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Title: Evaluation of Corrosion of the Dummy “EE” Plate 19 in YA Type ATR Fuel Element During Reactor PALM Cycles

Abstract

Advanced Test Reactor (ATR) Cycle 153B-1 was a 14-day, high-power, powered axial locator mechanism (PALM) operating cycle that completed on April 12, 2013. Cycle 153B-1 was a typical operating cycle for the ATR and did not result in any unusual plant transients. ATR was started up and shut down as scheduled. The PALM drive physically moves the selected experiments into and out of the core to simulate reactor startup and heat up, and shutdown and cooldown transients, while the reactor remains in steady state conditions. However, after the cycle was over, several thousand of the flow-assisted corrosion pits and “horseshoeing” defects were readily observable on the surface of the several YA-type fuel elements (these are “dummy” plates that contain no fuel). In order understand these corrosion phenomena a thermal-hydraulic model of coolant channel 20 on a YA-M fuel element was generated. The boundaries of the model were the aluminum EE plate of a YA-M fuel element and a beryllium reflector block with 13 horizontal saw cuts which represented regions of zero flow. The heat generated in fuel plates 1 through 18 was modeled to be passing through the aluminum EE plate. The coolant channel 20 width was set at 0.058more » in. (58 mils). It was established that the horizontal saw cuts had a significant effect on the temperature of the coolant. The flow, which was expected to vary linearly with gradual heating of the coolant as it passed through the channel, was extremely turbulent. The temperature rise, which was expected to be a smooth “S” curve, was represented by a series temperature rise “humps,” which occurred at each horizontal saw cut in the beryllium reflector block. Each of the 13 saw cuts had a chamfered edge which resulted in the coolant flow being re-directed as a jet across the coolant channel into the surface of the EE plate, which explained the temperature rise and the observed sscalloping and possibly pitting degradation on the YA-M fuel elements. In the case of scalloping (horseshoeing) a surprising similarity of that defect to those appearing on aluminum plate rolled in over-lubrication conditions, were established. In turn, this made us think that the principal feature responsible for the appearance of these defects, was horizontal cuts in the Be neutron reflector created to arrest the propagation of large vertical crack(s) in Be in PALM cycles with higher overall fluence. This assumption was confirmed by the results of thermo-hydraulic simulations. The neutronics data for these modeling experiments were provided using rradiation simulations (MCNP, HELIOS). In the case of FAC and pitting corrosion the following corrective measures were proposed based upon the results of JMatPro modeling (TTT- and CCT-diagrams): change the practice of thermo-mechanical treatment of dummy plates in the future by adding blister anneal before program anneal, immediately after cold rolling of AA6061 ingot. This step will allow achieving complete recrystallization, eliminating of strengthening due to metastable precipitates, and reduce the possibility of forming sharp microstructural features upon the surface. Additionally it may prevent the formation of Fe-Al galvanic couples localized around such sharp particles. These recommendations were discussed with BWXT representatives and agreed upon by all parties. The new batch of plate manufactured using thus modified thermo-mechanical treatment is expected to be loaded into the ATR soon.« less

Authors:
 [1];  [1];  [1];  [1]
  1. Idaho National Lab. (INL), Idaho Falls, ID (United States)
Publication Date:
Research Org.:
Idaho National Lab. (INL), Idaho Falls, ID (United States)
Sponsoring Org.:
USDOE Office of Nuclear Energy (NE)
OSTI Identifier:
1364230
Report Number(s):
INL/EXT-16-38324
TRN: US1703342
DOE Contract Number:
AC07-05ID14517
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS; PITTING CORROSION; FUEL PLATES; THERMAL HYDRAULICS; FUELS; TEST REACTORS; THERMOMECHANICAL TREATMENTS; NEUTRON REFLECTORS; ATR; CFD Modeling; Computational Thermodynamics; Corrosion; Erosion; Neutronics; Temper Development

