NUREG/IA-0156

Vol. 2

IPSN 99/08-2

NSI RRC 2179

International

Agreement Report

Data Base on the Behavior of High Burnup Fuel Rods

with Zr-1%Nb Cladding and U0 2 Fuel (VVER Type)

under Reactivity Accident Conditions

Description of Test Procedures and Analytical Methods

Prepared by

L. Yegorova, V Asmolov, G. Abyshov, V. Malofeev, A. Awakumov, E. Kaplar, K. Lioutov, A. Shestopalov

Nuclear Safety Institute of Russian Research Centre "Kurchatov Institute"

Kurchatov Square 1, Moscow 123182, Russia

A Bortash, L. Maiorov, K. Mikitiouk, V Polvanov

Institute of Nuclear Reactors of Russian Research Centre "Kurchatov Institute"

Kurchatov Square 1, Moscow 123182, Russia

V Smirnov, A Goryachev, V Prokhorov

State Research Centre "Research Institute of Atomic Reactors"

Dimitrovgrad 433510, Russia

V Pakhnitz, A. Vurim

Institute of Atomic Energy of National Nuclear Centre of Kazakhstan Republic

Semipalatinsk 490021, Kazakhstan

Office of Nuclear Regulatory Research

U.S. Nuclear Regulatory Commission

Washington, DC 20555-0001

July 1999

Prepared for

U.S. Nuclear Regulatory Commission, Institute for Protection and Nuclear Safety (France) and

Ministry of Science and Technologies of Russian Federation

Published by

U.S. Nuclear Regulatory Commission
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owned rights.
NUREG/IA-0156

Vol. 2

IPSN 99/08-2

-I r iNSI RRC 2179

International

Agreement Report

Data Base on the Behavior of High Burnup Fuel Rods

with Zr-1%Nb Cladding and U0 2 Fuel (VVER Type)

under Reactivity Accident Conditions

Description of Test Procedures and Analytical Methods

Prepared by

L Yegorova, V. Asmolov, G. Abysbov, V. Malofeev, A. Awakumov, F. Kaplar, K ljoutov, A Shestopalov

Nuclear Safety Institute of Russian Research Centre "Kurchatov Institute"

Kurchatov Square 1, Moscow 123182, Russia

A. Bortash, L Maiorov, K. Mikitiouk, V. Polvanov

Institute of Nuclear Reactors of Russian Research Centre "Kurchatov Institute"

Kurchatov Square 1, Moscow 123182, Russia

V. Smirnov, A. Goryachev, V. Prokhorov

State Research Centre "Research Institute of Atomic Reactors"

Dimitrovgrad 433510, Russia

V. Pakhnitz, A. VuArim

Institute of Atomic Energy of National Nuclear Centre of Kazakhstan Republic

Semipalatinsk 490021, Kazakhstan

Office of Nuclear Regulatory Research

U.S. Nuclear Regulatory Commission

Washington, DC 20555-0001

July 1999

Prepared for

U.S. Nuclear Regulatory Commission, Institute for Protection and Nuclear Safety (France) and

Ministry of Science and Technologies of Russian Federation

Published by

U.S. Nuclear Regulatory Commission

ABSTRACT

This volume of the report contains the following information on test conditions and basic procedures used to develop the

data base:

" objects and conditions of the IGR reactor tests;

* test parameters of fuel rods before, during and after the RIA tests;

" parameters of fuel rods during RIA tests calculated by FRAP-T6 and SCANAIR computer codes;

* measured mechanical properties of Zr-I %Nb cladding obtained due to special tests;

* parameters of Zr-l%Nb cladding failure of the ballooning type measured under the burst test conditions;

* input data with original material properties of Zr-1%N'b cladding for the MATPRO package and SCANAIR code.

iii

TABLE OF CONTENTS

Page

1. EXECUTIVE SUMMARY 1.1

1.1 I. Introduction ...................................................................................................................................... 1.1

1.2. The IGR/RIA tests with VVER high burnup fuel rods .................................................................... 1.1

1.3. Experiments to measure mechanical properties of Zr-l%Nb cladding ............................................ 1.4

1.4. Computational analysis of W ER fuel rod behavior under IGR/RIA test conditions ..................... 1.5

1.5. Structure of the generalized data base for IGR/RIA tests of VVER fuel rods ................................. 1.5

1.6. R eferences ........................................................................................................................................ 1.6

2. OBJECTIVES AND CONDITIONS OF THE IGR REACTOR TESTS 2.1

2. 1. Test objects ....................................................................................................................................... 2.1

2.2. Test conditions ................................................................................................................................. 2.3

2.3. References ........................................................................................................................................ 2.10

3. CHARACTERISTICS OF FUEL RODS BEFORE AND AFTER IGR TESTS 3.1

3.1. High burnup commercial fuel elements of power unit No 5 of NV NPP ......................................... 3.1

3.1.1. Geometric and thermo-physical characteristics of fuel elements [1, 2] ................................ 3.1

3.1.2. Burnup, fuel isotopic composition and chemical composition of the gas inside the fuel

elem ent .................................................................................................................................. 3.1

3.2. Characteristics of refabricated fuel rods before IGR tests ............................................................... 3.2

3.2.1. High bumup fuel rods ............................................ 3.3

3.2.2. Axial distribution of the fuel mass in high burnup fuel rods ............................... 3.3

3.2.3. Isotopic composition of the high burnup fuel rods ................................................................ 3.7

3.2.4. Fuel rods with fresh fuel and irradiated cladding ................................................................. 3.13

3.2.5. Fresh fuel rods ....................................................................................................................... 3.14

3.2.6. Axial distribution of the gas volume in fuel rods .................................................................. 3.14

3.3. Procedure to manufacture the fuel rods ............................................................................................ 3.15

3.4. Post test examinations of fuel rods ................................................................................................... 3.15

3.5. References ........................................................................................................................................ 3.16

4. ENERGY DEPOSITION, POWER OF FUEL RODS AND FUEL ENTHALPY UNDER IGR REACTOR

TEST CONDITIONS 4.1

4.1. Main provisions of the procedure .................................................................................................... 4.1

4.2. IGR reactor power versus time ......................................................................................................... 4.2

4.3. Number of fissions in special fuel samples ...................................................................................... 4.3

4.4. Number of fissions in central fuel pellets of fresh fuel rods .......................................................... 4.7

4.5. Input data on the geometry and the material composition of the reactor, the capsule, fuel rods

and special fuel samples ................................................................................................................... 4.9

4.6. Procedure to adjust the input data characterizing the power profile of IGR reactor ........................ 4.12

v
4.7. Neutronics parameters of fuel rods ....................................... I ............................................................ 4.19

4.8. r, z, t distribution of the energy deposition and power of fuel rods .................................................. 4.28

4.9. Dependence of the number of fissions in fuel rods on the temperature ........................................... 4.32

4.10. Uncertainty analysis ...................................................................................................................... 4.34

4.10.1. Methodological aspects of the procedure ............................................................................ 4.34

4.10.2. Energy deposition error in the elementary volume of fuel rods .......................................... 4.35

4.10.3. Errors for the fuel rod power and t distribution of the energy deposition ........................... 4.40

4.10.4. Errors in z distributions of the energy deposition ................................................................ 4.41

4.10.5. Errors in r distributions of the energy deposition ................................................................ 4.41

4.10.6. Summation of errors ............................................................................................................ 4.42

4.11. Fuel enthalpy ................................................................................................................................. 4.43

4.12. R eferences ..................................................................................................................................... 4.44

5. COMPUTATIONAL ANALYSIS OF FUEL ROD BEHAVIOR AT IGR/RIA TESTS 5.1

5.1. Formulation of a problem ................................................................................................................. 5.1

5.2. Assessment of required input data on VVER material properties to calculate IGR tests with

FRAP-T6 and SCANAIR codes ....................................................................................................... 5.2

5.3. Specific requirements for computer codes to simulate geometry of VVER fuel rods and IGR test

conditions ........................................................................................................................................ 5.15

5.4. Development of IGR/V ER version of FRAP-T6 code .................................................................. 5.16

5.4.1. Description of FRAP-T6 code ............................................................................................... 5.16

5.4.2. Preliminary adaptation of FRAP-T6 code to analysis IGR/RIA tests ................................... 5.18

5.4.3. Description of FRAP-T6 version to predict VVER fuel rod performance under IGR test

conditions .............................................................................................................................. 5.21

5.4.3.1. Calculational scheme ............................................................................................... 5.21

5.4.3.2. Input data to characterize the geometry of VVER fuel rods and IGR test

conditions ................................................................................................................. 5.22

5.4.3.3. Output data ............................................................................................................... 5.24

5.4.3.4. Selection of FRAP-T6 models to calculate VVER fuel rod performance ................. 5.24

5. 4.3.5. Approach to determine the input data characterizing fission product distribution

in the high burnup VVER fuel before IGR tests..... ................. 5.24

5.4.3.6. Modified models in FRP4P-T6 code......................................................................... 5.25

5.5. Development of IGR/VVER version of the SCANAIR code .......................................................... 5.30

5.5.1. Description of the SCANAIR code ...................................................................................... 5.30

5.5.2. Preliminary adaptation of the SCANAIR code to analysis of IGR/RIA tests ....................... 5.32

5.5.3. Description of SCANAIR code version to predict WER fuel rod performance under

IGR test conditions ................................................................................................................ 5.38

5.5.3.1. Calculational scheme ............................................................................................... 5.38

5.5.3.2. SCANAIR input data to characterize the VVER fuel rods and IGR test conditions. 5.39

5.5.3.3. Input data to calculate fission gas release from high burnup fuel ........................... 5.39

5.5.3.4. Output data of SCANAIR code ................................................................................. 5.41

vi
5.5.3.5. Selection of SCANAIR models to calculate VVER fuel rod performance ................ 5.42

5.6. Input data on material properties of fuel rods and coolants ............................................................ 5.44

5.7. Validation of IGR/VVER versions of FRAP-T6 and SCANAIR codes .......................................... 5.49

5.7.1. General principles of validation ........................................................................................... 5.49

5.7.2. Assessment of verification results ....................................................................................... 5.50

5.7.2.1. Assessment of integral check results ....................................................................... 5.50

5.7.2.2. Assessment of results of separate phenomena check .............................................. 5.52

5.8 Main provisions of the procedure to obtain calculation results by FRAP-T6 and SCANAIR

codes ............................................................................................................. 5.60

5.9. Data base to verify FRAP-T6 and SCANAIR codes with respect to thermal parameters ............... 5.61

5.10. Analysis of the computational data base to characterize VVER fuel rod performance under

IGR test conditions ......................................................................................................................... 5.64

5.10.1. Analysis of the scenario first stage .................................................................................... 5.64

5.10.2. Analysis of the scenario second stage ................................................................................ 5.66

5.10.3. Joint analysis of the second and third stages of scenario for unfailed fuel rods cooled

w ith w ater ........................................................................................................................... 5.68

5.10.4. Analysis of the third stage of scenario for the failed fuel rods ........................................... 5.72

5.10.5. Analysis of peak fuel enthalpies at the cladding failure ..................................................... 5.74

5.10.6. Analysis of fission gas release calculated by FRAP-T6 and SCANAIR codes .................. 5.75

5.11. References ................................................................................................................................... 5.78

6. TEST PROCEDURES TO OBTAIN THE MECHANICAL PROPERTIES OF ZR-1 %NB CLADDING

AND DEVELOPMENT OF THE ORIGINAL INPUT DATA FOR MATPRO-V11 AND SCANAIR

CODES 6.1

6.1. Formulation of the problem ............................................................................................................ 6.1

6.1.1. Peculiarity analysis of unirradiated VVER claddings .......................................................... 6.1

6.1.2. Analysis of peculiarities of irradiated VVER cladding ........................................................ 6.5

6.1.3. Assessment of approaches developed in MATPRO and SCANAIR codes to characterize

the data base with mechanical properties of cladding .......................................................... 6.10

6.1.3.1. MATPRO package .................................................................................................. 6.11

6.1.3.2. Input data base for the SCANAIR code .................................................................. 6.11

6.1.4. Justification of the program main provisions to obtain the data base with mechanical

properties of Zr- 1%Nbcladdings for FRAP-T6 and SCANAIR codes .................. 6.12

6.2. Measurements of mechanical properties of Zr-l%Nb cladding by using simple ring specimens .... 6.16

6.2.1. Measurement procedure ...................................................................................................... 6.16

6.2.1.1. Main provisions of the procedure of testing simple ring specimens ................... 6.16

6.2.2. Methodological aspects of the tests with simple ring specimens ......................................... 6.17

6.2.3. Program of research to obtain the data base characterizing mechanical properties of the

VVER cladding tested in IGR reactor ................................... 6.19

6.2.4. Parameters of simple ring specimens used for tests ............................................................. 6.21

6.2.5. Types of procedures to obtain mechanical properties .......................................................... 6.21

vii
6.2.6. Validation of the procedure to measure mechanical properties with simple ring

specimens ................................................................................................................................ 6.23

6.2.7. Modified procedure to obtain mechanical properties using simple ring specimens ............... 6.24

6.2.7.1. Determination of the specimen absolute elongation ................................................. 6.24

6.2.7.2. Determ ination of the gauge length ............................................................................ 6.31

6.2.7.3. Confirmation of the modified procedure in general .................................................. 6.34

6.2.8. Results of the tests to measure mechanical properties of Zr-l%Nb cladding ........................ 6.35

6.2.9. Summarizing of the obtained data base with mechanical properties of Zr-l%Nb cladding,

and its analysis ........................................................................................................................ 6.45

6.3. Measurements of parameters characterizing mechanical behavior of Zr-l%Nb cladding under

ballooning conditions ......................................................................................................................... 6.46

6.3.1. Program and procedure of the burst tests ................................................................................ 6.46

6.3.2. Results of burst tests ............................................................................................................... 6.54

6.3.3. Analysis of burst test results ................................................................................................... 6.56

6.4. Development of the data base with mechanical properties of Zr-l%Nb for the MATPRO

package and SCANAIR code ............................................................................................................. 6.58

6.4.1. Data base for M ATPRO package ........................................................................................... 6.58

6.4.2. Data base for the SCANAIR code .......................................................................................... 6.65

6.5. References .......................................................................................................................................... 6.67

viii
LIST OF FIGURES

Page

Fig. 1.1. Structure of researches .................................................................................................................. 1.2

Fig. 2.1. Scheme of high burnup fuel rod ..................................................................................................... 2.1

Fig. 2.2. Scheme of fuel rod with preirradiated cladding and fresh fuel ...................................................... 2.2

Fig. 2.3. Scheme of unirradiated fuel rod .................................................................................................... 2.2

Fig. 2.4. Axial and cross-sections of the guide tube with special fuel samples ............................................ 2.3

Fig. 2.5. Scheme of the experimental capsule .............................................................................................. 2.4

Fig. 2.6. Cross-section of IGR reactor .......................................................................................................... 2.5

Fig. 2.7. Axial section of IGR reactor .......................................................................................................... 2.6

Fig. 2.8. Cross-section of the IGR reactor central part ................................................................................. 2.7

Fig. 2.9. Axial section of IGR reactor central part ....................................................................................... 2.8

Fig. 3.1. Arrangement of fuel samples taken from the cross-section of fuel element #317 to measure the

burnup radial distribution and the fuel isotopic composition ......................................................... 3.2

Fig. 3.2. TRIFOB verification versus burnup using Monte Carlo code ....................................................... 3.9

Fig. 3.3. TRIFOB verification vs. radial isotope distribution using Monte Carlo code ............................... 3.10

Fig. 3.4. Special TRIFOB verification vs. burnup using NV NPP fuel elements ......................................... 3.11

Fig. 3.5. Special TRIFOB verification vs. radial isotope distribution using NV NPP fuel element #317 ... 3.12

Fig. 4.1. The reactor power profile measured by ionization chambers and in-core neutron detectors ......... 4.3

Fig. 4.2. Number of fissions in the special fuel samples vs. the energy deposition in the reactor ............... 4.6

Fig. 4.3. Number of fissions in fuel pellets of E-type fuel rods vs. the energy deposition in the reactor ..... 4.8

Fig. 4.4. Cross-section of the calculation geometrical model of IGR reactor for DINAR computer code... 4.13

Fig. 4.5. Axial section of the calculation geometrical model of IGR reactor for DINAR computer code ... 4.14

Fig. 4.6. Total relative error in determining IGR reactor energy deposition by the ionization chamber

and D IN A R code ............................................................................................................................ 4.16

Fig. 4.7. Relative IGR reactor power profile measured by ionization chambers and calculated with

D IN A R code ................................................................................................................................... 4.17

Fig. 4.8. Verification of the DINAR code simulation quality of small power levels of IGR reactor ........... 4.18

Fig. 4.9. IGR reactor power simulating by DINAR code ............................................................................. 4.19

Fig. 4.10. Axial section of calculation geometrical model of object V for MCU computer code ................ 4.22

Fig. 4.11. Cross-section of the calculation geometrical model of object V for MCU computer code ......... 4.23

Fig. 4.12. Axial section of calculation geometrical model of IGR reactor for MCU computer code .......... 4.23

Fig. 4.13. The cartogram of MIR reactor core .............................................................................................. 4.26

Fig. 4.14. The arrangement of fuel rods in the loop channel at MIR reactor ............................................... 4.26

Fig. 4.15. The calculation cell for MCU code 4.27

Fig. 4.16. E4(t) normalized on the one fission vs. time for fuel rod #H1T ................................................... 4.32

