes in zirconium hydride morphology during dry storage. Recent studies have shown that above a certain level of cladding hoop stress, the decaying temperature history during dry storage can cause the hydrogen in solid solution to precipitate in the form of radial hydrides, which, depending on their relative concentration, can induce brittle failures in the cladding. From a US regulatory perspective such cladding failures, if they were to cause fuel reconfiguration, could invalidate the cask's criticality and shielding licensing analyses, which are based on coherent geometry. This paper describes a methodology for high-burnup spent fuel to determine the frequency of cladding failure and failure modes under drop accidents, considering end-of-storage spent fuel conditions. The degree to which spent fuel reconfiguration could occur during handling or transport accidents would depend to a large extent on the number of fuel rod failures and the type and geometry of the failure modes. Such information can only be developed analytically, as there are no direct experimental data that can provide guidance on the level of damage that can be expected. To this end, this paper focuses on the development of a methodology for modelling and analysis that deals with this general problem on a generic basis. First, consideration is given to defining accident loading that is equivalent to the bounding hypothetical transport accident of a 9 m drop onto an essentially unyielding surface. Second, an analytically robust material constitutive model, an essential element in a successful structural analysis, is required. A model of material behaviour, with embedded failure criteria, for cladding containing various concentrations of circumferentially and radially oriented hydrides has been developed and implemented in a finite-element code. The hydride precipitation model, which describes the hydride structure of the cladding at the end of dry storage, and the hydride-dependent properties of high-burnup fuel cladding form the main input to the constitutive model. The third element in the overall process is to utilise this material model and its host finite-element code in the structural analysis of a transport cask subjected to bounding accident loading to calculate fuel rod failures and failure mode configurations. This requires detailed modelling of the transport cask and its internal structure, which includes the canister, basket, fuel assembly grids and fuel rods. The overall methodology is described.     

Rock-like oxide fuel behavior under reactivity initiated accident conditions

Pulse irradiation tests of two types of rock-like oxide (ROX) fuel, i.e. yttria stabilized zirconia (YSZ) and YSZ/Spinel composite, were conducted in the Nuclear Safety Research Reactor (NSRR) to investigate the fuel behavior under reactivity-initiated accident conditions. The ROX fuels failed with cladding burst at fuel volumetric enthalpies above 10 GJ m⁻³, which was comparable to that of UO₂ fuel. The failure of the ROX fuels, however, occurred with considerable fuel melting and was quite different to that of UO₂ fuel, which was caused by cladding melting and embrittlement due to heavy oxidation. Lower fuel melting temperature of the ROX fuels compared to that of UO₂ contributed to the different fuel failure modes. Certain amount of molten ROX fuel dispersed out at the failure. However, the mechanical energy generation due to the molten fuel/water interaction was negligible for the ROX fuels at peak fuel enthalpies below 12 GJ m⁻³.     

Evaluation of implementation of thorium fuel cycle with LWR and MSR

In order to construct a sustainable society, it is necessary to consider fairness beyond generations and between countries. It is expected that Asian countries continue growing their economy and will result consuming more energy. More CO₂ emission is not acceptable.Nuclear power has many advantages for reducing CO₂ emission. However, it still has concerns of nuclear proliferation, radioactive waste and safety. It is necessary to overcome these concerns if nuclear power is expanded to Asian countries. Thorium utilization as nuclear fuel will be an opening key of these difficulties because thorium produces less plutonium, less radioactive waste. Safety will also be enhanced. The use of molten-salt reactor (MSR) triggered by plutonium supply from ordinary light water reactor (LWR) with uranium fuel will allow implementation of thorium fuel cycle with electricity capacity of about 446 GWe around at 2050.The other important sector in a view of sustainability is transportation. Transportation is essential for economy growth. Therefore it is inevitable to reduce CO₂ emission from transportation sector. Electric vehicle (EV) will be used as a major mobility instead of gasoline engine cars. Rare-earth materials such as neodymium and dysprosium are necessary for producing EV. These materials are expected to be mined from Asian countries. It is often obtained with thorium as by-product. Thorium has not been used as nuclear fuel because it is not good for nuclear weapon and it does not have fissionable isotopes. Recent global trend of nuclear disarmament and accumulation of plutonium from uranium fuel cycle can support starting the use of thorium.Thorium utilization will help both to provide clean energy and to produce rare-earth for clean vehicle. These will create new industries in developing Asian countries. An international collaborative framework can be established by supplying resource from developing countries and supplying technology from developed countries. “THE Bank (THorium Energy Bank)” is proposed here as one part of such a framework.     

Results of a long-term wet storage demonstration test with intact and operational defective LWR fuel rods

28 spent fuel rods — 18 intact and 10 operational defective rods — were included in the storage test program. Within 7 years the spent fuel rods were inspected four times. To characterize the spent fuel rods the following methods were applied during pool inspections: visual inspection, profilometry, eddy current testing, and oxide thickness recording.Summarizing the results of the intermediate and of the final inspection it has to be concluded that — as predicted — no change exceeding the detection limit could be found either at the intact or at the operational defective fuel rods. These results must be regarded as conservative because handling of the different spent fuel rods during inspection provided additional and atypical loads — especially for the operational defective spent fuel — in comparison with the long term storage of complete fuel bundles.The results of this carefully documented demonstration test has shown agreement with the theoretical analysis and with the overall experience available from pool storage that wet spent LWR-fuel storage can be performed without any problems even for extended periods of time.     

The effect of fuel rod supporting conditions on fuel rod vibration characteristics and grid-to-rod fretting wear

The grid-to-rod fretting wear-induced fuel rod failure observed in PWRs may be caused by excessive fluid-induced vibration and inadequate fuel rod support by the spacer grid spring. In order to simulate in-reactor grid-to-rod fretting wear behaviors, the grid-to-rod fuel rod supporting conditions as a function of time were predicted by taking into account cladding creep rate, initial spacer grid spring deflection, spacer grid spring force relaxation, etc. Based on these grid-to-rod supporting conditions, the fuel rod vibration modes and natural frequencies were calculated with the help of the ANSYS code, while the fuel rod vibration amplitudes were estimated by the Paidoussis’ empirical formula. With these vibration characteristics that depend upon the grid-to-rod supporting conditions, the in-reactor fretting wear axial profile observed on the fuel rod surface are found to be simulated quite well. In addition, key design guidelines for the fuel assembly and the spacer grid are proposed to minimize the grid-to-rod fretting wear that may be utilized to develop an advanced fuel design against fretting wear.     

Leakage potential of LWR containment penetrations under severe accident conditions

This paper is an overview of a Sandia National Laboratories, Albuquerque (SNLA) study of the performance of mechanical penetrations in light-water reactor (LWR) containment buildings that are subjected to severe accident environments. The study is concerned with modes of failure as well as the magnitude of leakage. The following tests have been completed, are under way, or are planned: (a) seals and gaskets have been tested to register the effects of radiation aging, thermal aging, seal geometry, and squeeze on seal and gasket materials in severe accident environments; (b) the performance of a full-scale airlock will be evaluated at severe accident temperature and pressure levels; (c) personnel airlock and equipment hatch tests were made on a model of a steel containment building; and (d) tests of mechanical penetrations are planned as part of a test on a model of a reinforced concrete building. This program is part of an overall US Nuclear Regulatory Commission (USNRC) effort to evaluate the integrity of LWR containment buildings.