Citation Formats

Brower, Jeffrey Owen, Glazoff, Michael Vasily, Eiden, Thomas John, and Rezvoi, Aleksey Victor. Evaluation of Corrosion of the Dummy “EE” Plate 19 in YA Type ATR Fuel Element During Reactor PALM Cycles. United States: N. p., 2016. Web. doi:10.2172/1364230.
Brower, Jeffrey Owen, Glazoff, Michael Vasily, Eiden, Thomas John, & Rezvoi, Aleksey Victor. Evaluation of Corrosion of the Dummy “EE” Plate 19 in YA Type ATR Fuel Element During Reactor PALM Cycles. United States. doi:10.2172/1364230.
Brower, Jeffrey Owen, Glazoff, Michael Vasily, Eiden, Thomas John, and Rezvoi, Aleksey Victor. Mon . "Evaluation of Corrosion of the Dummy “EE” Plate 19 in YA Type ATR Fuel Element During Reactor PALM Cycles". United States. doi:10.2172/1364230. https://www.osti.gov/servlets/purl/1364230.
@article{osti_1364230,
title = {Evaluation of Corrosion of the Dummy “EE” Plate 19 in YA Type ATR Fuel Element During Reactor PALM Cycles},
author = {Brower, Jeffrey Owen and Glazoff, Michael Vasily and Eiden, Thomas John and Rezvoi, Aleksey Victor},
abstractNote = {Advanced Test Reactor (ATR) Cycle 153B-1 was a 14-day, high-power, powered axial locator mechanism (PALM) operating cycle that completed on April 12, 2013. Cycle 153B-1 was a typical operating cycle for the ATR and did not result in any unusual plant transients. ATR was started up and shut down as scheduled. The PALM drive physically moves the selected experiments into and out of the core to simulate reactor startup and heat up, and shutdown and cooldown transients, while the reactor remains in steady state conditions. However, after the cycle was over, several thousand of the flow-assisted corrosion pits and “horseshoeing” defects were readily observable on the surface of the several YA-type fuel elements (these are “dummy” plates that contain no fuel). In order understand these corrosion phenomena a thermal-hydraulic model of coolant channel 20 on a YA-M fuel element was generated. The boundaries of the model were the aluminum EE plate of a YA-M fuel element and a beryllium reflector block with 13 horizontal saw cuts which represented regions of zero flow. The heat generated in fuel plates 1 through 18 was modeled to be passing through the aluminum EE plate. The coolant channel 20 width was set at 0.058 in. (58 mils). It was established that the horizontal saw cuts had a significant effect on the temperature of the coolant. The flow, which was expected to vary linearly with gradual heating of the coolant as it passed through the channel, was extremely turbulent. The temperature rise, which was expected to be a smooth “S” curve, was represented by a series temperature rise “humps,” which occurred at each horizontal saw cut in the beryllium reflector block. Each of the 13 saw cuts had a chamfered edge which resulted in the coolant flow being re-directed as a jet across the coolant channel into the surface of the EE plate, which explained the temperature rise and the observed sscalloping and possibly pitting degradation on the YA-M fuel elements. In the case of scalloping (horseshoeing) a surprising similarity of that defect to those appearing on aluminum plate rolled in over-lubrication conditions, were established. In turn, this made us think that the principal feature responsible for the appearance of these defects, was horizontal cuts in the Be neutron reflector created to arrest the propagation of large vertical crack(s) in Be in PALM cycles with higher overall fluence. This assumption was confirmed by the results of thermo-hydraulic simulations. The neutronics data for these modeling experiments were provided using rradiation simulations (MCNP, HELIOS). In the case of FAC and pitting corrosion the following corrective measures were proposed based upon the results of JMatPro modeling (TTT- and CCT-diagrams): change the practice of thermo-mechanical treatment of dummy plates in the future by adding blister anneal before program anneal, immediately after cold rolling of AA6061 ingot. This step will allow achieving complete recrystallization, eliminating of strengthening due to metastable precipitates, and reduce the possibility of forming sharp microstructural features upon the surface. Additionally it may prevent the formation of Fe-Al galvanic couples localized around such sharp particles. These recommendations were discussed with BWXT representatives and agreed upon by all parties. The new batch of plate manufactured using thus modified thermo-mechanical treatment is expected to be loaded into the ATR soon.},
doi = {10.2172/1364230},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Mon Aug 01 00:00:00 EDT 2016},
month = {Mon Aug 01 00:00:00 EDT 2016}
}