Fig. 5.1. Specific heat (a), specific enthalpy (b), thermal conductivity (c), thermal expansion (d) vs.

temperature for unirradiated Zry and Zr-1%Nb ............................................................................. 5.4

Fig. 5.2. Young's modulus (a), Poisson's ratio (b), yield stress (c) vs. temperature and ZrO2 thickness

(d) vs. time for unirradiated Zry and Zr-1oNb .............................................................................. 5.5

Fig. 5.3. Specific heat (a) and thermal expansion (b) for unirradiated fuel of PWR and VVER type ......... 5.6

Fig. 5.4. Thermal conductivity of uranium dioxide fuel vs. temperature and burnup.. ................................ 5.7

Fig. 5.5. Thermal expansion (a), Young's modulus (b), Poisson's ratio (c), and yield stress (d) vs.

temperature for unirradiated fuel of PWR and VVER type ........................................................... 5.8

ix
Fig. 5.6. Response of fuel enthalpy, clad temperature and hoop stress to 20% disturbance of the fuel

specific heat .................................................................................................................................... 5.10

Fig. 5.7. Response of fuel enthalpy, clad temperature and clad hoop stress calculated by SCANAIR

code to the 30% disturbance of clad yield stress ............................... 5.12

Fig. 5.8, Response of fuel enthalpy, clad temperature, clad hoop stress calculated by FRAP-T6 code on

30% disturbance of strength coefficient K ..................................................................................... 5.12

Fig. 5.9. Response of fuel enthalpy, clad temperature, clad hoop stress calculated by FRAP-T6 code on

30% disturbance of strain hardening exponent n ........................................................................... 5.13

Fig. 5.10. Response of fuel enthalpy, clad temperature, clad hoop stress calculated by FRAP-T6 code on

30% disturbance of strain rate sensitivity exponent m .................................................................. 5.13

Fig. 5.11. Response of fuel enthalpy and internal gas pressure on 30%/o disturbance of K and n ................. 5.15

Fig. 5.12. Order of general m odels [1] ......................................................................................................... 5.17

Fig. 5.13. Flow chart of methodology using FRAP-T6 ................................................................................ 5.18

Fig. 5.14. Comparison of the measured clad outer temperature and calculated by FRAP-T6 with

Brom ley-Pom erantz m odel ............................................................................................................. 5.20

Fig. 5.15. Comparison of the measured clad outer temperature and calculated by FRAP-T6 with

Labuntzov m odel ............................................................................................................................ 5.20

Fig. 5.16. Calculational scheme of fuel rod .................................................................................................. 5.21

Fig. 5.17. Heat flux from cladding to coolant vs. wall temperature used in FRAP-T6 code for IGR tests.. 5.27

Fig. 5.18. Principal scheme of SCANAIR code ........................................................................................... 5.30

Fig. 5.19. Cladding temperature vs. time ...................................................................................................... 5.33

Fig. 5.20. Verification of SCANAIR code with Thom model for nucleate boiling and original

SCANAIR DNB criterion .............................................................................................................. 5.34

Fig. 5.21. Verification of SCANAIR code with CHF model ........................................................................ 5.35

Fig. 5.22. Verification of SCANAIR code with Labuntzov model .............................................................. 5.36

Fig. 5.23. Verification of original gas pressure model in SCANAIR code .................................................. 5.37

Fig. 5.24. Verification of modified gas pressure model in SCANAIR code ................................................ 5.38

Fig. 5.25. Calculational scheme of VVER fuel rod SCANAIR code ........................................................... 5.38

Fig. 5.26. Wall to coolant heat flux vs. wall temperature used in VVER/IGR version of SCANAIR code. 5.43

Fig. 5.27. Scheme of verification for FRAP-T6 and SCANAIR .................................................................. 5.49

Fig. 5.28. Measured and calculated cladding temperature for air coolant .................................................... 5.50

Fig. 5.29. Measured and calculated cladding temperature for nucleate boiling regime ............................... 5.51

Fig. 5.30. Measured and calculated cladding temperature including post-CHF regimes ............................. 5.52

Fig. 5.31. Specific fission gas generation vs. burnup calculated by FRAP-T6, TOSUREP, TRIFOB

computer codes for fuel elements #317 during the fuel cycles of NV NPP ................................... 5.53

Fig. 5.32. Radial distributions of fission gas generated in fuel calculated by FRAP-T6, TOSUREP,

TRIFOB computer codes for fuel element #317 at burnup 48 MWd/kg U .................................... 5.53

Fig. 5.33. Calculated and measured internal gas pressure vs. time for failed fuel rod cooled with air ........ 5.56

Fig. 5.34. Calculated and measured internal gas pressure vs. time for failed fuel rod cooled with water .... 5.56

Fig. 5.35 Calculated and measured cladding residual hoop strain vs. axial coordinate for fuel rod #HIT .. 5.58

Fig. 5.36. Measured and calculated peak clad residual hoop strain for ballooning area (original

approach) ........................................................................................................................................ 5.58

Fig. 5.37. Calculated cladding circumferential elongation at burst vs. azimuth variation of temperature ... 5.59

Fig. 5.38. Measured and calculated cladding residual hoop strain for ballooning area (modified

approach) ....................................................................................................................................... 5.60

Fig. 5.39. View of the instrumented VVER fuel rod .................................................................................... 5.61

Fig. 5.40. Cross-section of the VVER fuel rod after IGR test ...................................................................... 5.63

Fig. 5.41. Parameters of some fuel rods for the first stage of IGR tests ....................................................... 5.65

X
Fig. 5.42. Parameters of some fuel rods for the second stage of IGR tests .................................................. 5.67

Fig. 5.43. Time histories of some parameters for the fuel rod #B22T .......................................................... 5.68

Fig. 5.44. Calculated parameters of some fuel rods for the second and third stages of IGR tests ................ 5.69

Fig. 5.45. Time history of fuel enthalpy, leakage of energy from fuel rod, gap heat transfer coefficient

vs. gas gap w idth ............................................................................................................................ 5.70

Fig. 5.46. Measured results to estimate cladding residual hoop strain for fuel rod #H4T ............................ 5.71

Fig. 5.47. Parameters calculated by FRAP-T6 code for fuel rods ##H5T, B22T vs. time ........................... 5.73

Fig. 5.48. Comparison of FRAP-T6 results with burst test data ................................................................... 5.74

Fig. 5.49. Comparison of peak fuel enthalpies calculated by FRAP-T6 and SCANAIR codes ................... 5.74

Fig. 5.50. Calculated and measured Xe and Kr volume inside the fuel rod free volume vs. peak fuel

enthalpy .......................................................................................................................................... 5.76

Fig. 5.51. Comparison of the FRAP-T6 and SCANAIR results on FGR for IGR fuel rods ........................ 5.76

Fig. 6.1. Mechanical properties of Zry-4 and Zr-1%Nb vs. temperature ..................................................... 6.2

Fig. 6.2. Demonstration of dynamic strain aging effect for Zr-l%Nb alloy ................................................ 6.5

Fig. 6.3. Mechanical properties of Zry-4 vs. neutron fluence [1] ................................................................. 6.6

Fig. 6.4. Recrystallization rate of Zry-2 vs. temperature .............................................................................. 6.7

Fig. 6.5. Total elongation of Zr-lNb specimens vs. temperature and oxygen weight gain ....................... 6.8

Fig. 6.6. Total elongation of Zr-l%Nb alloy (a) and hoop strain of pressurized zircaloy tubes (b) vs.

hydrogen concentration and temperature ....................................................................................... 6.8

Fig. 6.7. Hoop strain of pressurized Zr-lNb tube vs. coefficient of hydride orientation .......................... 6.9

Fig. 6.8. Time histories of thermal mechanical behavior of fuel rod #HIT calculated by FRAP-T6 and

SCA N A IR codes ............................................................................................................................ 6.13

Fig. 6.9. Time history of thermal mechanical behavior of fuel rod #H7T calculated. by FRAP-T6 code .... 6.14

Fig. 6.10. Cross-section of mandrels with simple ring specimen and general view of simple ring

specim en after the test ................................................................................................................... 6 17

Fig. 6.11. Schematic view of load-displacement diagram ............................................................................ 6.17

Fig. 6.12. Schematic view of azimuth profile of residual elongation for simple ring specimen .................. 6.18

Fig. 6.13. Schematic view of machined ring specimen and azimuth profile of elongation for its ............... 6.18

Fig. 6.14. Processing of stress-strain curve obtained with simple ring specimen of Zr-l%Nb .................... 6.22

Fig. 6.15. Comparison RIAR, ANL and IPSN data for true stress-strain curve ........................................... 6.24

Fig. 6.16. Cross-sections of simple ring specimen before and after mechanical test with r << ay .............. 6.25

Fig. 6.17. Comparison of slopes for the linear part of stress-strain curve for ideal and imperfect

specim ens ....................................................................................................................................... 6.27

Fig. 6.18. Modified method to determine uniform and total elongation. ..................................................... 6.27

Fig. 6.19. Curve of the deformation with a partial relief ............................................................................. 6.28

Fig. 6.20. Diagram of the cylindrical specimen deformation ....................................................................... 6.29

Fig. 6.2 1. Dependence of the inclination angle of partial relief lines on the temperature ............................ 6.29

Fig. 6.22. Method to determine the proportionality limit using the second derivative ................................. 6.30

Fig. 6.23. Determination of the proportionality limit using the second derivative ....................................... 6.31

Fig. 6.24. Appearance of the original specimen with marks ........................................................................ 6.32

Fig. 6.25. Scheme of the processing of measurement results to determine the gauge length ....................... 6.33

Fig. 6.26. Determination of the gauge length ............................................................................................... 6.33

Fig. 6.27. Dependence of the specimen gauge length on the temperature .................................................. 6.34

Fig. 6.28. Confirmation of the modified procedure on the test results for the specimen which was

annealed after prestretching ........................................................................................................... 6.34

Fig. 6.29. Example of corrected stress-strain curve ...................................................................................... 6.35

Fig. 6.30. Engineering yield stress vs. temperature for unirradiated and irradiated Zr- %Nb cladding ...... 6.39

xil
Fig. 6.31. Engineering ultimate strength vs. temperature for unirradiated and irradiated Zr-i%Nb

cladding ............................................................................................................................................ 6.39

Fig. 6.32. Total elongation vs. temperature of unirradiated and irradiated Zr-l%Nb cladding ..................... 6.40

Fig. 6.33. Uniform elongation depending on temperature of unirradiated and irradiated claddings ............. 6.42

Fig. 6.34. Yield stress vs. strain rate for unirradiated Zr-l%Nb cladding ..................................................... 6.43

Fig. 6.35. Yield stress vs. strain rate for irradiated Zr-l%Nb cladding ......................................................... 6.44

Fig. 6.36. Data base to characterize yield stress of Zr-I%Nb cladding vs. temperature and strain rate ........ 6.44

Fig. 6.37. Data base to characterize total elongation of Zr-l%Nb cladding vs. temperature and strain

rate .................................................................................................................................................... 6.45

Fig. 6.38. Principle part of experimental setup for the burst tests .................................................................. 6.46

Fig. 6.39. Time history of the temperature and pressure for one of the burst tests ........................................ 6.47

Fig. 6.40. Scheme to determine the middle line profile of the cladding cross-section .................................. 6.48

Fig. 6.41. Scheme of the procedure to determine cladding thickness vs. azimuth angle ............................... 6.49

Fig. 6.42. Method to obtain cross-sections of A-A and B-B types ................................................................ 6.50

Fig. 6.43. MATPRO procedure to determine cleavage-like line presented for Zr-l%Nb specimen after

the burst test ..................................................................................................................................... 6.50

Fig. 6.44. Scheme of the cladding necking .................................................................................................... 6.51

Fig. 6.45. Procedure to determine cladding burst thickness ........................................................................... 6.51

Fig. 6.46. Method to determine the axial radius of ballooning using MATPRO procedure .......................... 6.52

Fig. 6.47. View of Zr-i%Nb cladding burst under the superplasticity conditions ........................................ 6.52

Fig. 6.48. Scheme of geometric procedures to determine axial radius-of ballooning (rz) ............................. 6.53

Fig. 6.49. Comparison of the cladding cross-section in A-A position after burst test and the restored

profile of the cladding middle line at the burst moment .................................................................. 6.54

Fig. 6.50. Burst pressure vs. temperature for unirradiated and irradiated Zr-1%Nb cladding ....................... 6.54

Fig. 6.51. Circumferencial strain at burst vs. temperature for unirradiated and irradiated Zr-l%Nb

clad ding ............................................................................................................................................ 6.55

Fig. 6.52. Burst pressure vs. pressure increase rate at different temperatures for unirradiated and

I irradiated Zr-i%Nb cladding ........................................................................................................... 6.56

Fig. 6.53. Generalized data base to characterize burst pressure vs. temperature for Zr-l%Nb and Zry

clad dings .......................................................................................................................................... 6.57

Fig. 6.54. Circumferencial elongation vs. temperature and pressure increase rate for unirradiated Zr1% N b cladding ................................................................................................................................. 6.57

Fig. 6.55. Comparison of the Zr-i %Nb tensile and burst test results ............................................................ 6.58

Fig. 6.56. Processing of the measured data to obtain strain rate sensitivity exponent of the irradiated Zr1%Nb cladding for T = 1123 K ............................. ......................................................................... 6.60

Fig. 6.57. Comparison of the strain rate sensitivity exponents for Zr-I%Nb alloy and Zircaloy .................. 6.60

Fig. 6.58. Strength coefficient vs. temperature for unirradiated and irradiated Zr-1%Nb cladding ............ 6.62

Fig. 6.59. Strain hardening exponent vs. temperature for unirradiated and irradiated Zr-l%Nb cladding ...6.62

Fig. 6.60. Measured local burst stresses and new MATPRO correlation for Zr-l%Nb cladding ................. 6.65

xii
LIST OF TABLES

Page

Table 2.1. Main characteristics of IGR reactor .............................................................................................. 2.9

Table 3.1. Verification results for procedure to determine fuel mass in high burnup fuel rods ................... 3.6

Table 3.2. Errors in determining the total fuel mass in C-type fuel rods ....................................................... 3.6

Table 3.3. Calculated and measured isotopic concentrations and burnups for fuel element #317 ................ 3.9

Table 4.1. Measured number of fissions in central fuel pellets of E-type fuel rods, special fuel samples,

measured integrals of current readings of the ionization chamber and integrals of corrected

readings of the ionization chamber .................................................................................................. 4.5

Table 4.2. Errors in characteristics in the formula to determine number of fissions in the special fuel

sam ples ............................................................................................................................................ 4.5

Table 4.3. Errors in characteristics in the formula to determine the number of fissions in fuel pellets of

E-type fuel rods ................................................................................................................................ 4.8

Table 4.4. Main characteristics of IGR reactor .............................................................................................. 4.9

Table 4.5. Verification results of MCU code based on MIR reactor experiment .......................................... 4.28

Table 4.6. Kinetic energy of fragments ................................................. ......................................................... 4.30

Table 4.7. Energy deposition due to the prompt radiation in fuel rods of C-, D-, E- types .......................... 4.31

Table 4.8. Energy fraction of the delayed gamma radiation absorbed in fuel rods of C-, D-, E- types vs.

tim e .................................................................................................................................................. 4.31

Table 4.9. Values of the temperature coefficient f for C-type fuel rods ........................................................ 4.34

Table 4.10. Sensitivity coefficient of the fission density in the elementary volume of fuel rod #H7T to

incom ing param eters ........................................................................................................................ 4.37

Table 4.11. Energy deposition error in elementary volume of fuel rod #H7T .............................................. 4.38

Table 4.12. Energy deposition error in elementary volume of fuel rod #B9T .............................................. 4.39

Table 4.13. Energy deposition error in elementary volume of fuel rod #H16T ............................................ 4.40

Table 4.14. Energy deposition error in elementary volume of fuel rod #B20T ............................................ 4.41

Table 4.15. Power error and energy deposition error vs. time for fuel rod #H7T ......................................... 4.42

Table 4.16. Power error and energy deposition error vs. time for fuel rod #B 16T ....................................... 4.42

Table 5.1 Physical phenomena and capabilities of codes ............................................................................. 5.1

Table 5.2. Material properties required to calculate fuel rod behavior in IGR test with computer codes ..... 5.3

Table 5.3. Response of output parameters of codes to the disturbance of some input parameters ............... 5.9

Table 5.4. Response of peak fuel enthalpy in case failure due to ballooning onto disturbances of the

cladding mechanical properties .......................................... 5.14

Table 5.5. List of codes modifications ........................................................................................................... 5.19

Table 5.6. Set of input data on fuel rod design .............................................................................................. 5.23

Table 5.7. A, B coefficients for Zr-1%Nb oxidation .............. I ..................................................................... 5.26

Table 5.8. C, n coefficients vs. Ra, Pr ............................................................................................................ 5.27

Table 5.9. Set of input data on fuel rod design .............................................................................................. 5.40

Table 5.10. Thermal physical constants of Zr-l%Nb .................................................................................... 5.45

Table 5.11. Specific heat and specific enthalpy for temperature region 1100 - 1200 K ............................... 5.46

Table 5.12. Thermal expansion coefficients for Zr-1%Nb cladding in axial and radial directions [5]......5.46

Table 5.13. Thermal expansion for Zr-1%Nb alloy for temperature region above 923 K ............................ 5.47

Table 5.14. Specific heat of VVER fresh fuel vs. temperature [8] ................................................................ 5.48

Table 5.15. Comparison of measured and calculated parameters of fission gases ........................................ 5.54

