On certain aspects of alternative core disruption accidents in LMFBRs

This paper examines the initial course of a postulated accident scenario in an LMFBR, involving the rupture of all piping connected to the reactor vessel, in the event of an earthquake (or an equivalent scenario involving both loss of heat removal and system rupture). The core is successfully shut down, but decay heat imposes a threat to core integrity.At the onset of pipe rupture, the fuel elements are cooled by natural circulation, followed by subcooling and nucleate boiling. Continuation of sodium evaporation leads to core dryout, clad melting, and subassembly wall failure. Clad melting is found to occur at a location close to the top of the core at a rate of 0.08 ft³/s. The sodium vapor velocity is not high enough to carry the molten steel to the upper blanket region; therefore, flow-channel blockage in the lower axial blanket region is expected.At the time of clad melting, the fuel temperature rises by approximately 2°F/s, while the temperature-rise rate at the can wall, due to heat radiation from the fuel pin, is 10°F/s. Failure of the can wall initiates gross fuel motion. Continuation of the heat generation in the fuel pellet leads to the melting of the control rod support. Both the fuel motion and the control rod failure mark the start of reactivity insertion.     

Transient Cooling Process of Fuel Rod in Reactivity Initiated Accident

Out-of-pile experiments were performed with Zircaloy-4 rods in subcooled water environment to study the basic phenomena occurring in the transient cooling process undergone by a fuel rod during a reactivity-initiated accident (RIA) affecting a light water reactor (LWR). The experimental results show that the cooling process of the fuel rod during an RIA can be divided into three phases separated by the quenching temperature T_q and the rewetting temperature T_q .

It is also noted from the experimental results that with increasing degree of subcooling, T_q tends to rise to levels far exceeding the maximum liquid superheat temperature of water; T_q , on the other hand, is little affected by the cooling water temperature, and remains close to that of the maximum superheat temperature.

Numerical calculations indicate conclusively that radial heat transfer to coolant water is the dominant factor that governs the transient cooling process in an RIA affecting the cold start-up of a BWR, rather than the axial heat conduction through rod which is considered to be the basic mechanism of cooling that governs the reflooding process during a LOCA.     

The physics of rewetting in water reactor emergency core cooling

Surface rewetting is essential for the re-establishment of normal and safe temperature levels following dryout in rod clusters or boiler tubes, or following postulated loss-of-coolant accidents in water reactors. Rewetting experiments have been performed with tubes and rods with a wide range of materials and experimental conditions (surface temperatures 300–800°C, constant water flows 0.1–30 g s⁻¹). The physical processes involved in the rewetting of high temperature surfaces have been shown to be identical for both falling water films and bottom flooding. The variation of rewetting velocity with mass flow has been determined, and shown to be independent of hydraulic diameter over the range 0.2–6 mm of practical interest. Data have also been obtained on the mass ‘carryover’ fraction. Theoretical solutions for the rewetting velocities have been obtained by analysis of thermal conduction in the surface. At low mass flows, effectively one-dimensional (axial) conduction cools the surface ahead of the rewetting front, and gives agreement with experiment. At higher mass flows the rewetting velocity is substantially independent of surface thickness and conductivity. The present data and the available world data for rewetting are shown to be in agreement with the theory.     

An experimental investigation on thermal striping: Mixing phenomena of a vertical non-buoyant jet with two adjacent buoyant jets as measured by ultrasound Doppler velocimetry