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  • Advanced Test Reactor (ATR) Cycle 153B-1 was a 14-day, high-power, powered axial locator mechanism (PALM) operating cycle that completed on April 12, 2013. Cycle 153B-1 was a typical operating cycle for the ATR, and did not result in any unusual plant transients. ATR was started up and shut down as scheduled. The PALM drive physically moves the selected experiments into and out of the core to simulate reactor startup and heat up, and shutdown and cooldown transients, while the reactor remains in steady-state conditions. However, after the cycle was over, when the fuel elements were removed from the core andmore » inspected, several thousand flow-assisted erosion pits and “horseshoeing” defects were readily observed on the surface of the several YA-type fuel elements (these are aluminum “dummy” plates that contain no fuel). In order to understand these erosion phenomena, a thermal-hydraulic model of coolant channel 20 on a YA-M fuel element was generated. The boundaries of the model were the aluminum EE plate of a YA-M fuel element and a beryllium reflector block with 13 horizontal saw cuts which represented regions of zero flow. The heat generated in fuel plates 1 through 18 was modeled to be passing through the aluminum EE plate. The coolant channel 20 width was set at 0.058 in. (58 mils). It was established that the horizontal saw cuts had a significant effect on the temperature of the coolant. The flow, which was expected to vary linearly with gradual heating of the coolant as it passed through the channel, was extremely turbulent. The temperature rise, which was expected to be a smooth “S” curve, was represented by a series temperature rise “humps,” which occurred at each horizontal saw cut in the beryllium reflector block. Each of the 13 saw cuts had a chamfered edge which resulted in the coolant flow being re-directed as a jet across the coolant channel into the surface of the EE plate, which explained the temperature rise and the observed scalloping and pitting degradation on the YA-M fuel elements. In the case of scalloping (horseshoeing) a surprising similarity of that defect to those appearing on aluminum plate rolled in over-lubrication conditions, were established. In turn, this made us think that the principal feature responsible for the appearance of these defects, was horizontal cuts in the beryllium reflector block created to arrest the propagation of large vertical crack(s) in Be in PALM cycles with higher overall fluence. This assumption was fully confirmed by the results of thermo-hydraulic simulations. The neutronics data for these modeling experiments were provided using advanced irradiation simulations (MCNP, HELIOS). In the case of pitting erosion the following corrective measures were proposed based upon the results of JMatPro v.8.2 modeling (TTT- and CCT-diagrams): change the fabrication process by adding blister anneal before program anneal, immediately after cold rolling of AA6061plate. This step will allow achieving complete recrystallization, eliminating of strengthening due to metastable precipitates, and reduce the possibility of forming sharp microstructural features upon the surface.« less
  • During the normal operation of reactors ionic, particulate and colloidal substances in the coolant are activated as they pass through the neutron flux. The parent substances for the activated materials come from several sources: transient corrosion products from the coolant system piping and fuel element cladding, coolant additives and coolant impurities. Previous studies have shown that a major portion of these substances do not simply pass through the neutron flux field but undergo complex sorption phenomena that result in effluent radio-nuclide levels considerably in excess of what would be expected from activation on a once-through basis. This report is beingmore » written to outline studies that will provide activity inventory data that will aid in defining radionuclide retention reactions in reactor coolant systems.« less
  • The premature failure of fuel Element M22, which had six compartments of 0.100-in.-thick, 96% TD UO/sub 2/ + 6 wt% ZrO/sub 2/ fuel, was attributed to the large irradiation-induced solid volume swelling of the UO/sub 2/ fuels. This volume swelling was the result of incomplete homogenization during fabrication of the mixed and sintered U/sup E/O/sub 2/ and U/sup N/O/sub 2/ fuel s in Element M22. In addition, heavy hydriding of the Ni-free Zircaloy-2 cladding occurred in the relatively hot areas adjacent to the fuel and to a lesser extent at the external cladding surfaces. By postulation, H/sub 2/ was apparentlymore » formed by the radiolytic decomposition of water entrapped between fuel and cladding after formation of the initial cladding defect, and was absorbed by the cladding so rapidly that it could not diffuse adequately down the thermal gradient to the cold side of the cladding. The corrosion behavior of the cladding was as expected and did not contribute to the hydriding. Analysis of the CR-X-3 loop operating history indicates that no abnormal conditions external to Element M22 existed in the loop other than U from inpile intentionally defected fuel elements. (auth)« less