Table 5.16. Measured and calculated ZrO2 thickness for VVER fuel rods with water coolant .................... 5.55

xiii
Table 5.17. Data base to characterize cladding residual hoop strain for fuel rod #H4T ................................ 5.71

Table 6.1. Concentration of doping elements in zirconium alloys ................................................................. 6.1

Table 6.2. Mechanical properties of VVER tubes vs. oxygen concentration at 200C [1] ............................. 6.3

Table 6.3. Parameters of mechanical anisotropy for Zr-1%Nb alloy [1] ....................................................... 6.4

Table 6.4. Parameters of allotropic transformation for Zry and Zr-I%Nb alloys .......................................... 6.5

Table 6.5. Parameters of oxidation and hydriding for irradiated fuel rods of PWR type before CABRI

and N SRR tests ................................................................................................................................ 6.9

Table 6.6. Mechanical properties of irradiated and unirradiated VVER claddings ....................................... 6.10

Table 6.7. General principles to determine mechanical properties of Zr-l%Nb cladding for FRAP-T6

and SCAN AIR codes ....................................................................................................................... 6.16

Table 6.8. Correlations for mechanical properties of unirradiated Zr-l%Nb cladding vs. temperature ........ 6.38

Table 6.9. Correlations for mechanical properties of irradiated Zr-l%Nb cladding vs. temperature ............ 6.38

Table 6.10. Correlations for yield stress vs. strain rate for unirradiated and irradiated Zr-l%Nb cladding..6.43

Table 6.11. Correlations for burst pressure and maximum circumferential elongation vs. temperature ....... 6.55

Table 6.12. Correlations to calculate strength coefficient and strain hardening exponent vs. temperature

for Zr-I % Nb cladding ..... ............................................................................................................... 6.63

Table 6.13. Measured data base for local burst stress in Zr-l%Nb cladding ................................................. 6.64

Table 6.14. Correlations for local burst stress of Zr-l%Nb cladding ............................................................ 6.64

Table 6.15. Correlations to calculate engineering yield stress vs. temperature for Zr-1%Nb cladding ........ 6.65

xiv
ACKNOWLEDGMENTS

This volume of the Report is a result of cumulative efforts of many experts involved in the experimental and

analytical research. Therefore, the authors express their gratitude to each of the collaborators. The following

experts made a special contribution to the development and modification of the procedures presented in this

volume:

" Nuclear Safety Institute of RRC "Kurchatov Institute" (Moscow, Russia):

A. Kalugin, G. Poletaev, A. Konobeyev;

* Institute of Nuclear Reactors of RRC "Kurchatov Institute" (Moscow, Russia):

P. Slavyagin, T. Makarova, A. Zvyageen, M. Kalugin;

* Research Institute of Atomic Reactors (Dimitrovgrad, Russia):

A. Smimov, Yu. Kosvintsev, 0. Makarov, G. Kobyliansky, A. Chetverickov, G. Liadov, V. Jitelev;

" Institute of Atomic Energy of National Nuclear Center (Semipalatinsk, Kazakhstan):

Yu. Karzmin, A. Levin.

In addition, the authors express their deep appreciation to the experts who evaluated the procedures presented in

this volume and who contributed to their improvement. In this context we would like to give a special

prominence to the following experts:

* R.O. Meyer, H. Scott, D. Carlson (US Nuclear Regulatory Commission, USA);

* F. Schmitz, J. Papin (Institute for Protection and Nuclear Safety, France);

" H.M. Chung, L.A. Neimark, A.B. Cohen (Argonne National Laboratory, USA);

* R.K. McCardell (Idaho National Engineering Laboratory, USA);

* C. Beyer (Pacific Northwest Laboratory, USA);

* D. Diamond (Brookhaven National Laboratory, USA).

Ms N. Jouravkova (Nuclear Safety Institute of RRC "Kurchatov Institute", Russia) made a special contribution to

the computer make-up of this volume. The authors believe that this complex and multi-sided task was fulfilled at

a very high professional level, therefore, they would like to thank N. Jouravkova for the well done job.

xv

LIST OF ACRONYMS

ANL

AO MZ

CABRI

CE-Saclay

FGR

FRAP-T6

IAEKI

IAE NNC

IGR

IPSN/CEA

LOCA

NSI RRC KI

NSRR

NV NPP

PCMI

PWR

RIA

RIAR

RRC KI

SCANAIR

VNIINM

VVER

Argonne National Laboratory (USA)

AO Mashinostroitelny Zavod (Electrostal, Russia)

name of the test reactor (France)

Research Centre Saclay (France)

fission gas release

fuel rod analysis program, transient version 6 (USA)

Institute of Atomic Energy "Kurchatov Institute" (former name of RRC KI)

Institute of Atomic Energy of National Nuclear Centre of Kazakhstan Republic

(Kazakhstan)

Impulse Graphite Reactor (Kazakhstan)

Institute for Protection and Nuclear Safety of Commissariat of Atomic Energy

(France)

loss-of-coolant accident

Nuclear Safety Institute of Russian Research Centre "Kurchatov Institute" (Russia)

Nuclear Safety Research Reactor (Japan)

NovoVoronezh nuclear power plant

pellet-cladding mechanical interaction

pressurized-water reactor

reactivity-initiated accident

State Research Centre "Research Institute of Atomic Reactors" (Russia)

Russian Research Centre "Kurchatov Institute" (Russia)

code for describing the fuel behavior under an RIA transient (France)

All-Russian Research Scientific Institute for Inorganic Materials (Russia)

Russian type of pressurized-water reactor

xvii

1. ExEcuTivE SUMMARY

1.1. Introduction

As it was noted in Volume 1, this Report summarizes the development of the data base under the long-term

research program aimed at investigating the behavior of high burnup VVER fuel rods under RIA conditions.

Fig. 1.1 presents the structural diagram of the basic investigations conducted under this program.

The analysis of the diagram enables two important statements:

" there is a direct relation between quality of the obtained results and quality of analytical and

experimental tools used to produce these results;

" practical value of the developed data base and many original procedures goes far beyond the scope of

this work.

These statements lead to a conclusion that it is appropriate to describe in detail the used test procedures,

analytical methods and obtained data base. That is why this volume of the Report is intended to provide an

overview of corresponding information. The following main approaches were therewith taken in preparation

of this volume:

* standard well known procedures are described very schematically; 1*

* main emphasis in description of new or modified methods is placed on justification of procedures,

including verification investigations;

complex and essential procedures are described in individual original reports which have been made

specifically for this purpose.

1.2. The IGR/RIA tests with VVER high burnup fuel rods

The main purpose of testing fuel rods of VVER-1000 type at IGR reactor was comparative studies of the

behavior of preirradiated and unirradiated fuel rods under conditions simulating reactivity initiated accidents.

These tests were conducted at IGR impulse research reactor (Semipalatinsk, Kazakhstan) in 1991.

The program of the tests provided for the solution of the following problems:

* determination of failure thresholds of WER-1000 fuel rods as a function of the bumup;

* determination of failure mechanisms of fuel rods versus test parameters.

Three types of fuel rods were prepared for tests at IGR reactor:

* 13 re-fabricated fuel rods, manufactured from commercial fuel elements of VVER-1000 type (C-type

fuel rods);

• 10 re-fabricated fuel rods containing irradiated cladding of commercial fuel elements of VVER-1000

type and unirradiated fuel of VVER-1000 type (D-type fuel rods);

* 20 unirradiated fuel rods of VVER-1000 type (E-type fuel rods).

Taking into account the world experience of testing LWR fuel under conditions simulating RIA and corresponding experience of testing unirradiated VVER-1000 fuel rods, the following conditions were selected to

test fuel rods of C, D, E type:

* test type is the reactor capsule test;

* mode of changing the reactor power is the power pulse;

• coolant in the capsule is the water, air,

" initial coolant parameters are atmospheric pressure, ambient temperature, no flow rate;

* number of fuel rods in the capsule are 2 (with the exception of 3 tests performed with I rod).

1.1
I Program of RIA/IGR tests I

Manufacture of fuel rods

Development

of experimental

procedures

Pre-test examination of fuel rods

4v

_+ I Capsule tests of fuel rods at IGR reactor under pulse power

conditions I

4,

Post-test examination of fuel rods

I, I, I~r I

Preliminary analysis of test results and

formulation of tasks for next stages of

investigations

- S - S - S -

4 Development of preliminary data base with

4-- test results

I -

Development of Development of procedure to

procedure to determine fuel enthalpy in

determine energyrods

deposition in fuel rods

i a t Modifications of thermal

aSeitinal tsto obtain mechanical computer codes

additional data baseSCANAIR)(FRAP- T 6,SAAR

Technical requirements for

additional pre- and post-test

examinations of fuel rods

Development of

input data with

VVER material

7 " properties 4]

r Devel~opment of the

Verification of the

procedure

Verification

of modified

versions of

codes

Development

of the

data

base for

program and

procedures to

measure

4-

Special

tests and

measurem

ents code ve- mechanical

rifi- properties of

cation Zr-lNb cladding

4, 4. .L

Determination

ofrz~t

distribution of

energy

deposition in

each fuel rod

I

Calculations of

r, z, t distribution

of fuel enthalpy

and other

parameters in

each fuel rod

-ISpecial tests to

measure yield

stress, ultimate

strength, total

elongation, uniform

elongation versus

burnup,

temperature,

strain rate

-IBiaxial burst

tests to measure parameters

of the cladding

rupture versus

burnup,

temperature,

strain rate

I

Summarization of results and analytical studies

Final variant of data base

Fig. 1.1. Structure of researches

1.2
The air was selected as the second type of the coolant in the capsule because of the desire to obtain the data

base for the analysis and computer simulation of the fuel rod behavior, in rather simple boundary conditions

of the heat exchange between fuel rods and the coolant. Besides this obtained data base can be used to

analyze the behavior of fuel rods under LOCA conditions.

The technical requirements on test modes were developed taking into account the following factors:

* absence, in the world data base, of experimental results on failure thresholds of high bumup fuel rods

under RIA conditions (as of the beginning of 1991);

" absence, by the beginning of these tests, of reliable data on ratios between the energy deposition in the

fuel of high burnup fuel rods and the energy deposition in IGR reactor;

" absence of technical devices that would allow to determine directly at IGR reactor whether a high burnup

fuel rod is intact or destroyed after the test.

A special scoping test was conducted at MIR research reactor (Dimitrovgrad, Russia) to obtain input data

characterizing the ratio between number of fissions in the unirradiated fuel of WER-1000 type and in the

high burnup fuel of VVER-1000 type under the same irradiation conditions in the stationary mode. The

results were used to determine the operating ratio connecting the energy deposition in IGR reactor with the

energy deposition in unirradiated fuel rods and the energy deposition in high bumup fuel rods.

Unfortunately, later it turned out that the experimental coefficient obtained in the scoping test at MIR reactor

was determined with a large error (about 30%); this circumstance affected some results of testing fuel rods in

IGR reactor.

In the final form, the following logic was used as the basis of the development of specific technical

requirements on the tests:

1. The number of high burnup fuel rods tested in capsules with the water coolant is 8.

2. The number of high burnup fuel rods tested in capsules with the air coolant is 5.

3. The number of fuel rods with the preirradiated cladding and the fresh fuel tested in capsules with the

water coolant is 5.

4. The number of fuel rods with the preirradiated cladding and the fresh fuel tested in capsules with the air

coolant is 5.

5. 20 unirradiated fuel rods were used as reference rods tested under the same conditions as preirradiated

fuel rods. Thus, each of these fuel rods was installed in capsules in addition to the main fuel rod of C or D

type.

6. The total number of tests was 23.

7. All fuel rods of the same type for each coolant type are to be tested in the conditions when only one

integral parameter is varied, namely, the energy deposition in the fuel rod. The power pulse half width

must remain more or less constant. This requirement was satisfied using automatic power regulator of

IGR reactor.

8. The entire test cycle was divided into two stages. At the first stage 12 tests were performed, which

included tests of three types of fuel rods for two coolant types. The series of tests of fuel rods of the same

type (for the same coolant type) was conducted with a gradual increase in the energy deposition from one

rod to another by step-by-step method for a selected energy deposition range. After the first stage of tests

was completed, twelve capsules with tested fuel rods were sent to hot cells in RIAR (Dimitrovgrad,

Russia), where the capsules were opened and the fuel rods were visually examined to determine the scale

of destruction. According to the results of the visual examination of fuel rods, the test program of the

second stage was developed; the main task of the second stage was to adjust of fuel rod failure thresholds.

9. Special scoping tests were to be conducted at IGR reactor to obtain experimental coefficients connecting

the energy deposition in the unirradiated fuel sample with the energy deposition in IGR reactor.

I0.Based on safety considerations, it was necessary to ensure the absolute leak-tightness of the capsules with

the high burnup fuel rods at all technological stages of the tests including the railway transportation of the

capsule devices (-2500 kIn) from the place of their assembly to IGR reactor and back. Due to this

1.3
requirement the idea of measuring thermo-physical parameters of fuel rods in the test process was

rejected (i.e. there were no instrument penetrations through the capsules with high bumup fuel rods).

In general, the technological scheme of the tests included the following stages:

" manufacturing of E-type fuel rods and fuel pellets of D-type fuel rods in AO MZ "Electrostal"

(Electrostal, Russia);

* manufacturing of re-fabricated fuel rods of C, D types, capsules for them, assembly of capsules with

fresh and irradiated fuel rods in RIAR (Dimitrovgrad, Russia);

* transportation of capsules with fuel rods to IGR reactor and back by RIAR, Dimitrovgrad, Russia);

* fuel rod tests at IGR reactor in IAE NNC (Semipalatinsk, Kazakhstan);

* post-test examinations of commercial fuel elements of NV NPP, pre- and post-test examinations of fuel

rods of C, D types in RIAR (Dimitrovgrad, Russia).

The program of post-test examinations of commercial fuel elements was coordinated with programs

implemented within the framework of other studies and provided for the conduct of only those measurements

which were necessary for supplementing the data base on input characteristics of re-fabricated fuel rods of C,

D types.

The program of pre- and post-test examinations of C, D types fuel rods included a set of studies to solve

problems of this project.

The management of this project as a whole, coordination of all types of studies, development of the program

and methodological documentation, development of the procedure to determine r, z, t distribution energy

deposition, validation of the tests, consolidation and analysis of test results were carried out by RRC

"Kurchatov Institute" (Moscow, Russia).

L3. Experiments to measure mechanical properties of Zr-i %Nb cladding

It is evident that the full-scope analysis of the data base obtained during testing of the WER fuel rods in

IGR reactor can be done only by computer codes. Therefore original input data characterizing mechanical

properties of WER fuel rods are to be prepared. Still, the assessment of the existing data base with

mechanical properties of Zr-l%Nb claddings has demonstrated that it was necessary to perform new special

tests in order to get mechanical properties of irradiated claddings. Besides, some additional tests were to be

performed to complete the data base with the properties of unirradiated Zr-l%Nb claddings.

The testing program worked out by NSI RRC KI called for the performance of two types of tests:

" testing of the plain ring specimens fabricated of the commercial WER tubes and of irradiated claddings

of commercial WER high burnup fuel elements;

* burst, tests of pressurized specimens fabricated of the commercial WER tubes and of irradiated

claddings of commercial VVER high burnup fuel elements.

The first type of tests was performed to measure yield stress, ultimate strength, uniform elongation, total

elongation versus temperature and strain rate. The objective of the second type of tests was to measure burst

parameters of the claddings versus temperature and strain rate, as well as the number of specific

characteristics of the ballooning type cladding deformation. The set of special procedures was developed for

these tests by the specialists of RRC KI and RIAR. The experimental part of work was performed in RIAR,

and analytical part of work was carried out in NSI RRC KI.

1.4
1.4. Computational analysis of VVER fuel rod behavior under IGR/RL4 test

conditions

Two computer codes were used for computational analysis of VVER fuel rod behavior under IGR test

conditions:

" FRAP-T6 code [1];

" SCANAIR code [2].

Neither of the codes was intended to calculate behavior of the VVER fuel rods. Therefore, special attention

was paid to develop the data base with original mechanical properties of the VVER fuel rods. Besides,

preliminary verification of the codes for the IGR test conditions has demonstrated that it was necessary to

modify some of the code's models prior to using them as the tools to analyze VVER fuel rod behavior. That

is why code modification was a separate stage of the work. After that the final verification of the codes was

performed, and the boundaries of their applicability to analyze IGR test results were determined. Final stage

of this research included computer analysis of 25 fuel rods tested in IGR reactor and processing of these

results as the computational data base. The whole complex of work in this direction was performed by the

specialists of RRC KI.

1.5. Structure of the generalized data base for IGRIRIA tests of VVER fuel rods

The generalized data base is included into Volumes 2, 3 of this Report. The data base of Volume 3 consists

of the following main sub-bases:

" Test data to characterize parameters of VVER fuel elements prior to irradiation at NPP (Appendix A);

" Test data to characterize the irradiation history of VVER fuel elements at NPP (Appendix B);

" Test data to characterize parameters of fuel rods fabricated of VVER fuel elements prior to IGR tests

(Appendixes C, D, E);

" Test data to characterize IGR test conditions (Appendix F);

" Test and calculated (by FRAP-T6 and SCANAIR codes) data to characterize fuel rod behavior during

IGR tests and after IGR tests (Appendixes G, H, I);

" Test data to characterize the results of tests on the measurement of mechanical properties of VVER

claddings using ring specimens (Appendix J);

" Test data to characterize the results of burst tests with Zr-lNb claddings (Appendix K).