An experimental investigation on the thermal mixing phenomena of three quasi-planar vertical jets, with the central jet at a lower relative temperature than the two adjacent jets, was conducted. The central jet was unheated (‘cold’), while the two adjacent jets were heated (‘hot’). The temperature difference and velocity ratio between the heated (h) and unheated (c) jets were, ΔT_hc=5°C, 10°C and r=V_cold,exit/V_hot,exit=1.0 (isovelocity), 0.7, 0.5 (non-isovelocity) respectively. The typical Reynolds number was Re_D=1.8×10⁴, where D is the hydraulic diameter of the exit nozzle. Velocity measurement of a reference single-jet and triple-jet arrangement were taken by ultrasound Doppler velocimetry (UDV) while temperature data were taken by a vertically traversed thermocouple array. Our UDV data revealed that, beyond the exit region, our single-jet data behaved in the classic manner. In contrast, the triple-jet exhibited, for example, up to 20 times the root-mean-square velocity values of the single-jet, especially in the regions in-between the cold and hot jets. In particular, for the isovelocity case (V_exit=0.5 m/s) with ΔT_hc=5°C, we found that the convective mixing predominantly takes place at axial distances, z/D=2.0–4.5, over a spanwise width, x/D|2.25|, centered about the cold jet. An estimate of the turbulent heat flux distribution semi-quantitatively substantiated our results. As for the non-isovelocity case, temperature data showed a localized asymmetry that subsequently delayed the onset of mixing. Convective mixing however, did occur and yielded higher post-mixing temperatures in comparison to the isovelocity case.     

Heat flux on limiters in low-q discharges

Heat flux on the Doublet III limiters was measured with an infrared camera and thermocouples during low-q discharges. The total heat load to the limiters increases with in both Dee and circular plasmas. The peak heat flux on the limiters in low-q discharges of q_a^* ≈ 2 is ≈ 2 times higher than that in high-q discharges of q_a^* ≈ 4. Since a low-q discharge is essential in order to have a high-β tokamak reactor in the future, higher heat flux on the limiters may be an inevitable problem. It is proposed that the increase in peak heat flux during low-q discharges can be reduced by modification of the limiter to an asymmetric shape.     

Natural convection heat transfer from horizontal rod bundles in liquid sodium. Part 2: Correlations for horizontal rod bundles based on theoretical results

Natural convection heat transfer from horizontal rod bundles in N_xm × N_ym arrays (N_xm, N_ym = 5–9) in liquid sodium was numerically analyzed for three types of the bundle geometry (in-line rows, staggered rows I and II). The unsteady laminar two-dimensional basic equations for natural convection heat transfer caused by a step heat flux were numerically solved until the solution reaches a steady state. The PHOENICS code was used for the calculation considering the temperature dependence of thermophysical properties concerned. The surface heat fluxes for each cylinder were equally given for a modified Rayleigh number, R_f, ranging from 0.0637 to 63.1 (q = 1×10⁴ to 7×10⁶ W/m²). S_x/D and S_y/D for the rod bundle, which are the ratios of the distance between center axes on the abscissa and the ordinate to the rod diameter, respectively, were ranged from 1.6 to 2.5 on each bundle geometry. The spatial distribution of Nusselt numbers, Nu, on horizontal rods of a bundle was clarified. The average value of Nusselt number, Nu_av, for three types of bundle geometry with various values of S_x/D and S_y/D were calculated to examine the effect of the array size, S/D and R_f on heat transfer. The bundle geometry for the higher Nu_av value under the condition of S_x/D×S_y/D = 4 was examined by changing the ratio of S_x/S_y. A correlation for Nu_av for the three types of bundle geometry above mentioned including the effects of S_x/D and S_y/D was developed. The correlation can describe the theoretical values of Nu_av for the three types of bundle geometry in N_xm × N_ym arrays (N_xm, N_ym = 5–9) for S_x/D and S_y/D ranging from 1.6 to 2.5 within 10% difference.     