The data base of Volume 2 includes the material properties of VVER fuel rods.

The main objective of the present Volume of the Report is to describe, justify, and analyze the whole set of

experimental and calculational procedures used to obtain the data base presented in Volume 3.

1.5
1.6. References

[1] L. Siefken, Ch. Allison, M. Bohn, S. Peck "FRAP-T6: Computer code for the transient analysis of oxide

fuel rods." NUREG/CR-2148 EGG-2104, May 1981.

[2] F. Lamare, J.C. Latche, "SCANAIR. A Computer Code for Reactivity Initiated Accidents in LWRs",

Rapport Technique SEMAR 95/01

1.6
2. OBJECTIVES AND CONDITIONS OF THE IGR REACTOR TESTS

2.L Test objects

Refabricated high burnup fuel rods (fuel rods of C-tvpe)

Refabricated C-type fuel rods were manufactured from commercial fuel elements #317 and #22 of fuel

assembly #1114 removed from power unit NoS of NovoVoronezh Nuclear Power Plant (NV NPP-5).

Operating cycles of VVER-1000 fuel elements took place from June 25, 1984 to June 25, 1987.

Characteristics of commercial fuel elements before the irradiation are presented in Appendix A, Volume 3 of

the Report [1]. Characteristics of operating cycles [2] and characteristics of commercial fuel elements after

the irradiation are presented in Appendix B, Volume 3 of the Report. Procedures used to obtain

characteristics are described in section 3.1. The general appearance of the refabricated C-type fuel rod is

presented in Fig. 2.1.

L,,L2,L,,L,- individual values for each fuel rod 1. Lower cap 4. Connector

2. Fixing ring 5. Upper plenum

3. Fuel pellet 6. Upper cap

Diameter of central hole in fuel is 2.4 mm

Fig. 2.1. Scheme of high burnup fuel rod

The refabricated C-type fuel rod contains the active part (fuel stack and cladding), which was a part of one

out of two commercial fuel elements, and technological components (top and bottom caps), the fixing ring

which fixes the fuel stack in the axial direction, the connector and the cladding that forms the upper gas

plenum. All technological components of the fuel rod were made of unirradiated materials. The procedure to

manufacture refabricated fuel rods is described in section 3.3 of the present Volume.

The material of the C-type fuel rod cladding is Zr-i %Nb alloy, fuel rod pellets are of cylindrical form, there

is a hole along the axis of the pellet. The source fuel material is U0 2. The average fuel burnup in C-type fuel

rods is 48 MWd/kg U. The internal plenum of the fuel rod is filled with helium under the pressure of 1.7

MiPa. Characteristics of C-type fuel rods before tests in IGR reactor are presented in Appendix C, Volume 3

of the Report. Procedures to obtain these characteristics are described in section 3.1 of the present Volume.

Refabricated fuel rods with fresh fuel and irradiated cladding (fuel rods of D-type)

Refabricated D-type fuel rods contain, in the fuel rod active part, a segment of the cladding of commercial

fuel element #22 (see description of C-type fuel rod), a stack of unirradiated fuel pellets of VVER-1000 type

and technological components similar to those of C-type fuel rods. The general appearance of D-type fuel

rod is presented in Fig. 2.2.

2.1
Fig. 2.2. Scheme of fuel rod with preirradiated cladding and fresh fuel

The fuel rod cladding material is Zr-lNb alloy; the fuel material is U0 2 with the average enrichment of

4.4%. D-type fuel rod pellets are of cylindrical form with facets at external edge parts, there is a hole along

the pellet axis. The internal environment of the fuel rod is helium under the pressure of 1.7 MPa.

Characteristics of D-type fuel rods before tests in IGR reactor are presented in Appendix D, Volume 3 of the

Report. Procedures to obtain these characteristics are described in section 3.2 of the present Volume.

Fresh fuel rods (fuel rods of E-type)

The procedure of manufacturing unirradiated E-type fuel rods is described in section 3.3 of the present

Volume. The general appearance of E-type fuel rods is presented in Fig. 2.3.

L,, L2- individual values

for each fuel rod

Fuel pellet

.4- 0.1

1. Lower cap

2. Fuel pellet

3. Cladding

4. Fixing ring

5. Upper plenum

6. Uppcr cap

Diameter of central hole infuel Is 2.2 mm

Fig. 2.3. Scheme of unirradiated fuel rod

The fuel rod contains the cladding made of Zr-l%Nb alloy, the fuel stack about 150 mm long, the upper

plenum, the fixing ring and caps. The fuel rod is filled with helium to the pressure of about 2-2.5 MPa.

2.2
E-type fuel rod pellets are of cylindrical form with facets at edges. Fuel pellet material is U0 2 with the

enrichment of about 4.4%; there is a hole in the pellet centre. Characteristics of E-type fuel rods are

presented in Appendix E, Volume 3 of the Report. Procedures to obtain these characteristics are described in

section 3.2 of the present Volume.

2.2. Test conditions

As it has already been noted, 23 leak-tight capsules with test fuel rods were delivered to IGR reactor before

the beginning of pulse tests. 20 capsules contained two fuel rods - one of them was refabricated, the other

one was unirradiated. The three capsules contained one refabricated fuel rod. The load scheme of fuel rods in

capsules and the coolant type in each capsule are presented in the Table of Appendix F, Volume 3 of the

Report. Before the installation of the capsule with fuel rods into IGR reactor, special fuel samples were

positioned in the capsule. These samples, the capsule and IGR reactor are described below.

Special fuel samples

Two special fuel samples were installed in the capsule with fuel rods before the beginning of the tests at IGR

reactor.

After the completion of the test at IGR reactor the fuel samples were removed from the capsule, and number

of fissions in them was measured. Results of these measurements were used as the input data for the

procedure of determining the energy deposition in fuel rods of C-, D-, E- types tested at IGR reactor (see

sections 4.1, 4.3). The design scheme of special fuel samples is presented in Fig. 2.4.

A

LA A-A A

.o5xl_

1. Guide tube

2. Special fuel samples

3. Aluminium box

Fig. 2.4. Axial and cross-sections of the guide tube with special fuel samples

There was a guide tube in each capsule, intended for installing the aluminum box with two fuel samples.

Each fuel sample was about 20 mm long and represented a spiral-rod fuel element of two-blade profile, 1.5

mm thick. The fuel element was in the cladding Zr-INb alloy, 0.3 mm thick. Each special fuel element had

a certification of the manufacturing plant and was qualified regarding its fuel composition [3]. Before the installation in capsules, all special fuel samples were subjected to input spectrometric monitoring of U23

.

content.

Experimental capsule

The geometric scheme of the capsule with fuel rods is presented in Fig. 2.5.

2.3
guide tube for

fuel samples A-A

core centre

fuel rods

Capsule material - SS

Water volume = 3670 cm 3

Fig. 2.5. Scheme of the experimental capsule

The capsule represented a steel leak-tight vessel filled with the coolant and equipped with structural elements

intended for the installation of fuel rods to be tested in them. The capsule design provided for a free axial

movement of fuel rods during the test process due to thermal expansion. The fixation of fuel rods in a certain

position during transportation and handling was provided by springs. The capsules were filled with water and

had an air-filled gas plenum in the upper part. Each capsule had four guide tubes intended for positioning

special fuel samples. The axes of two fuel rods and of four guide tubes were located along the circumference

with a uniform angular step.

Initial thermo-physical parameters in the capsule were as follows:

" atmospheric pressure;

" ambient temperature;

2.4
* no flow rate;

* water or air as coolant.

IGR reactor

IGR reactor is a pulse uranium-graphite self-quenching reactor of thermo-capacity type [4]. Fig. 2.6, Fig. 2.7

show cross and axial sections of IGR reactor.

Fig. 2.6. Cross-section of IGR reactor

The reactor core consists of graphite blocks impregnated with uranium salt. The reactor core includes two

parts: immovable part and movable part of the core, which can move in the axial direction using a special device. The side reflector, top and bottom edge reflectors consist of the same graphite blocks (but without uranium). The reactor core is located in the leak-tight reactor vessel filled with helium. The reactor vessel with

the core is located in the water-filled tank. Therefore, the heat generated during the reactor operation is

accumulated in the reactor core, and then is gradually transferred to the coolant circulating in the water tank.

The reactor power is controlled using control rods positioned in special holes of the reactor core. In addition

to control rods there are four lateral rods in the reactor, which are also located in the holes of the reactor core.

The reactor power is monitored using a group of ionization chambers installed at a certain angle along the

circumference in the water tank. In addition, in-core sensors of the neutron flux are used in some cases.

These sensors are installed in the central plenum of the reactor. Cross and axial sections of the reactor central

part are presented in Fig. 2.8, Fig. 2.9.

2.5
water

level

1.

2.

3.

4.

5.

6.

Water tank

Reactor vessel

Thermal shield

Reactor core

Side reflector

Ionization chamber channel

7. Temperature sensor channel

8. Control rod channel

9. Central experimental channel

10. Biological shield

11. Ceiling

Fig. 2.7. Axial section of IGR reactor

2.6
1. Graphite 'nsert

2, 3, 4. Three shrouds of reactor

capsule

5. In-core neutron detector

6. Protective shroud

7. Capsule

8, 9. Fuel rods

10. Tube for fuel samples

Fig. 2.8. Cross-section of the IGR reactor central part

2.7
1. Graphite insert 7. Capsule

2, 3, 4. Three shrouds of reactor capsule 8, 9. Fuel rods

5. In-core neutron detector 10. Guide tube with special fuel samples

6. Protective shroud

Fig. 2.9. Axial section of IGR reactor central part

2.8
This part consists of the graphite insert with the central hole, in which the central experimental channel of the

reactor is located. The central experimental channel of the reactor consists of the following elements:

" reactor capsule consists of three shrouds, water circulates in the gap between two of them to provide

protection of the internal plenum of the central experimental channel against the heat generated in the

reactor core;

* protective shroud intended to protect reactor structural components in case of the destruction of test

objects;

" central cavity 150 mm in diameter intended for positioning test object at IGR reactor.

Test objects (in our case, the capsule with fuel rods) are positioned in the central cavity of the central

experimental channel.

There are two main types of the reactor power mode:

" uncontrolled power pulse;

" controlled power pulse.

The uncontrolled power pulse mode is implemented by withdrawing a required group of control rods to a

required height. This results in the introduction of the initial positive reactivity in the range up to 10 3

eff and,

thus, in the formation of the forward front of the reactor power pulse. The reactor quenching, i.e. reduction of

the positive reactivity, is carried out without control rods due to the negative temperature reactivity

coefficient.

The controlled power pulse mode is implemented using the automatic regulator of the reactor power. It is

possible to implement practically any reactor power profile as a function of time, including the stationary

one. In this case the only limitation is the reactor core temperature. It must not exceed certain values

provided for in the safety requirements,

Main characteristics of IGR reactor are presented in Table 2.1. During the tests of fuel rods of C-, D-, Etypes the reactor operated in the controlled power pulse mode with the pulse half width of about 700 ms. A

more detailed description of reactor operating modes during these tests is contained in section 4.6.

Table 2.1. Main characteristics of IGR reactor

Characteristic Value

1. Approximate overall dimensions of the reactor core (mm) 1400.1400.1400

2. Outer diameter of the central experimental channel (mm) 270

3. Material of fuel elements of the reactor core graphite

impregnated with

uranyl nitride

4. U 235 mass in the reactor core (kg) 9

5. Fuel enrichment in U 235 (%) 90

6. Nuclear ratio (carbon/uranium) 8040

7. Moderator material graphite

8. Reflector material graphite

9. Maximum thermal neutron flux density in the reactor central experimental 7.1016

channel (n/cm2.sec)

10. Maximum thermal neutron fluence in the central experimental channel (n/cm2) 3.7 1016

11. Excess reactivity (8,f) 31.6

12. Effective fraction of delayed neutrons (fl) 0.00685

13. Temperature reactivity coefficient (fi,8K) -0.03

14. Maximum permissible temperature of the reactor core (K) 1400

2.9
2.3. References

[1] V.Zhitelev, B.Kanashov, V.Polenoc, A.Smirnov. "Data Base and Postirradiation Examination Results of

Spent VVER-1000 Fuel Elements and Assemblies", BNES Conference-Fuel Management and Handling,

Edinburg, England, 20-22 March, 1995.

[2] Yu.Vikhorev, V.Voznesensky, V.Goncharov et.al "Fuel Assembly Operation Experience in VVER-1000

Reactor of Unit 5 of NV NPP", Rus., At. Energia, Vol. 54, Iss.3, 1983.

[31 "Passport for Special Fuel Samples", Rus., Scientific and Industrial Association "LUCH", Passport No.

837.5.02.00.03ET, Podolsk, 1990.

[4] I.Kurchatov, S.Feinberg, N.Dollegal et.al "IGR Pulse Graphite Reactor", Report No. 322A, Proceedings

of the 3-rd International Conference on the Peaceful Uses of Atomic Energy, Geneva, Vol. 7, p. 461-472,

UN Press, New-York, 1965.

2.10
3. CHARACTERISTICS OF FUEL RODS BEFORE AND AFTER IGR TESTS

3.1. High burnup commercial fuel elements ofpower unit No 5 of NVNPP

Procedures described in this section were developed in RIAR (Dimitrovgrad, Russia) and were used to

determine characteristics of commercial fuel elements, which are presented in Appendix B, Volume 3 of the

present Report.

3.1.1. Geometric and thermo-physical characteristics of fuel elements [1, 21

Average pellet outer diameter

The outer diameter of fuel pellets was determined by direct measurements at metallographic specimens of

fuel elements #22 and #307 using metallographic microscope (fuel element #307 is practically the analog of

fuel element #317 regarding the whole set of important irradiation parameters).

Length of fuel stack

The length of the fuel stack was determined by processing a statistically representative series of results of

gamma spectrometric scanning of fuel elements #22 and #317 along their length.

Pellet-cladding gap

The gap was determined by direct measurements at several metallographic specimens made of fuel element

sections with different axial coordinates.

Pressure inside fuel element

The gas pressure inside fuel elements was measured using the manometer method after the cladding was

punched with the laser. Since the accuracy of determining the pressure by this method is about 7%, the

average gas pressure in a group of fuel elements of the same type is presented as measurement results.

Fuel densiW

The fuel density for a series of axial coordinates was measured by the immersion method for fuel element

#307.

3.1.2. Burnup, fuel isotopic composition and chemical composition of the gas inside the

fuel element

Determination of the element cross-section-average burnup and the fuel isotopic composition

These characteristics were measured at fixed axial sections of fuel element #317 by the mass-spectrometric

method [3]. The procedure included the following stages:

* cutting the sample and fuel removal from the sample;

" fuel dissolution in the nitric acid;

" separation of isotope fractions of uranium, plutonium, americium, cerium, neodymium by methods of ion

exchange and extraction chromatography;

" determination of the isotopic composition of elements;

" determination of the quantitative composition of isotopes by methods of isotopic dilution and alpha

spectrometry.

Measurements were conducted using two possible variants of the mass-spectrometric method, namely:

" method of heavy atoms;

" method of determining the accumulation of fission products.

The mass-spectrometric method is a qualified procedure, and its error is about 4.4%.

3.1
Determination of the bumup axial distribution [11

The processing of results of y-scanning of the irradiated fuel element for Cs137 isotope forms the basis of the

method to determine the burnup axial distribution. The experimental part of the procedure consists of two

stages:

" y-scanning of commercial VVER-1000 fuel element;

" y-scanning of the reference sample calibrated for the burnup by the mass-spectrometric method.

The comparison of Cs137 gamma line intensity in VVER-1000 fuel element and in the reference sample

forms the basis of the calculation procedure to determine the burnup axial distribution in absolute units of

burnup measurements. In general, this procedure is qualified; its burnup determination error does not exceed

7%.

Determination of the burnup radial distribution and the fuel isotopic composition

These characteristics were determined by the mass-spectrometric method. The measurements were

performed for five fuel micro-samples taken from the cross-section of fuel element # 317. The arrangement

of these samples is presented in Fig. 3.1.

2

1. Cladding

2. Fuel

3. Microsample for analysis

Fig. 3.1. Arrangement of fuel samples taken from the cross-section of fuel element #317 to measure the

burnup radial distribution and the fuel isotopic composition

The samples were taken using a tube-type sampler connected to the generator of ultrasonic oscillations.. The

diameter of a sample was 0.5 mm. The error in determining of the radial coordinate of the sample centre did

not exceed 5 %.

Gas composition inside fuel element.

The gas composition inside fuel elements was determined after punching the cladding with the laser, taking

the gas sample and mass-spectrometric measurements of its composition. Taking into account the error of a

single measurement, this procedure was implemented for.a group of fuel elements, which were in similar

irradiation conditions. Average measurement values are presented as the measurement results.

3.2. Characteristics of refabricated fuel rods before IGR tests

All measured characteristics of fuel rods of C and D types (with the exception of the fuel of D-type fuel rods)

were obtained within the framework of corresponding procedures in RIAR (Dimitrovgrad, Russia). All

measured characteristics of D-type fuel rods were obtained in AO MZ "Electrostal" (Electrostal, Russia). All

calculation procedures to determine axial distribution of free gas volume, fuel mass etc. were developed in

the Russian Research Centre "Kurchatov Institute" (Moscow, Russia).

Results obtained using procedures described in this section are presented for C-type fuel rods in Appendix C,

Volume 3; for D-type fuel rods in Appendix D, Volume 3; and for E-type fuel rods in Appendix E,

Volume 3.

3.2
3.2.1. High burnup fuel rods

Representative values of initial characteristics for C-type fuel rods

Characteristics of this group were not determined individually for each fuel rod. They are typical for the

whole batch of fuel rods. A majority of characteristics of this group for C-type fuel rods are completely

identical to corresponding characteristics of commercial fuel elements in Appendix B, Volume 3. The

following characteristics were additionally measured for a batch of several metallographic samples using

standard procedures:

" grain size;

" corrosion thickness of cladding;

" H2 content in cladding;

The outer diameter of fuel rod cladding and the free gas volume of fuel rods were determined as the

arithmetic mean for a group of corresponding measurements performed for each fuel rod.

The initial gas pressure was determined by averaging the results of manometer pressure measurements

conducted in the chamber where the fuel rods were filled with helium and sealed. The composition of the gas

in the fuel rod was determined under the same conditions using the mass-spectrometric method.

Consolidated characteristics for C-type fuel rods

Procedures to determine characteristics, which either do not depend on r, z coordinates in the fuel rod or are

average values, are presented here.

Axial coordinates of the top and the bottom of the fuel stack of each fuel rod, as well as coordinates of

undamaged sections of the fuel stack (i.e. which were not fragmented in the process of the fuel rod

refabrication) were determined within the framework of a specially developed calculation procedure used to

analyze and process the results of the axial y-scanning of fuel rods and X-ray photographs of fuel rods.

The average burnup in each fuel rod was obtained by the mathematical processing of measurement results of

the burnup axial distribution at the section of the commercial fuel element used for refabrication of this fuel

rod.

The procedure to determine the total free gas volume is described in section 3.2.6.

The geometric dimensions L1, L2, L3, L4 were determined by processing the results of y-scanning of each fuel

rod and X-ray photographs of the fuel rod; the outer diameter of the fuel rod cladding was determined as an

average value based on fuel rod profilometry results.

Individual measured r, z distributions of C-Wte fuel rod characteristics

Z distribution of the cladding outer diameter of each fuel rod was obtained by the profilometry in two

azimuth positions using the converter of magnet scale type. The scanning step was 2 mm, the measurement

error was ±0.01 mm. The radiation intensity of isotopes Cs134

, Cs'37, Ru'O° along the fuel rod length was

measured by the gamma spectrometric method using Ge (Li) detector. The width of the spectrometer

collimator was 5 mm, the scanning step was 5 mm (in three cases - 10 mm). Fuel rod cladding quality was

checked using the standard eddy current method at two different frequencies. The burnup axial distribution

was determined by tying the file of burnup measured distributions in fuel elements to axial coordinates of the

fuel stack in each C-type fuel rod.

Calculation procedures to determine r, z distribution of fissile isotopes in the fuel rod, r distribution of the

burnup, z distribution of the fuel mass and z distribution of the gas free volume are described in

sections 3.2.2, 3.2.3, 3.2.6.

3.2.2. Axial distribution of the fuel mass in high burnup fuel rods

The determination of the fuel mass distribution in C-type fuel rods was a rather complex methodological

problem. This was related to the fact that direct measurements of the mass of each fuel pellet were not

performed because it was impossible to remove the fuel from fuel rods without the risk of damaging it. An

additional complicating factor was the consequences of the fuel rod refabrication procedure. These were the

3.3
consequences of the process of the fuel removal from the upper and lower parts of the commercial fuel

element which resulted in a destruction of a part of fuel pellets used to form the fuel stack of the refabricated

fuel rod. That is why it was impossible to assess the fuel stack mass in refabricated fuel rods on the basis of

data on the mass of a corresponding section of the commercial fuel element. Thus, a special procedure was

developed to determine the fuel mass in refabricated fuel rods.

Main provisions of the procedure

Results of spectrometric measurements of Cs137, Cs'34 and RU106 activity in the fuel were used as basic

measurements to determine the mass axial distribution in refabricated C-type fuel rods.

The count rate of the spectrometer during the y-scanning of the axial section of the irradiated fuel rod was

determined using the following expression:

S --•.ci X k, n m,

where S= the count rate in the photopeak while recording gamma quanta of a certain energy (1/s);

e = the photo-efficiency of recording gamma quanta of a certain energy with the spectrometer

(per-unit);

,n = the quantum yield of gamma quanta (per-unit);

2, = the decay constant of a given isotope (11s);

k, = the coefficient of self absorption of gamma quanta of a certain energy in the fuel pellet (perunit);

n = the average concentration of a given isotope in the fuel (1/g);

m = the fuel mass in this axial section (g).

The above expression can be written in another form:

S=Clknm,

where C= the coefficient which does not depend on the fuel mass in the section and on fuel irradiation

conditions (1/s).

Thus, the fuel mass in a given axial section can be determined if S, C, Y, n values are known. However, only

S value is the result of spectrometric measurements in this section of the fuel. To determine other parameters,

it is possible to use the data base describing characteristics the commercial fuel element from which this fuel

rod was refabricated.

The following expressions for spectrometer count rates can be written for two axial sections of the

commercial fuel element:

S =,i C ks,f.,i nf.,i mfj,,

Sf.,= C k.,&,. nf.,o mf.,o,

where fe = the index for the fuel element;

i,o = indexes of axial sections of the fuel element.

According to corresponding measurements, the fuel density of commercial fuel elements after irradiation at

power unit No 5 of NV NPP is not changed along the height of the fuel element (with the exception of upper

and lower parts of the fuel element). Thus, mfe.,=mfo expression will be valid for any axial section of the

commercial fuel element. In this case the following expression will also be valid:

nfe.o Sfeo. •

Let us further assume that these are the it* and the osh sections of the commercial fuel element that were

subjected to the procedure of the gamma scanning for the second time, but within the composition of the

refabricated fuel rod. In this case the following expressions are valid:

Sfri C ksr, i nfrt mfri,

Sf,.o = C ks,,o nfro mfr,.,

3.4
while:

Sfrj Sk., mk,.f.m• ,

Sfr0, S.o kA,,.o mfr,

0

where fr = the index of the fuel rod.

If the selection of the refabricated fuel rod section with the index "o" was made in accordance with the

condition that mr,-r=maf.i, the following formula can be obtained to determine the fuel mass in the ith section

of the refabricated fuel rod:

mfr,' = Mfeo , S,.ok,

Sfe,i Sfr.o ks,+r.,

In this formula all spectrometer count rates are the results of direct measurements. The fuel mass in the

commercial fuel element (mfa, 0 ) is determined by the following expression:

MAL mfe"o =L L'

where M = the total fuel mass in the fuel element (g);

L = the effective fuel stack length of the fuel element, i.e. without gas gaps (cm);

ATL = is the gamma scanning section length (cm).

Corresponding values mfe.o were determined for fuel elements #22 and #317 on the basis of measured values

of M and L.

The last stage of this procedure is to determine coefficients of gamma quanta self absorption of Cs 37, Cs'34

and Ru"°6 in the fuel of the refabricated fuel rod for the id' section of the gamma scanning. Coefficients of self

absorption for commercial fuel elements were calculated according to standard procedures.

The fuel of the iý section of the refabricated fuel rod can be in two states:

" undamaged, i.e. in conditions similar to fuel conditions in the commercial fuel element (in this case

" damaged, i.e. fragmented.

Coefficient k, for the damaged section of refabricated fuel rod was calculated for two extreme variants in

which the fuel can theoretically exist:

" fuel is homogeneously distributed in the entire section volume;

* fuel with the density of the commercial fuel rod occupies a local cylindrical volume.

The mass of the refabricated fuel rod was calculated for each of the two variants. Taking into account that

k,= f(m), the calculations were performed by the iteration method. The average mass value obtained on the

basis of two calculation variants was taken as the final mass value in the i' section.

The above procedure was used to calculate the mass in refabricated fuel rods of C type using individual sets

of spectrometric measurement results for isotopes Cs137, CsI34, Ru'06. The average weighted value of three

measurements was used as the final mass value.

Verification of the procedure

A special test was conducted in RIAR (Dimitrovgrad, Russia) to verify the procedure of determining the fuel

mass in C-type fuel rods. The schematics of the test can be described asfollows:

1. A sample of commercial fuel element 70 mm long was cut from commercial fuel element #295 removed

from fuel assembly No 1114, irradiated at power unit No 5 of NV NPP.

2. The fuel burnup in the sample was determined (48.1 MWd/kg U).

3. X-ray photographs of the sample were taken; according to them, the cut-out sample had the undamaged

fuel stack.

3.5
4. y-scanning of the cut-out sample for Cs" 4 , Cs13 7

, Zr95 was performed with 1 mm step (collimator width of

I mm), with 5 mm step (collimator width of 5 mm), with 10 mm step (collimator width of 10 mm),

5. Then the fuel was removed from the cladding and weighed. A careful monitoring was provided to ensure

the complete removal of the fuel from the cladding. The fuel weight in the sample was 29.2'°.°0 g.

6. The removed fragmented fuel was placed in the unirradiated cladding of VVER-1000 type. The fuel stack

length in this cladding was 120 mm (according to the data of X-ray radiography).

7. y-scanning of the unirradiated cladding with irradiated fuel was performed in the same modes as in item

4.

Results of this test were used to verify the indirect procedure of mass determination in fuel rods of C-, D-, Etypes. All parameters used in the verification are presented in Table 3.1.

Table 3.1. Verification results for procedure to determine

fuel mass in high burnup fuel rods

Parameter Measured Calculated

Value of mass (g) 29.2 28.55

Total error (%) 0.02 2.4

Procedure error assessment

The error analysis of this procedures was carried out in a number of areas:

* assessment of spectrometric measurement errors;

" assessment of the error in determining the fuel mass in the e section of the commercial fuel element;

" assessment of the error in determining the self-absorption coefficient for damaged and undamaged

sections of the refabricated fuel rod;

" assessment of the error in determining the axial c6ordinates of ith sections in the commercial fuel element

and in the refabricated fuel rod.

Results of error calculations of the fuel mass in each C-type fuel rod are presented in Table 3.2.

Table 3.2. Errors In determining the total fuel mass In C-type fuel rods

Number of fuel Mass (g) Relative error of mass (%)

rod in fuel rod in undamaged section standard deviation systematic error

HIT 60.4 53.4 0.43 0.75

H2T 61.2 61.2 0.44 0.87

H3T 60.6 51.1 0.43 1.05

H4T 59.8 56.7 0.43 0.84

H5T 57.0 39.5 0.43 0.89

H6T 49.2 16.6 0.42 1.90

H7T 56.8 42.6 0.43 1.25

HST 56.2 30.7 0.42 1.20

B9T 58.9 56.1 0.44 0.87

BlOT 55.9 43.5 0.45 0.95

B11T 57.7 38.5 0.43 1.24

B12T 47.9 10.2 0.42 2.07

B13T 59.7 56.2 0.43 0.81

3.6
3.2.3. Isotopic composition of the high burnup fuel rods

Purpose of the procedure

The purpose of the procedure was the calculation determination of the axial and radial distribution of main

isotopes in C-type fuel rods.

Input data

The following characteristics were selected as the input data:

* isotopic composition of the fuel of commercial fuel elements before the irradiation at NovoVoronezh

Nuclear Power Plant (NV NPP);

" geometry and material composition of fuel elements and fuel assemblies, scheme of the fuel element

arrangement in the fuel assembly;

" NV NPP operational characteristics;

" load schedule of fuel elements ##317, 22 in the fuel assembly;

" thermo-hydraulic parameters of fuel cycles;

" schedule of boron control in the primary circuit;

" cooling time of fuel elements #317 and #22 after the end of operating cycles.

Selection and validation of computer codes and description of the numeric method

The selection of the computer code to determine the spatial distribution of the isotopic composition in

refabricated C-type fuel rods manufactured from irradiated commercial fuel elements was made taking into

account the following requirements on the simulation of these processes:

* consideration of the non-uniformity of nuclide formation and bumup along the radius of fuel pellets of the

commercial fuel element during operating cycles (consideration of the rim-zone formation);

" consideration of the scenario of the boron control during operating cycles of power unit No 5 of NV NPP;

" consideration of real conditions of the fuel irradiation to adjust the neutron spectrum hardness as a

function of time and z-coordinate;

" possibility of ensuring consistent information transfer procedures in the system of interconnected

calculations, using different codes, of neutronics characteristics of C-type fuel rods.

Taking into account the above requirements, TRIFOB code was selected to calculate the spatial r,z

distribution of the burnup and isotopic composition versus time for commercial fuel elements of NV NPP-5

[4].

TRIFOB code provides a flexible scheme of isotopic transitions and allows to change it depending on the

conditions of the problem. The data base of the code can be expanded to cover the data base on nuclides

which are included into the transition scheme in addition to the main nuclides.

Isotopic composition calculations with TRIFOB code were carried out using the calculation cell of WER1000 reactor, which represented the fuel pellet with the central-hole, surrounded with the zirconium cladding

and the coolant layer. The spatial and energy calculations of this reactor cell were performed with TRIFON

code by solving the multi-group ihtegral transport equation using the collision probability method [5].

TRIFON code allows to take into account'the detailed resonance structure of neutron cross-sections. Neutron

thermalization models are used for the thermal energy region. The isotropic return of neutrons at the cell

boundary is used as the boundary condition. TRIFON code was used to calculate process rates, which were

subsequently used as the input data for TRIFOB code to simulate the kinetics of nuclide burnup and

accumulation.

The calculations were conducted for discrete time intervals into which the fuel cycle was divided. Process

rate calculations taking into account discrete changes in the cell nuclide composition were performed for

each of time intervals.

3.7
TRIFOB code used the standard scheme of nuclide transformations. This scheme includes 16 heavy nuclides

from U2

34 through Cm244 and 8 main fission products (Xe'35, Rh1O5, Sm149

, Sm' 51, Pm149, Pm' 51, Cd,13 Gd1 57

).

Other fission products are presented in the form of four effective fission fragments for U235

, U238, Pu239 and

Pu 241.Each fragment is presented together with its precursor according to the known procedure [6].

TRIFOB code was improved to solve a specific problem. The improved version of TRIFOB code was

expanded to include the module that adjusts the neutron spectrum in the cell of VVER-1000 reactor during

the fuel cycle. The adjustment was made using parameter y, which takes into account the degree of the

neutron spectrum hardness. In the general form, the rates of neutronics processes taking into account

parameter y are presented as follows:

S = S& + r Sf,

where S = the identifier of a corresponding process rate (per-unit);

Sth, Sf = identifiers of rate components for the thermal and fast energy regions, respectively (per-unit);

y = the spectrum hardness parameter (per-unit).

Parameter y is determined as a function of time of the fuel cycle in the following form:

r~)= ro vFt Wt

w e - tvFo - r. vF (t)

where y the initial value of the spectrum hardness parameter (per-unit);

vFo = the initial rate of neutron generation (per-unit);

vFh(t), vF1(t) = rates of neutron generation versus time for the thermal and fast energy regions,

respectively (per-unit).

The spectrum hardness parameter is a global characteristic of the fuel cycle. Its value were determined on the

basis of the analysis of isotopic composition measurement results of fuel elements ## 61, 257, 317 of the fuel

assembly #1114 of NV NPP-5.

Special verification procedures for TRIFOB code

TRIFOB code was carefully verified using results of mass-spectrometric measurements of the isotopic

composition in the fuel of VVER-type reactors [7]. Within the framework of this work, special verification

procedures were implemented, which included three stages:

1. TRIFON code verification using Monte Carlo code;

2. TRIFOB code verification using Monte Carlo code;

3. TRIFOB code verification using experimental data obtained as a result of measurements of neutronics

characteristics of commercial fuel elements irradiated in NV NPP.

1. TRIFON code verification was conducted on the basis of results of benchmark calculations of LWR- and

VVER-type reactor cells using MCU code (see section 4.7) and MCNP code [8]. Both codes are of Monte

Carlo type. According to results of comparative calculations, the error in calculating the multiplication factor

K#ff and neutronic process rates does not exceed 0.5 and 5%, respectively, i.e. the error in calculating Kf

using TRIFON code is comparable with the error of Monte Carlo code calculations.

2. An additional verification of TRIFOB code using a code of Monte Carlo type was performed for

conditions of this problem. The burnup and nuclide composition were calculated for the standard cell of

WER-1000 as a function of time [9]. Calculations were carried out without taking into account the boron

poisoning and without spectrum hardness control. In the calculation scheme, the fuel pellet with the initial

enrichment of 4.4% was divided into several layers; 0.1 mm rim layer was separated. Results of comparative

calculations are presented in Fig. 3.2 and Fig. 3.3. According to the results of the analysis, the maximum

difference in concentrations of the main nuclides, obtained using two computer codes, does not exceed 5%

for the burnup range up to 50 MWd/kg U. Radial distributions of main nuclide concentrations for fuel with

the burnup of 50 MWd/kg U, obtained using two computer codes, are in good agreement with the exception

of Pu24' and Pu 4 isotopes. The maximum difference in concentration values for these isotopes was in the

rim layer (about 10%).

3.8
Fig. 3.2. TRIFOB verification versus burnup using Monte Carlo code

3. TRIFOB code verification on the basis of the original data was carried out in accordance with the

requirements of the present work. The verification was performed using results of mass-spectrometric

measurements of the nuclide composition of fuel samples taken from the middle part of fuel columns of

commercial fuel elements ## 61, 257, 317, irradiated in the fuel assembly of NV NPP-5. At the first stage

of the verification procedure, calculations of the standard VVER-1 000 cell were performed with TRIFOB

code for fuel elements #61 and #257 taking into account the boron poisoning during 3 fuel cycles.