Mechanical integrity analysis of TMI-1 OTSG unplugged tubes

Small I.D. circumferential defects have been identified in many steam generator tubes. The origin of the cracks is known to be chemical, not mechanical. A fracture mechanics evaluation has been conducted to ascertain the stability of tube cracks under steady-state and anticipated transient conditions. A spectrum of hypothetical crack sizes was interacted with tube stresses derived from the load evaluation using the methods of linear elastic fracture mechanics (LEFM). Stress intensities were calculated for part-through wall cracks in cylinders combining components due to membrane stress, bending stress, and stresses due to internal pressure acting on the parting crack faces as the loads are cycled.The LEFM computational code, “BIGIF”, developed for EPRI, was used to integrate over a range of stress intensities following the model to describe crack growth in INCO 600 at operating temperature using the equation (ΔK)^3.5.The code was modified by applying ΔK_Th, the threshold stress intensity range. Below ΔK_Th small cracks will not propagate at all. Appropriate R ratio values were employed when calculating crack propagation due to high cycle or low cycle loading.Cracks that may have escaped detection by ECT will not jeopardize tube integrity during normal cooldown unless these cracks are greater than 180° in extent. Large non-through-wall cracks that would jeopardize tube integrity are not expected to evolve because in axi-symmetric tensile stress fields, cracks propagate preferentially through the tube wall rather than around the circumference. Tube integrity can be demonstrated for mid-span tube regions and for the transition region as well.The as-repaired transition geometry is a design no less adequate than the original. The as-repaired condition represents an improvement in the state of stress due to mechanical and thermal loads as compared to the original.     

Application of a local approach to ductile-brittle transition in a low-alloyed steel

Both tensile tests on notched specimens and fracture mechanics experiments on axisymmetrically cracked specimens were performed on one heat of A508 steel (AFNOR: 16MND5). Tensile tests on notched geometries were made to determine the characteristic parameters used in a statistical analysis of cleavage fracture proposed previously [1]. Tests on cracked specimens were carried out between −80°C and −20°C to investigate the critical values of stable crack growth, Δa_c, occurring before unstable cleavage fracture. At a given temperature a large scatter in the values of critical crack growth, Δa_c, was observed.To interpret these results a model derived previously for cleavage crack initiation [1] is used. In this model the Weibull stress is calculated by the finite element method for three different initial crack lengths covering stable growth increments observed experimentally. It is shown that this model accounts reasonably well for the observed effects.     

Results on research of templates from Kozloduy-1 reactor pressure vessel

The studies on the specimens manufactured from the templates cut out from the weld 4 of Kozloduy NPP Unit 1 reactor vessel have been conducted. The data on chemical composition of the weld metal have been obtained. Neutron fluence, mechanical properties, ductile to brittle transition temperature (DBTT) using mini Charpy samples have been determined. The phosphorus and copper content averaged over all templates is 0.046 and 0.1 wt.%, respectively. The fluence amounted up to 5×10¹⁸ n cm⁻² within 15–18 fuel cycles, and about 5×10¹⁹ n cm⁻² for the whole period of operation. These values agree well with calculated data. DBTT was determined after irradiation (T_k) to evaluate the vessel metal state at the present moment, then after heat treatment at the temperature of 475°C to simulate the vessel metal state after thermal annealing (T_an), and after heat treatment at 560°C to simulate the metal state in the initial state (T_k0). As a result of the tests the following values were obtained: T_k, +91.5°C; T_an, +63°C; and T_k0, 54°C. The values of T_k and T_an obtained by measurements were found to be considerably lower than those predicted in accordance with the conservative method accepted in Russia (177°C for T_k and 100°C for T_an). Thus, the obtained results allowed to make a conclusion that it is not necessary to anneal Kozloduy NPP Unit 1 reactor vessel for the second time. The fractographic and electron-microscopic research allowed to draw some conclusions on the embrittlement mechanism.     

A study on the behavior of a crack located at the striping zone in a thermally stratified pipe

The behavior of a small crack located at the thermal striping zone in a thermally stratified piping is numerically investigated. The effects of the parameters such as fluctuation frequency/ amplitude of the density interface, heat transfer coefficient near the thermal striping zone, and crack depth on the behavior of the crack are examined to identify the governing parameters. The effect of the contact surfaces on the stress intensity factor range is also examined for several levels of the internal fluid pressure. The stress intensity factor range, ΔK_I, is used to describe the crack behavior due to the thermal striping. The findings of the numerical investigation are as follows: (1) the value of ΔK_I increases up to a specific Fourier number and then decreases beyond the specific Fourier number. (2) With the increasing Biot number the value of ΔK_I increases and the Fourier number(Fo) at which the ΔK_I vs. Fo curve has a peak decreases. This means that the behavior of a crack located at the thermal striping zone has a large dependence on the oscillating frequency of the density interface and the heat transfer coefficients. (3) The value of ΔK_I increases up to a specific crack depth and then decreases beyond the specific crack depth. (4) If the fluid pressure is lower than a specific value, the value of ΔK_I decreases because of the crack surface contact.     