According to the analysis of the results, TRIFOB code calculations agree with experimental results within

3-5% (the statistical experimental error 3c is 5%). Verification results for U235, Pu239, Pu240 and Pu24' are

presented in Fig. 3.4. At the second stage of the verification procedure, cell calculations of fuel element

#317 were conducted. The cell of this fuel element has another effective radius and another enrichment.

In this case the agreement between the calculated and experimental data was within 5% for the main

nuclides with the exception of Pu240, for which the difference is 7%. Results of this verification procedure

are presented in Table 3.3 and Fig. 3.4. The verification of calculated values of the radial distribution of

the nuclide composition of fuel element #317, obtained using TRIFOB code, was performed on the basis

of corresponding experimental data. The procedure to obtain experimental data is described in

sections 3.1, 3.2. Verification results are presented in Fig. 3.5.

Table 3.3. Calculated and measured isotopic concentrations and burnups for fuel element #317

Method Burnup Isotopic concentration (kg/t U)

(kg/t U) U235 u 236 u 238 Pu 238 PU239 Pu 240 Pu 24

1 pu242

Experi- 52.4(l1)* 4.35(3) 4.92(3) 928(1) 0.31(2) 5.00(5) 2.62(3) 1.64(2) 1.12(1)

ment

Calculated by 52.4 4.52 4.97 926 0.29 5.22 2.80 1.57 1.10

TRIFOB I I I I I I

* Here and below the statistical error of the experiment is indicated in brackets (error of determining the last digit).

3.9
Fig. 3.3. TRIFOB verification vs. radial isotope distribution using Monte Carlo code

3.10
Calculated by TRIFOB code:

o Experimental results for fuel element #6 1

oExperimental results for fuel elemntci 9257

8

Z 4 -'000,

10

0 10 20 30 40 50 60

Bumup (MWd/kg U)

Calculated by TRIFOB code

AExpermenetal results for fuel c leenitt #3 17

S6-

A

Pue

10dkgU Bumup) 

Fi.34 2pca- RFBveiiainv.bru sigN P uleeet

3.11
1.2'

1.0.

0.8.

U233

A

a

1.2 1.7 2.2 - 2.7 3.2 3.7

Radial coordinate (rmm) Radial coordinate (mu)

n, 2H

0.5.

pu39

A

.,• 1.5.

! 1.0.

Z0.5.

puf

-.. P- U' J

1.2 1.7 2.2 2.7 3.2 3.7

Radial coordinate (nam)

I| II

I7 

f

2 1.7 2.2 2.7 3.2 3.7

Radial coordinate (mm)

?a.r

S

,• 1.5

• 1.0

Z8 0.5.

Pu242

0.0 . . .

1.2 1.7 2.2 2.7 3.2 3.7

Radial coordinate (mm)

1.2 1.7 2.2 2.7 3.2 3.7

Radial coordinate (mm)

E Calculated by TRIFOB Bumup is 49 kg/tU J "3 Experimental results

Fig. 3.5. Special TRIFOB verification vs. radial Isotope distribution using NV NPP fuel element #317

3.12
Calculation scheme for C-tvpe fuel rods and results

Calculations of the nuclide composition of C-type fuel rods were carried out taking into account the

coordinates of cutting these fuel rods from commercial fuel elements #22 and #317. The calculation

procedure took into account the dependence of the coolant density in the commercial reactor on the axial

coordinate. This was done with the aim of preventing an additional error in burnup calculations, which can

exceed 5% for U2

35 and Pu239 if this effect is ignored (there are 10% changes in the coolant density along the

reactor core height for this fuel cycle). This effect was taken into account by introducing the following

approximating dependence for the coolant temperature:

T(z)=Tim+1.47 z+7.04 i2-1.38 z3,

where 7(z) = the coolant temperature as a function of the axial coordinate z (K);

T,= the coolant temperature at the reactor core inlet (K);

z = the axial coordinate (in).

In the final form, the procedure of variant calculations of 13 refabricated C-type fuel rods included:

" calculations of rz distribution of the isotopic composition in each fuel rod with the step of 5 mm along

the coordinate z for four radial zones which corresponded to the following set of fuel volume ratios 0.5,

0.3, 0.15, 0.05 (volume ratio of 0.05 corresponds to 0.086 mm thick rim layer).

* adjustment of the calculated set of r, z distribution of the isotopic composition taking into account

experimental data in Table 3.3 within the limits of 3-5 %.

Results of variant calculations of the isotopic composition of C-type fuel rods using TRIFOB code are

presented in Appendix C, Volume 3 of the Report.

3.2.4. Fuel rods with fresh fuel and irradiated cladding

Representative values of initial characteristics for D-type fuel rods

Fuel characteristics presented in this group were determined by the manufacturing plant in accordance with

standard procedures for VVER-1000 fuel [10]. All cladding characteristics of D-type fuel rods correspond to

cladding characteristics of C-type fuel rods and were obtained within the framework of the same procedures.

This is also true for the initial gas pressure, its composition and volume.

Consolidated characteristics for D-type fuel rods

All parameters characterizing the refabrication process of D-type fuel rod cladding were obtained according

to procedures similar to those for C-type fuel rods.

All fuel parameters were determined by the manufacturing plant in accordance with standard procedures for

WER-1000 fuel [10].

Individual geometric dimensions LI, L2, L3 were determined by the mathematical processing of results of

fuel rod X-ray photographs.

Individual rz distributions of D-type fuel rod characteristics

The manufacturing plant presented a set of individual characteristics of fuel pellets, that were obtained

within the framework of standard VVER-1000 procedures [10].

This set includes the following measurements:

" outer diameter of each fuel pellet, measured in two azimuth planes;

* fuel mass in each pellet.

Using a specially developed mathematical procedure, this set was converted to data files for z distributions of

corresponding characteristics.

z distributions of the cladding outer diameter were obtained as a result of the mathematical processing of

profilometry results, which was carried out using the same method as for C-type fuel rods.

3.13
z distributions of the free volume in fuel rods were obtained according to the procedure described in

section 3.2.6.

3.2.5. Fresh fuel rods

All input data on characteristics of E-type fuel rods were provided by the fuel rod manufacturing plant [10].

The input data include the following measured parameters:

" fuel and cladding composition;

" fuel enrichment;

" gas composition and pressure inside the cladding;

" fuel stack length in each fuel rod;

" cladding outer diameter in two azimuth planes as a function of fuel rod length;

" cladding wall thickness as a function of fuel rod length;

" average fuel-cladding gap for each fuel rod;

" outer diameter of each fuel pellet measured in two azimuth planes;

" mass of each fuel pellet;

" fuel mass in the fuel rod;

" characteristics of the thermal treatment of fuel rod cladding.

The following parameters were obtained on the basis of the input data using corresponding mathematical

procedures:

" representative values of characteristics for the fuel rod set;

" consolidated characteristics for each fuel rod;

" individual distributions of characteristics for each fuel rod.

3.2.6. Axial distribution of the gas volume in fuel rods

Individual measurements of the total free gas volume were not conducted for each fuel rod of C-, D-,

E-types. The total free gas volume was measured selectively; these measurements were used for the

verification of the indirect procedure to determine the axial distribution of the free gas volume for each fuel

rod. This procedure included the following main stages:

1. Determination of the axial distribution of the free gas volume inside the fuel rod without taking into

account the volume occupied by the fuel and the fixing ring. Fuel rod drawings and X-ray photographs of

each fuel rod were used for this purpose.

2. Determination of the axial distribution of the volume occupied by the fuel and the fixing ring. The axial

distribution of the fuel mass was used in this case.

3. Determination of the axial distribution of the free gas volume taking into account the fuel and the fixing

ring was carried out by subtracting the data set under item 2 from the data set under item 1.

4. The total free gas volume was determined by summing up the data under item 3 for each fuel rod.

According to the verification of the procedure using results of direct measurements of the total free gas

volume, the Relative standard deviation for calculated characteristics of the volume does not exceed 2%.

3.14
3.3. Procedure to manufacture the fuel rods

C-tpe fuel rods

A batch of C-type fuel rods was manufactured in RIAR (Dimitrovgrad, Russia) by refabricating commercial

fuel elements of WER -1000 type, that were irradiated at power unit No 5 of NV NPP. The refabrication

procedure included the following stages:

1. Manufacturing fuel rod blanks by cutting commercial fuel elements into samples of a required length and

with fixed axial cutting coordinates.

2. Fuel removal from the upper and lower parts of each blank by drilling.

3. Manufacturing structural components of the fuel rod, top and bottom caps, the fixing ring, the connector,

the cladding (for the upper plenum).

4. Installation of the fixing ring in the blank, welding of the bottom cap and the connector with the fuel rod

blank.

5. Welding of the top cap with the unirradiated cladding.

6. Welding of the upper and lower parts of the fuel rod.

7. Filling the fuel rod with helium through the hole in the top cap under the conditions of a special chamber

filled with helium at the initial helium pressure in the fuel rod.

8. Gas evacuation from the fuel rod and repeated filling with helium under the same conditions.

9. Welding the hole in the top cap.

10.Fuel rod tightness testing using helium leak detector.

D-tvpe fuel rods

Refabricated D-type fuel rods were manufactured in RIAR (Dimitrovgrad, Russia), unirradiated fuel pellets

were manufactured in AO MZ "Electrostal" (Electrostal, Russia).

The manufacturing procedure of D-type fuel rods was similar to that of C-type fuel rods. However, in this

case all fuel of the commercial fuel element was removed from the fuel rod blank and was replaced with

unirradiated fuel pellets of VVER-1000 type. Fuel pellets for D-type fuel rods were manufactured in

accordance with the technology, the main provisions of which correspond to the standard technology of fuel

manufacturing for VVER- 1000 reactors.

E-type fuel rods

Unirradiated E-type fuel rods were manufactured in AO MZ "Electrostal" (Electrostal, Russia).

Standard blanks for fuel elements of commercial VVER-1000 reactors were used for the manufacturing. The

fuel for E-type fuel rods was manufactured in accordance with the technology similar to that of fuel

manufacturing for D-type fuel rods.

Standard procedures used for manufacturing commercial fuel elements were applied for the thermal

treatment of fuel rod cladding and the monitoring of the fabrication quality.

3.4. Post test examinations offuel rods

The following set of non-destructive and destructive post-test examinations was implemented for fuel rods of

C-, D-, E- types in RIAR (Dimitrovgrad, Russia):

1. Taking photographs of the fuel rod appearance.

2. Taking X-ray photographs of each fuel rod that preserved its structural integrity.

3. Outer diameter measurements of all fuel rods that preserved their structural integrity and had minor

cladding deformation.

4. Preparation of cross-sectional metallographic specimens for each fuel rod.

5. Taking macro- and micro-photographs of metallographic specimens.

3.15
6. Measurements of the oxide film thickness and the thickness of a-Zi on the fuel rod cladding.

7. Measurements of the H2 concentration in the cladding and hydride orientation.

8. Measurements of Kr, Xe concentrations in the gas of fuel rods after the test.

9. Measurements of the Kr concentration in the high burnup fuel after the test.

Results of these studies are presented in Appendixes G, H, I, Volume 3 of the Report.

3.5. References

[1] "Post-Irradiation Examinations of Fuel Assembly No. 4436001114, which was Used at Unit 5 of NV

NPP within 3 Fuel Cycles up to Average Burnup of 44.7 MW days/kg U", Rus., Report No. 0-4011,

Research Institute of Atomic Reactors, Dimitrovgrad, 1991.

[2] A.Scheglov, V.Proselkov, A.Yenin. "Statistic Processing Results of Structural and Technological

Parameters of VVER-1000 Reactor Fuel Element", Rus., IAE "Kurchatov Institute", Report No. 5334/4,

Moscow, 1991.

[3] A.Chetverickov, V.Borisenkov, V.Chistiackov et.al "Identification of Nuclide Composition and Burnup

Degree of Spent Fuel of VVER-1000 Reactor", Rus., Report No. 21240014, Research Institute of Atomic

Reactors, 1991.

[4] M.Vostrikov, B.Kochurov. "TRIFOB -the Code for Calculation of Isotopic Composition in a Cylindrical

Reactor Cell Taking into Account Neutron Spatial-Energy Distribution", Rus., Report ITEP-106,

Moscow, 1981.

[5] A.Burmistrov, B.Kochurov, A.Kvaratshely. "The Code TRIFON Abstract", Rus., VANT, Ser. Nuclear

Reactor Physics and Engineering, Vol.4, p.35, 1985.

[6] A.Galanin. "Introduction to the Theory of Thermal Neutron Nuclear Reactor', Rus., Moscow,

Energoatomizdat, 1990.

[7] A.Gerasimov, T.Zaritskaya, A.Rudik. "Handbook on Build-up of Nuclides in Nuclear Reactors", Rus.,

Moscow, Energoatomizdat, 1989.

[8] J.Briesmeister, "MCNP - a General Monte Carlo Code for Neutron and Photon Transport", LA-7396-MRev.2, 1987.

[9] A.Avvakumov. "Method for Calculation of Isotopic Composition of High Burnt-out VVER Fuel Taking

into Account Radial Heterogeneous Burnup and Buildup of Nuclides", Rus., Report No. 90/1-16-95,

Nuclear Safety Institute of Russian Research Centre "Kurchatov Institute", 1995.

[10] "VVER-1000 Experimental Fuel Rods", Rus., Passport No. AB.01.021.00OPS, AO MZ "Electrostal",

1990.

3.16
4. ENERGY DEPOSITION, POWER OF FUEL RODS AND FUEL ENTHALPY

UNDER IGR REACTOR TEST CONDITIONS

The main purpose of this procedure is to determine the two-dimensional energy deposition and power field

(r, z geometry) of fuel rods as a function of time. It is impossible to directly measure these parameters in the

reactor test process. Therefore, special procedures are developed to implement this type of experimental

programs, which combine a set of calculation and experimental methods and take into account specific

features of the research reactor and the test objects.

In this case the following was used as the basic experimentally determined parameters:

* number of fissions in a fixed section of the fuel column (the section length is about 13 mm) of E-type fuel

rods (fresh fuel, fresh cladding) over the entire test;

" number of fissions in special fuel samples located in a fixed point inside the capsule.

In a schematic form, the procedure of determining the energy deposition and power of fuel rods included the

following stages:

" determination of the reactor power profile versus time using the results of the reactor power measurements by the ionization chamber and the results of adjusting the measured power profile near the zero

values;

" measurements of the number of fissions in fixed sections of the fuel of E-type fuel rods (fresh fuel, fresh

cladding);

" measurements of the number of fissions in special fuel samples;

" implementation of calculation neutronics codes to perform calculations of the system "IGR reactor -

capsule - fuel rods - special fuel samples";

" code verification using special reactor experiment;

" performance of the neutronics calculations of the system "reactor - capsule - fuel rods - special fuel

samples" to determine the ratio between the number of fissions in special fuel samples and fission

reaction fields for each fissile isotope in tested fuel rods;

" determination of isotope fission rates in rod fuel in r, z geometry as a function of time;

* determination of fuel rod energy deposition and power fields using thermal equivalents of one fission

event of various isotopes taking into account specific features which depend on the contribution of

prompt and delayed radiation components in fuel rods and in the reactor.

4.1. Main provisions of the procedure

Fuel rod power profile versus time

Readings of standard ionization chambers of IGR reactor were used as the input data (see section 4.2), which

were adjusted to take into account the contribution of delayed neutrons using the calculation procedure (see

section 4.6).

Numbers of fissions in central (along the column length) fuel pellets of E-tvye fuel rods and in special fuel

samples

Results of radiometric measurements of number of fissions in central fuel pellets of non-failed fuel rods of Etype, results of radiometric measurements of number of fissions in special fuel samples and measurement

results of the energy deposition in the reactor in units of ionization chamber readings were used as the input

data.

The standard mathematical procedure is applied to determine the regression coefficients that characterize

ratios between the above parameters for two types of the coolant in the capsule. The obtained coefficients are

used to determine the numbers of fissions in central fuel pellets of E-type fuel rods and in special fuel

samples (see sections 4.3, 4.4).

4.1
Determination of neutronics parameters of fuel rods of C-. D-, E- types

It will be demonstrated in section 4.7 that the spatial-time distribution of fission rate R (r, z, t) in test fuel

rods can be obtained based on the spatial distribution of the number of fissions in the fuel rod n (r, z)

determined by solving the stationary problem.

The purpose of this procedural stage was to determine n (r, z) for each of the tested fuel rods. The set of n

(r, z) values is determined based on the stationary calculations of the reactor at a fixed temperature of the

reactor core, the coolant and fuel rods (see section 4.7).

This approach to determine R (r, z, t) was selected because of the complexity of the geometric and material

structure of the capsule with fuel rods and the necessity of obtaining R (r, z, t) values with the accuracy not

less than that of experimental methods of measuring the number of fissions in fuel pellets of rods of C-, D-,

E- types. Due to these circumstances it was necessary to use accurate neutronics models, such as Monte

Carlo type, to calculate the distribution of the number of fissions in fuel rods. However, the full-scale

simulation of the "reactor-capsule-fuel rod" using precision codes is beyond the scope of the present work.

Thus, the problem of optimizing the calculation simulation was initially solved, and the capabilities of using

the above approach were demonstrated (see section 4.7).

Energy deposition and power fields of C. D. E - type fuel rods

The first stage of this procedure covered the adjustment of sets of fission density in fuel rods n(r, z), that

were calculated using Monte Carlo code. The adjustment was performed using norming coefficients

determined on the basis of the procedure of comparing calculated and experimental values of fission

densities in central fuel pellets of E-type fuel rods and in special fuel samples.

Sets of neutron fission rates R (r, z, t) in fuel rods were determined during the next step. This set was formed

using the normalized (on the basis of experimental data) set of fission densities nm (r, z), the set of values

characterizing the reactor power as a function of time P (t), and temperature adjusting coefficients to take

into account the kinetics of neutron gas temperature changes in the capsule.

The final stage of the procedure was the determination of fields of the energy deposition E (r, z, t) and fuel

rod power P (r, z, t). These characteristics were determined by calculating the energy released in each fission

event from the value set R (r, z, t). The following components of the energy deposition were taken into

account within the framework of this procedure:

" fission fragment energy;

" energy due to the prompt neutron and gamma radiation of the reactor and fuel rods;

" energy due to the delayed beta and gamma radiation.

The procedure to determine the energy deposition and the power of fuel rods is described in detail in

sections 4.8, 4.9.

4.2. IGR reactor power versus time

IGR reactor profile is recorded in the process of each test using standard ionization chambers of the reactor

installed in the water tank (Fig. 4.1). The ionization chambers are arranged with a certain angular step. The

measurement ranges of chambers are different. A. specific set of chambers for recording the reactor power

profile are selected in accordance with the program of the experiment taking into account the maximum

reactor power values, was implemented. For the present test series, the calibration of ionization chamber

measurement channels was performed at the stage of the scoping tests. The validation of IGR reactor power

profile identity -in the locations of ionization chambers and IGR reactor power profile in the central reactor

plenum was carried out repeatedly. An additional experimental check was performed within this series of

tests using in-core neutron detectors arranged along the external perimeter of the capsule with fuel rods.

Corresponding studies showed that the reactor power profile does not depend also on the azimuth angle, at

which the ionization chamber is located. Fig. 4.1 presents results of a typical experiment.

4.2
'I0

(4~

0

0

I

6~

0

.0

U

o

~

6

Time (s)

Fig. 4.1. The reactor power profide measured by ionization chambers and in-core neutron detectors

The measurement error for standard ionization chambers of IGR reactor is + 2.5 % of the signal value for the

operating measurement area.

In addition, it should be noted that, since the range of reactor power changes is wide during the pulse tests,

there is a problem of reconstructing the reactor power profile near the zero values at the back front of the

pulse. This problem is related to the fact that the reactor power level turns out to be lower than the parasite

signal initiated in the ionization chamber by the reactor gamma field. This is typical mainly for the time

interval when the process takes place only due to delayed neutrons. An approach to solve this problem within

a specific series of tests is described in section 4.6.

4.3. Number offissions in specialfuel samples

Measurement of number of fissions in special fuel samples

In 16 tests out of 23, special fuel samples were placed in the capsule with fuel rods before the capsule was

installed in IGR reactor and were removed from the capsule after the tests were completed (see section 4.6).

The La'40 activity was measured by recording gamma quanta with the energy of 1596 keV emitted by the

fuel sample. The measurements were performed using the semiconductor Ge (Li) gamma spectrometer [1].

The number of fissions in the special fuel sample was determined as:

n. = Ak,

t,776e mf~

where n, = the number of fissions in the sample (fiss./g U235);

A = the photopeak area for a corresponding gamma quantum with the energy of 1596 keV (counts);

4.3
k, = the coefficient of the self absorption of gamma quanta with the energy of 1596 keV in the

special fuel sample (per-unit);

m = the mass of U235 isotope in the special fuel sample (g);

ý = the live time of recording the gamma quanta in the spectrometer (s);

= the quantum yield of gamma quanta with the energy of 1596 keV per one decay of La140 (perunit) [2];

= the efficiency of recording the gamma quanta with the energy of 1596 keV by the spectrometer

(per-unit);

ft = the coefficient connecting the La140 activity at the time of measurements with the accumulated

uranium number of fissions in the special fuel sample over the total time of its irradiation (1/s).

The effect of the cascade summation of gamma quanta in this case was not taken into account since the

special fuel sample was located at the distance of about 100 mm from the spectrometer detector. The number

of repeated measurements performed for each fuel sample is 8 or more. This allowed to determine the

activity of each sample and the statistical measurement error.

The values of gamma quanta self absorption coefficient in the special fuel samples were calculated taking

into account the real geometry of samples and their material composition. Linear coefficients of gamma

quanta absorption were taken from [3]. The efficiency of recording the gamma quanta with the energy of

1596 keV was determined using the empirical dependence. The dependence was obtained on the basis of experimental data characterizing the ratio between the spectrometer efficiency and gamma quanta energy for

the real geometry of fuel samples. The spectrometer was calibrated using reference standard gamma-radiation sources of the first order qualified on the basis of the gamma yield with the error not exceeding 1.5 %.

The mass of U235 isotope in each of the special fuel samples was taken from the sample passport data [4]. In

addition, the checks of U235 mass in samples were carried out using a reference sample and radiometric

measurement procedure.

The value of coefficientf, is:

CA I-e t 0 {y Y [e(Ah.A)to - 11+ yL"

where )L., XBa = decay constants of La' 40 and Ba140, respectively (I/s) [2];

yBa = the cumulative yield of Ba' 40 for U235 fissions by thermal neutrons (per-unit) [5];

yh = the independent yield of La'40 for U235 fissions by thermal neutrons (per-unit) [5];

to = the time interval from the beginning of the fuel rod irradiation till the beginning of

this measurement using the gamma spectrometer (s).

Table 4.1 presents number of fissions values in special fuel samples, obtained on the basis of the above

procedure.

4.4
Table 4.1. Measured number of fissions in central fuel pellets of E-type fuel rods, special fuel samples,

measured integrals of current readings of the Ionization chamber and integrals of corrected

readings of the Ionization chamber

Number of Measured Integrals of n, 10-14 nE 10-14

Test fab td integral of cur- corrected cur- lgfiss (fissS numest fuelabrotd rent readings rent readings

number fuel rod (tpAs) (pAs) __gU______gU ___

103F-1 H14T 19210 19860 4.36 3.31

103F-2 H17T 29730 30870 6.69 5.04

1031F-3 H16T 41290 42660 9.37 6.92

103F-4 B21T 38550 39920 5.66 4.51

103F-5 H8T 45910 47240 10.8 7.58

103F-6 B20T 49200 50790 7.36 5.81

103F-7 H6T 68920 71040 15.7 11.13

103F-8 H4T 89820 92890 20.6 -

103F-9 H5T 109490 113300 - -

103F-10 H7T 111090 116700 - -

103F-11 B11T 158450 164200 - -

103F-12 B13T 224540 231300 - -

103F-13 HIT'• 120860 125100 -

103F-14 H2T 150970 157100 -

103F-15 H3T 185430 193700 - -

103F-16 B1OT 79740 82810 12.0 9.92

103F-17 H15T 65660 67980 15.4 11.5

103F-18 B9T 109720 114300 16.8 -

103F-19 B12T 123250 128700 17.3 -

103F-20 B19T 70060 72500 9.71 8.24

103F-21 B23T 97720 101700 14.0 -

103F-22 B22T 31400 32690 4.46 3.69

103F-23 H18T 51460 53400 10.8 -

Table 4.2 presents error values for parameters of the formula for the determination of the number of fissions

in special fuel samples. The procedure used to determine the error in the number of fissions in special fuel

samples is described in section 4.10.

Table 4.2. Errors In characteristics in the formula to determine number of fissions in the special fuel

samples

* Errors in characteristics which were calculated or taken from the literature were considered as systematic errors

4.5
r.fthp a,~t nfnipiaurprl v~Iuip~ nfth~ r~t~tnr nnw~r nrnfU~ v~r~11~ time

The data files of standard ionization chambers readings of IGR reactor were the input data to determine the

reactor power versus time. Results of these measurements are presented in Tables, Appendix F, Volume 3 of

the present Report.

The analysis of this set of results shows that their direct use will lead to an additional systematic error related

to a large error in recording low power levels of the reactor. The special procedure described in section 4.6

made it possible to adjust ionization chamber readings in this area. The corrected power measurement results

are presented in Tables, Appendixes G, H, I, Volume 3 of the Report.

Energy deposition in IGR reactor

The standard integration procedure was applied for each of 23 adjusted reactor power data files. The

obtained integrals characterize the energy deposition in IGR reactor and, thus, in special fuel samples, in the

measurement units of ionization chamber (pA s). Table 4.1 presents integration results. For comparison,

reactor power integrals before the adjustment are also presented.

Ratio between the energy.deposition in IGR reactor and the number of fissions in special fuel samples

Multiple studies performed earlier at IGR reactor show that, for reactor power pulses used at this series of

tests, the ratio between the energy deposition in the reactor and the number of fissions in the special fuel

sample (fissJg.U235

) does not depend on the value of the positive reactivity introduced, but is determined

only by the material composition of the capsule, of the sample and their geometry. The proof of this

statement is outside the framework of this Report, however the below results can be used for its verification.

Taking into account the above considerations, the standard methods of determining the linear regression

coefficients were used to process data sets of number of fissions in special fuel samples and of the energy

deposition in IGR reactor. Its own regression equation was obtained for each type of the coolant.

These equations are:

nsm = 2.2 1010 E, for the variant with water in the capsule,

nsm = 1.4 1010 Er for the variant with air in the capsule,

where nsm = the number of fissions in the special fuel sample (fiss./g U 235),

F, = the corrected energy deposition in the reactor in the measurement units of the

ionization chamber (pAs).

The obtained results are presented in the graphical form in Fig. 4.2.

25, 25

SWater Air

2- 20 U

10~.00

3 5-

Energy deposition (pA s 10*)

Fig. 4.2. Number of fissions in the special fuel samples vs. the energy deposition in the reactor

4.6
Number of fissions in special fuel samples

The above regression equation and the reactor energy deposition data were used to determine 23 values of

number of fissions in special fuel samples (for 7 tests, in which there were no fuel samples, the notion of a

conditional fuel sample was introduced). Out of 23 values, 20 were the final values, and three values were

additionally adjusted. This was done because in three tests there was no E-type fuel rod, therefore, there were

changes in the ratio between the number of fissions in the special fuel sample and the reactor energy

deposition. The inclusion of this effect using MCU (see section 4.7) and WIMS-4D computer codes shows

that the number of fissions in special fuel samples in this case increases by 8 %.

4.4. Number offissions in centralfuel pellets offresh fuel rods

Measurement of number of fissions in non-failed fuel rods of E-type

One fuel pellet was removed from the centre (along the length) of the fuel column of each non-failed fuel

rod. Each pellet was crashed to powder, the resulting mass was thoroughly mixed. Then three powder

samples with the weight of 0.1 g each were taken from each crashed pellet. Fuel samples were placed in the

form of a thin layer on organic glass plates. Then Zr95 isotope activity was measured for each fuel sample.

The activity was measured in gamma radiation with the energy of 724 keV using gamma spectrometer [6].

Several measurements were performed for each sample.

The duration of one measurement was about one hour, since the measurements were performed after the

completion of the cycle of non-destructive and destructive post-test examinations of fuel rods, i.e. several

months after the tests. The number of fissions in the fuel sample is:

nE ytrlm/"

where nE = the number of fissions in the central pellet of E-type fuel rod (fiss./g U235

);

A = the area of the photopeak that corresponds to gamma quanta with the energy 724

keV (counts);

k, = the self absorption coefficient of gamma quantum with the energy of 724 keV in

the fuel sample (per-unit);

yz, = cumulative yield of Zr 5 for U235 thermal neutron fission (per-unit) [3];

to = the time interval from the beginning of the fuel rod irradiation to the beginning of

this measurement using the gamma spectrometer (s);

= the quantum yield of gamma quanta with the energy of 724 keV for Zr95.decay

(per-unit) [2];

m = the mass of U 235 isotope in the fuel sample (g);

= the efficiency of recording the gamma quanta with the energy of 724 keV by the

spectrometer (per-unit);

Xzr = the decay constant of Zr95 (l/s) [2];

t, = the live time of recording the gamma quanta with the energy of 724 keV by the

spectrometer (s).

Procedures similar to those described in section 4.3 were used to calculate the self absorption coefficient and

the spectrometer efficiency. The mass ofU235 isotope in the fuel sample was determined using the measured

mass of the fuel sample and the uranium enrichment (data of the fuel rod manufacturing plant).

Table 4.1 presents measurement results of number of fissions in fuel pellets of E-type fuel rods. Errors in

characteristics that were used to determine the numbers of fissions are presented in Table 4.3. The procedure

of the measurement error calculation of the number of fissions in fuel pellets is described in section 4.10.

4.7
Table 4.3. Errors in characteristics in the formula to determine the number of fissions in fuel pellets of

E-type fuel rods

LecdStandard deviation ()>,Systematic error (11/0

Ap 1.5 0.5

k. 0" ,0.5

0* 0.5

Ti 0* 0.5

m 1.2 0.5

ey 1 1.5

0&" 0.06

to 0* 0.01

YZr 0 1.0

* Errors in characteristics, which were calculated or taken from the literature, were considered as systematic errors.

Fission numbers in central fuel pellets of E-tvve fuel rods

The procedure for determining the number of fissions in central fuel pellets of E-type fuel rods was similar to

the procedure of determining the number of fissions in special fuel samples described in section 4.3.

The regression equations for central fuel pellets of E-type fuel rods is:

nEm = 1.62 1010 Er for the variant with water in the capsule,

nFer = 1.16 1010 Er for the variant with air in the capsule,

where nEm = the number of fissions in the central fuel pellet of E-type fuel rod (fissJg U235);

Er = the energy deposition in the reactor in the measurement units of the ionization chamber (pAs).

Fig. 4.3. presents these results in the graphical form.

0

V

- 012

Vt~

o

.~

Ca

;z, 0

C~ 0 C

o

~C40

Energy deposition (pA a 10') Energy deposition (pA a 10)

Fig. 4.3. Number of fissions In fuel pellets of E-type fuel rods vs. the energy deposition In the reactor

In addition regression equations were obtained, that connect the number of fissions in central fuel pellets of

E-type fuel rods and the number of fissions in special fuel samples. These equations are:

nEm = 0.73 nm for the variant with water in the capsule,

nEm = 0.82 nm for the variant with air in the capsule,

4.8
Where hEm = is the number of fissions in the central fuel pellet of E-type fuel rod (fiss./g U235

);

nsm = is the number of fissions in the special fuel sample (fiss./g U23).

The final values of number of fissions in central fuel pellets of E-type fuel rods were determined using

coefficients from regression equations and energy deposition values in IGR reactor.

4.5. Input data on the geometry and the material composition of the reactor, the

capsule, fuel rods and specialfuel samples

The data base, described in Chapter 2 of the present Volume of the Report and presented in Appendixes to

Volume 3 of the Report, was used as the input data characterizing the geometry and the material composition

of fuel rods, the capsule and special fuel samples. The set of input data characterizing IGR reactor was

formed using corresponding special reports [7, 8].

General characteristics from this set are presented in Table 4.4.

Table 4.4. Main characteristics of IGR reactor

Parameter Value

* overall dimensions:

horizontal cross-section (cm) 140-140

height of immovable part (cm) 133

height of movable part (cm) 146

" shape parallelepiped

* composition U-impregnated graphite

• horizontal cross-section (cm) 9.8.9.8

* height (cm) 13.3

* enrichment (%) 90

* U235 density (g/cm3) 4.7 103

* graphite density (g/cm3

) 1.72

" shape double-layer cylinder

" composition of the external absorbing layer Gd2O 3 and graphite

" Gd2O 3 content in graphite (% by weight) 2

" thickness of external absorbing layer (cm) 0.8

" rod outer diameter (cm) 50

" internal rod material graphite

" internal rod density (g/cm3) 1.72

" absorbing layer height in the control rod (cm) 170

4.9
Table 4.4. Main characteristics of IGR reactor

Parameter Value

" shape multi-layer cylinder

" height (cm) 150

" outer diameter (cm) 10

" composition of the external absorbing layer Gd2O3 and graphite

* absorbing layer thickness (cm) 0.8

" composition of the gap between the absorbing layer and the internal rod air

* internal rod material steel

" internal rod diameter (cm) 0.8

* material graphite

* density (g/cm3) 1.67

* maximum thickness of the side reflector (cm) 50

" maximum height of the top end reflector (cm) 79.5

" maximum height of the bottom end reflector (cm) 227.5

6.1 Cross-like insert with the internal hole

" material graphite

" maximum dimensions in the cross-section (cm) 40.40

" hole diameter (cm) 29

6.2 Gap

* material He

" thickness (cm) 1

6.3 External shroud

" material Zr alloy

" outer diameter (cm) 27

" thickness (cm) 0.2

6.4 Gap

" material 1H20

" thickness (cm) 0.3

6.5 Separating shroud

" material Al-Mg alloy

" outer diameter (cm) 26

" thickness (cm) 0.15

6.6 Gap

* material 1H20

" thickness (cm) 0.35

4.10
Table 4.4. Main characteristics of IGR reactor

Parameter Value

6.7 Internal casing

* material Al-Mg alloy

* outer diameter (cm) 25

* thickness (cm) 1.1

6.8 Gap

* material air

* thickness (cm) 2.4

6.9 Protective shroud

* material Al-Mg alloy

outer diameter (cm) 18

* thickness (cm) 1.5

6.10 Experimental cavity

* material air

* outer diameter (cm) 15

7.1 External shroud

* material steel

* outer diameter (cm) 10.2

* thickness (cm) 0.1

7.2 Gap

* material water

* thickness (cm) 0.2

7.3 Separating shroud

• material steel

* outer diameter (cm) 9.6

* thickness (cm) 0.1

7.4 Gap

* material water

* thickness (cm) 0.2

7.5 Internal shroud

* material Al

* outer diameter (cm) 9.0

* thickness (cm) 0.4

7.6 Experimental cavity

* material air

e diameter (cm) 8.2

4.11
4.6. Procedure to adjust the input data characterizing the power profile of IGR

reactor

Purpose and tasks of the procedure

The adjustment of the input data characterizing the power profile of IGR reactor versus time was performed

with the aim of the calculation reconstruction of the reactor power profile in the area of small power values,

below 2.5 % of the maximum power.