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.     

Investigation of the ductile fracture properties of type 304 stainless steel plate, welds, and 4-inch pipe

J-integral fracture toughness tests were performed on welded 304 stainless steel 2-inch plate and 4-inch diameter pipe. The 2-inch plate was welded using a hot-wire automatic gas tungsten arc process. This weldment was machined into 1T and 2T compact specimens for single specimen unloading compliance J-integral tests. The specimens were cut to measure the fracure toughness of the base metal, weld metal and the heat affected zone (HAZ). The tests were performed at 550°F, 300°F and room temperature. The results of the J-integral tests indicate that the J_Ic of the base plate ranged from 4400 to 6100 in lbs/in² at 550°F. The J_Ic values for the tests performed at 300°F and room temperature were beyond the measurement capacity of the specimens and appear to indicate that J_Ic was greater than 8000 in lb/in². The J-integral tests performed on the weld metal specimens indicate that the J_Ic values ranged from 930 to 2150 in lbs/in² at 550°F. The J_Ic values of the weld metal specimens tested at 300°F and room temperature were 2300 and 3000 in lbs/in² respectively. One HAZ specimen was tested at 550°F and found to have a J_Ic value of 2980 in lbs/in² which indicates that the HAZ is an average of the base metal and weld metal thoughness. These test results indicate that there is a significant reduction in the initiation fracture toughness as a result of welding.The second phase of this task dealt with the fracture toughness testing of 4-inch diameter 304 stainless steel pipes containing a gas tungsten arc weld. The pipes were tested at 550°F in four point bending. Three tests were performed, two with a through wall flaw growing circumferentially and the third pipe had a part through radial flaw in combination with the circumferential flaw. These tests were performed using unloading compliance and d.c. potential drop crack length estimate methods. The results of these test indicate that the presence of a complex crack (radial and circumferential) reduces in the initiation toughness and the tearing modulus of the pipe material compared to a pipe with only a circumferentially growing crack.     

Thermo-physical properties and transient heat transfer of concrete at elevated temperatures

The objective of this study is to produce our own experimental data of physical properties of domestic concrete used in Korean NPPs, and to study on the thermal behavior of concrete exposed to high temperature conditions. The compressive strength and chemical composition of the concrete used in the Yonggwang NPP units 3 and 4 were analyzed. The chemical composition of Korean concrete is similar to that of US basaltic concrete. The thermal properties of the concrete, such as density, conductivity, diffusivity, and specific heat were also measured with a wide temperature range of 20–1100 °C. Most thermo-physical properties of concrete decrease with an increase in temperature except for the specific heat, and particularly the conductivity and the diffusivity are a 50% lower at 900 °C as compared with the values at room temperature. The specific heat increases until 500 °C, decreases from 700 to 900 °C, and then increases again when temperature is above 900 °C. In this work, we also have performed CORCON analysis and MCCI experiments to simulate a transient thermal behavior of concrete exposed to high temperature conditions. The measured maximum downward heat flux to the concrete specimen was estimated to be about 2.1 MW m⁻² and the maximum erosion rate of the concrete to be 175 cm h⁻¹ with maximum erosion depth of about 2 cm. In the CORCON analysis, it is found that the concrete compositions have an important effect upon concrete erosion.     

Toughness investigation on simulated weld HAZs of SQV-2A pressure vessel steel

In order to get detailed information about weld HAZs toughness of SQV-2A steel and determine the optimum welding and heat treatment parameters, the toughness of simulated CGHAZs (coarse grained heat affected zone) and CGHAZs (intercritically reheated CGHAZ) were systematically investigated. The influence of tempering thermal cycles on weld ICCGHAZs toughness was clarified. The effect of post weld heat treatments (PWHT) on weld CGHAZs toughness was also determined. The results showed that high toughness (absorbed energy >200 J) of weld HAZs could be achieved by selecting the optimum welding and PWHT parameters (cooling time Δt_8/5: 6–40 s, PWHT: 893 K, 3.6–7.2 ks). Tempering thermal cycles with peak temperature of above 573 K could remarkably improve the toughness of deteriorated ICCGHAZs and reduce the hardness, when cooling time Δt_8/5(2) of the reheating thermal cycle was 6 s, which implies that welding of SQV-2A without PWHT is possible, provided that low heat input welding is adopted and welding procedure is correctly arranged. Metallography and fractography revealed that M–A constituents in weld HAZs played an important role in controlling weld HAZ toughness.     

Study on the characteristic points of boiling curve by using wavelet analysis and genetic neural network

Local singularity of a signal includes a lot of important information. Wavelet transform can overcome the shortages of Fourier analysis, i.e., the weak localization in the local time- and frequency-domains. It has the capacity to detect the characteristic points of boiling curves. Based on the wavelet analysis theory of signal singularity detection, Critical Heat Flux (CHF) and Minimum Film Boiling Starting Point (q_min) of boiling curves can be detected by using the wavelet modulus maxima detection. Moreover, a genetic neural network (GNN) model for predicting CHF is set up in this paper. The database used in the analysis is from the 1960s, including 2365 data points which cover a range of pressure (P), from 100 to 1000 kPa, mass flow rate (G) from 40 to 500 kg m⁻² s⁻¹, inlet sub-cooling (ΔT_sub) from 0 to 35 K, wall superheat (ΔT_sat) from 10 to 500 K and heat flux (Q) from 20 to 8000 kW m⁻². GNN mode has some advantages of its global optimal searching, quick convergence speed and solving non-linear problem. The methods of establishing the model and training of GNN are discussed particularly. The characteristic point predictions of boiling curve are investigated in detail by GNN. The results predicted by GNN have a good agreement with experimental data. At last, the main parametric trends of the CHF are analyzed by applying GNN. Simulation and analysis results show that the network model can effectively predict CHF.     

Reactivity feedback coefficients of a material test research reactor fueled with high-density U3Si2 dispersion fuels

The reactivity feedback coefficients of a material test research reactor fueled with high-density U₃Si₂ dispersion fuels were calculated. For this purpose, the low-density LEU fuel of an MTR was replaced with high-density U₃Si₂ LEU fuels currently being developed under the RERTR program. Calculations were carried out to find the fuel temperature reactivity coefficient, moderator temperature reactivity coefficient and moderator density reactivity coefficient. Nuclear reactor analysis codes including WIMS-D4 and CITATION were employed to carry out these calculations. It is observed that the average values of fuel temperature reactivity feedback coefficient, moderator temperature reactivity coefficient and moderator density reactivity coefficient from 20 °C to 100 °C, at the beginning of life, followed the relationships (in units of Δk/k × 10⁻⁵ K⁻¹) −2.116 − 0.118 ρ_U, 0.713 − 37.309/ρ_U and −12.765 − 34.309/ρ_U, respectively for 4.0 ≤ ρ_U (g/cm³) ≤ 6.0.     

Investigation of pre- and post-dryout heat transfer of steam-water two-phase flow in a rod bundle

Pre- and post-dryout heat transfer experiments were performed for steam-water two-phase flow in a 5 × 5 rod bundle under conditions of total mass fluxes from 80 to 320 kg/m²s, inlet qualities from 0.1 to 0.8, heat fluxes from 3 to 26 W/cm² and a pressure of 3 MPa. Heater rod surface temperatures or heat transfer coefficients predicted by several correlations were compared with experimental data with emphasis on the applicability of the correlations to the present experimental conditions which were pertinent to thermal-hydraulic conditions during a LOCA in a nuclear reactor. The Chen and Biorge et al. correlations underestimated heat transfer coefficients in the pre-dryout region. The Varone-Rohsenow prediction which accounted for the thermal nonequilibrium effect, calculated heater rod surface temperatures relatively well in the post-dryout region over the whole region of the present experimental conditions. The Dittus-Boelter and Groeneveld correlations predicted heater rod surface temperatures relatively well in the post-dryout region under high total mass flux conditions, but underestimated considerably under low total mass flux conditions.     

Effect of thermal aging on fracture toughness of RPV steel

The effect of thermal aging on mechanical properties and fracture toughness was investigated on pressure vessel steel of light water reactors. Submerged are welded plates of ASME SA508 C1.3 steel were isothermally aged at 350°C, 400°C and 450°C for up to 10,000 hrs. Tensile, Charpy impact and fracture toughness testings were conducted on the base metal and the weld heat affected zone (HAZ) material to evaluate whether thermal aging induced by the plant operation is critical for the integrity of the pressure vessel or not. Tensile properties of the base metal was not changed by thermal aging as far as the thermal aging conditions were concerned. Relatively distinct degradation was observed in fracture toughness J_IC and J-resistance properties of both the base metal and the weld HAZ material, while only slight changes were observed in Charpy impact properties for both of them. However, it was concluded that the effect of thermal aging estimated by 40–80 years of plant operation on fracture toughness of both materials is small.     

Break up time of fragmentating-solidifying UO2 spheres when quenched in sodium

When molten UO₂ is quenched in sodium, a sand-like debris results containing about 80% of fractured particles and 20% of smooth particles and spheres. The production of the fractured particles is normally explained by the thermal stress fragmentation model. Previously brittle fracture mechanics was applied to the complete solid shell of a freezing UO₂ drop, i.e. where 954°C < T < 2850°C; a calculation of fragmentation time was not possible. In this contribution the solid shell is continuously subdivided in a plastic or ductile layer for 1300°C < T < 2850°C and a brittle one for 945°C < T < 1300°C. Cracking occurs in the brittle layer only. In the present model a layer of a predescribed depth is assumed to ablate instantaneously, when the temperature reaches the transition point of elastic of ductile behavior (T = 1300°C) at its inner boundary. A new layer is formed within a time step, governed by the heat conduction equation. The discontinuous ablation process is thus related to the continuous progression of the solidification front. A calculation of the fragmentation time is possible: in principle it comprehends the summation of a large number of time steps for the formation of brittle layers. The thickness of the cracked brittle layer is parametrized to 20, 10, 5 and 1 μm. The concept of instantaneous ablation was suggested by the experience that the violent boiling forces of sodium are very effective on the UO₂ surface. The introduction of these minor changes makes the thermal stress model more realistic, because it can explain now, why UO₂ does not fragment in argon and water. The fragmentation time assessed for a UO₂ drop of 7.2 mm diameter in sodium, brittle layer 10 μm, is 250 ms.     

Fracture mechanical properties and neutron irradiation effects of fuel compacts for the HTTR

To simulate the nuclear fuel for High Temperature Engineering Testing Reactor (HTTR), fuel compact models using SiC-kernel coated particles instead of UO₂-kernel coated particles were prepared under the same conditions as those for the real fuel compact. The mechanical and fracture mechanics properties were studied at room temperature. The thermal shock resistance and fracture toughness for thermal stresses of the fuel compact were experimentally assessed by means of arc discharge heating applied at a central area of the disk specimens. These model specimens were then neutron irradiated in the Japan Material Testing Reactor (JMTR) for fluences up to 1.7 × 10²¹n/cm² (E ·> 29 fJ) at 900°C ± 50°C. The effects of irradiation on a series of fracture mechanical properties were evaluated and compared with the cases of graphite IG-110 used as the core materials in the HTTR.