The following problems were solved to reconstruct the lacking information on the power profile of IGR

reactor:

" special scoping tests were conducted in 1995 at IGR reactor (132F series) with the aim of obtaining a

corresponding experimental data base using sensitive measurement channels of the neutron flux [9];

" 3D dynamic computer code DINAR was improved to take into account the temperature feedback as

applied to specific features of IGR reactor [10];

" the three-dimensional full-scale computer simulation of IGR reactor power pulses was performed for 23

tests of fuel rods of C-, D-, E- types;

* IGR reactor power profile was corrected.

Validation of computer code selection.

During the controlled power pulse in IGR reactor the following takes place: increase in the reactor core

temperature, increase in the leakage of thermal neutrons, changes in the insertion depth of control rods. The

process is accompanied by the spatial deformation of the neutron flux distribution and by changes in the

control rod efficiency due an increased temperature in the reactor core. Such a complex process can be only

described with an acceptable accuracy using a full-scale neutronics model. Therefore, the non-stationary

reactor calculations were carried out using the 3D dynamic code DINAR [11], which was improved to take

into account the temperature feedback of IGR reactor [10].

DINAR code is intended for 3D simulation of fast transients in the reactor taking into account reactivity

feedbacks. The model of DINAR code, that describes reactor neutronics characteristics in space and time, is

based on the generic theory of the heterogeneous reactor [11-13]. Within the framework of this model the

reactor is divided into a number of cells. Non-stationary boundary conditions that connect neutron fluxes and

currents through cell interface matrixes are set for the surface of each cell. In this case there is no need in the

validity of the diffusion approximation for the entire volume of the reactor. It is assumed that the diffusion

equation describes the process only at the boundaries of selected cells. Unlike traditional finite difference

algorithms, the heterogeneous method allows to correctly calculate heterogeneous reactor components such

as control rods, content of the central reactor plenum, etc., without using the cell homogenization.

The spatial neutron flux distribution in DINAR code is calculated by TREC code in the few-group

approximation [14]. IGR reactor calculations used 4-group energy division. The neutron flux distribution for

TREC code is constructed in the form of Green's functions. The amplitudes of Green's functions. are

determined through cell interface matrix using the difference approximation [15]. The axial distribution of

the neutron flux is described by expanding the axial component of the flux into Fourier series (i.e. without

using the axial discretization).

The cell interface matrix calculations for reactor geometric components were performed using TRIFON code

described in section 3.2.3.

Within the framework of the present work the improvement of DINAR code was carried out as applied to

requirements on the code with the aim to describe IGR reactor The code was supplemented with the module

to calculate the non-stationary temperature distribution in the reactor core; 3D calculations of temperature

changes in the reactor core were performed using heat balance equations. To determine the amplitude

function, a strong negative energy deposition feedback was explicitly introduced into the calculation module.

This procedure resulted in a considerable reduction of the calculation efforts in the process of the pulse

development dynamics simulation.

4.12
Input data for calculation modeling

In addition to the input data presented in section 4.5, the following input data were used for DINAR code:

" insertion depth of each of the control rods in the critical conditions of the reactor before the power pulse

(measured values for each of 23 tests);

" initial temperature of the reactor core (measured values for each test);

" geometry and material composition of the capsule with fuel rods;

" insertion depth of each of the control rods versus time for each test (measured values).

The input data are described in more detail in [10].

Calculation scheme and main assumptions

Cross- and axial sections of the calculation geometrical model of IGR reactor are presented in Fig. 4.4,

Fig. 4.5.

4 5 6

I Tank water

2 Reactor vessel and thermal shield

3 Side experimental channel

4 Central expermental channel

5 Graphite insert

6 Control rod

7 Lateral rod

8 Side reflector

9,10 Reactorcorc (movable and immovable parts)

Fig. 4.4. Cross-section of the calculation geometrical model of IGR reactor for DINAR computer code

4.13
12

A-A

7 7 8

1. Tank water 7. Lateral rod

2. Reactor vessel and thermal shield 8. Side reflector

3. Side experimental channel 9. Reactor core - movable part

4. Central experimental channel 10. Reactor core - unmovable part

5. Graphite insert 11. Lower reflector

6. Control rods 12. Upper reflector

Fig. 4.5. Axial section of the calculation geometrical model of IGR reactor for DINAR computer code

The calculation model includes the following main elements:

" reactor fuel elements (graphite columns impregnated with the uranium salt);

" graphite columns of the reactor core with control rods;

" graphite columns of the reflector and graphite columns of the reactor core, non impregnated with the

uranium salt;

* graphite columns of the reflector with lateral rods;

" central reactor plenum with all its internals;

" side experimental channel;

" tank water.

The total number of calculation elements in the cross-section equals 1900. The cell interface matrix of fuel

rods of the reactor core was calculated as the temperature function in the range of 290-560 K, which is

characteristic for these tests. Gaps-between elements of the reactor core were taken into account by reducing

the graphite density by 3-4%. The non-uniformity of the uranium concentration in the graphite was not taken

into account because of the absence of adequate input data. Due to a small duration of the neutron pulse and

4.14
the presence of gaps between fuel elements of the reactor core, the heat exchange between them was not

taken into account. The capsule with fuel rods was described for these calculations approximately in the

cylindrical r, z geometry.

Verification of DINAR computer code

Results of special scoping tests performed at IGR reactor were used to verify the results of reconstructing the

pulse shape of IGR reactor using DINAR computer code.

The following features characterize the series of scoping tests at IGR reactor (series 132F):

* total number of tests- 7;

" tests were conducted without the installation of the capsule with fuel rods into the reactor central test

channel;

" IGR reactor power profile was recorded by six standard ionization chambers and by three in-core neutron

detectors; high sensitivity channels were connected to two out of six ionization chambers to provide

correct recording of the back front on the reactor power pulse;

• one test was performed in the uncontrolled power pulse mode; other tests - in controlled pulse mode;

" modes of the controlled pulse corresponded to test modes of fuel rods of C-, D-, E- types in 103F series;

* the controlled pulse was formed by a group of 8 control rods;

" the introduction of the initial positive reactivity in the range of 0.9-1.8 fief was provided by the

withdrawal of 1 start-up rod.

The verification of DINAR code was carried out in the following two areas:

(a) Checks of the quality of the code simulation of IGR reactor power pulses starting from the initial time till

the moment when the power value of the pulse back front is 2.5 % of the maximum.

(b) Checks of the quality of the code simulation of IGR reactor small power levels (less than 2.5 % of the

maximum).

The following characteristic of the energy deposition in the reactor as a function of time t was used as the

verification criterion:

EQt) = P(t)dt"

where E(t) = the energy deposition in the reactor in relative units (per-unit s);

P(t) = the reactor power (MW for calculations), (pIA for measurements);

P.=, = the maximum reactor power in this test (MW for calculations), (pA for measurements).

For each test in 132F series, the set of relative deviations of calculated and experimental values E(t) was

determined:

Eý(Q) - E.(t) 100,

where Sa0 = the relative deviation of calculated and experimental values E(t) (%);

E•(t), E,(t) = the measured and calculated values of the relative energy deposition in the reactor as a

function of time (per-unit s);

E,.. = the measured values of the relative energy deposition for t--- (per-unit s).

The typical kt) error distribution is presented in Fig. 4.6 (kt) error characterizes the integral error of the

"experiment-calculations" system).

The results of IGR pulse simulating by DINAR code are presented in Fig. 4.7, Fig. 4.8.

4.15
*0

P)

I II I

Test number is 132F-2 (uncontrolled power pulse) j

0

0 5 10 15 20 25 30

Time (s)

II U

0 5 10 15 20 25 30

Time (s)

Fig. 4.6. Total relative error In determining IGR reactor energy deposition by the ionization chamber

and DINAR code

4.16
1.2

4-.

0

Time (s)

4-

0

00

. - "41

0.;

0.1

0.4

0.:

Test nUmbbr is 132F-3 - Calculated

by DINAR

0 ,0__ _ O -IC4

0 - IC-14

A -D-1

85

6-

IC-4, IC-14are ionization

chamber numbers

D-I is in-Core neutron

detector number

m

nfl-T- - I + -I---~----~- tP -

S0 3 6 9 12 15

Tune (s)

Fig. 4.7. Relative IGR reactor power profdle measured by Ionization chambers and calculated with

DINAR code

4.17
0

0.04

0.02

0

0.06-

0.04

o 0.02-

oc

TImC (s)

Tune (s)

Fig. 4.8. Verification of the DINAR code simulation quality of small power levels of IGR reactor

4.18
Algorithm of adjusting the back front of IGR reactor power pulse

The adjustment of the input data for all 23 tests of C-, D-, E- types was carried out using the readings of the

ionization chamber No 6 (IC-6). The adjustment was performed for the power pulse section starting at 2.5%

of the maximum power (according to readings of the chamber IC-6). Starting with this value and later,

DINAR code calculation results were used as the time-dependent IGR reactor power profile. The adjustment

procedure was implemented individually for each of 23 tests. Fig. 4.9 contains an example illustrating

specific results of applying this procedure for tests 103F-19.

Fig. 4.9. IGR reactor power simulating by DINAR code

4.7. Neutronics parameters offuel rods

purpose and tasks of the procedure

The purpose of this procedure is to calculate the time integral function of the spatial distribution of the

number of fissions in fuel rods of C-, D-, E- types and in special fuel samples.

The main tasks of this research area included the following:

" conduct of a series of full-scale neutronics dynamic calculations of IGR-type reactor using DINAR code

to determine the axial distribution of IGR reactor power at the external surface of the central experimental

channel of the reactor as a function of time for each of 23 tests of fuel rods of C-, D-, E- types;

" conduct of the stationary calculation simulation of IGR reactor including the capsule and fuel rods for 23

tests of fuel rods of C-, D-, E- types.

Input data

The following was used as the input data:

" geometry and material composition of IGR reactor (see sections 4.5, 4.6);

" geometry and material composition of fuel rods, the capsule, special fuel samples (see Chapter 2).

4.19
Procedure validation and computer code selection

Since the geometric and material structure of the capsule with fuel rods is complex, adequate calculation

simulation of such object with the aim of determining the number of fissions in fuel rods requires a rather

accurate neutronics model using, for example, Monte Carlo method. However the use of precision

calculation methods based on Monte Carlo for detailed non-stationary full-scale calculations of IGR reactor

is an extremely effort-intensive procedure which is beyond the capabilities of the present work. Therefore,

the problem of searching for the ways to simplify the calculation method without affecting the accuracy of

the results was solved at the first stage of the procedure development to determine the neutronics parameters

of fuel rods of C-, D-, E- types. This problem was solved by conducting detailed calculations of IGR reactor

using 3D dynamic code DINAR (see section 4.6). The analysis of the obtained results allowed to identify an

important feature of the spatial neutron distribution in IGR reactor in the tests with the controlled power

pulse. It was found out that the axial power profile of IGR reactor at the outside surface of the graphite insert

of the central experimental channel depends slightly on the reactor core heating up.

On the other hand, because of similar schedules of control rod movement with small changes in the insertion

depths, this axial power profile depends slightly on the position of control rods in the reactor (these

statements are valid for the test series under consideration).

Thus, in this case the axial profile of the neutron flux to the capsule depends mainly on the geometry and the

material composition of the reactor and the capsule with fuel rods. This circumstance results in two

conclusions:

* using the three-dimensional dynamic code, IGR reactor can be simulated in all 23 tests, and it is possible

to obtain axial profiles of the neutron flux to the central experimental channel;

" the solution of the stationary criticality problem can be used to find the detailed spatial distribution of the

number of fissions in fuel rods of C-, D-, E- types.

These conclusions form the basis of the procedure to determine the number of fissions in fuel rods of C-, D-,

E- types.

Using DINAR code, the first stage of the procedure covered the three dimensional dynamic simulation of

IGR reactor for tests of fuel rods of C-, D-, E- types. The time-average axial profile of IGR reactor power,

obtained as a result of the calculations, was used as the boundary condition for the second stage of the

procedure.

During the second stage of the procedure calculations by Monte Carlo method were performed using model

in which the reactor core was described approximately, and its characteristics did not depend on time. All

other reactor elements, primarily its central part, including the central experimental channel, the capsule and

fuel rods, were accurately described.

The variant for the approximate reactor description was selected on the basis of the optimization procedure,

during which neutronics characteristics of the reactor core (its absorbing properties) were selected in such

way as to obtain the identical boundary conditions for MCU and DINAR codes on the axial profile of the

reactor power. The criticality problem was solved within the framework of this computer model. Taking into

account the requirements on results of the calculations performed at the second stage, Monte Carlo MCU

computer code was selected for calculations. The use of this code provides the solution of the problem on the

neutron transfer with the accuracy which is limited only by the accuracy of nuclear data libraries.

MCU-RFFI code description

MCU-RFFI code is of modular structure and is written in FORTRAN-77 [16-19]. Three dimensional

elements of the reactor, the capsule and fuel rods are described in the code by methods of the combinatorial

geometry as Boolean combinations of a simple body set. Various options of MCU-RFFI program are

generated from MCU program modules. MCU-RFFI has a number of optional physical modules, which are

different in model types used to describe the interaction of neutrons with the matter and in libraries of

constants.

The simulation of the interaction of neutrons with nuclei of the environment in physical models can be

carried out using the model of continuous energy changes at collisions or the model in the multi-group

approximation. A combination of these two models is possible for different energy regions. The pointwise

and stepwise presentation of cross-sections can be used in the continuous slowing-down model.

4.20
Taking into account the accuracy requirements on the calculation simulation, the most verified option of the

physical module and the corresponding library of constants were selected for the use within the framework

of this task. The main features of the selected module are described below.

Neutron slowing down is simulated taking into account continuous changes in their energy at collisions. In

the unresolved resonance region the cross-sections are calculated in the subgroup approximation or using

Bondarenko's f-factors. In the resolved resonance region the subgroup and pointwise descriptions are used.

For the most important nuclides, cross-sections are described by infinite number of points, i.e. cross-sections

in each energy point are calculated directly in the simulation process on the basis of the resonance parameter

library. This approach allows to perform calculations taking into account Doppler cross-section broadening

without a prior tabulation of cross-sections. Cross-section approximation with step functions is used for less

important isotopes. Collision simulation in the thermalization area is carried out either in the multi-group

approximation, or on the basis of the model of continuous energy changes taking into account the correlation

between the energy changes and the scattering angle.

Chemical bonds, thermal movement of nuclei, coherent effects for elastic scattering are considered in both

cases.

Constants for the above version of MCU-RFFI physical module are provided by DLC/MCUDAT - 1.0 bank

of neutronics data which includes the following libraries:

* ABBN/MCU expanded and modified version of 26-group of ABBN system of constants [20];

" LIPAR, containing resonance parameters of nuclides in the resolved resonance region [21];

" TEPCON, containing multi-group cross-sections for the thermalization region [ 19];

" VESTA library to simulate neutron collisions with nuclei taking into account continuous changes in the

neutron energy in the thermalization region, arranged in the form of probability tables obtained from S

(ca,13) scattering laws [19].

DLC/MCUDAT-I.0 bank and MCU-RFFI program, with the above physical module, were verified using

results of more than 300 integral benchmark experiments and results of the comparison with calculations

using MCNP program with constants calculated on the basis of ENDF/B-V files [22, 23]. The verification

results demonstrated that the critical benchmark experiment calculation error of MCU-RFFI code is not

worse than 0.2-0.4 % in KI,. The reliability of this code was tested as a result of thousands of applied

calculations of various types of reactors conducted in Russia during 15 years. The documentation on MCU

code verification is contained in [19-27].

Calculation schemes and main assumptions

The calculation scheme of IGR reactor and main assumptions for DINAR code are described in section 4.6.

The present section describes of the calculation scheme of MCU-RFFI code.

The stage of selection and validation of the calculation scheme of IGR reactor for MCU-RFFI code revealed

a specific difficulty of this problem. It is related to the fact that the ratio between the volume of the fuel rod

and of the special fuel sample, and the reactor volume is less than 10-6 for the special fuel sample. Due to this

fact, the direct simulation of the reactor is impossible. A series of attempts were directed at reducing the

variance using standard methods such as splitting and the Russian roulette. However these procedures turned

out to be not very efficient, for example, the statistical error of calculations for the capsule with the air could

not be reduced below 25-50 %, despite of the simulation of several millions of histories. That is why it was

necessary to modify MCU-RFFI code as applied to the condition of this problem.

The code modification was carried out by developing the corresponding procedure [28, 29]. This procedure

enables to solve the problem in two stages.

During the first stage, the criticality problem is solved. For this purpose, a relatively small object V, which

contains fuel rods, is separated in the capsule (Fig. 4.10 - Fig. 4.12), and neutronfluxes to the surface of this

volume are calculated. In other words, all neutrons, that cross the surface V, are recorded and stored in the

disk during the simulation of the critical reactor.

4.21
1. Guide tube with

special fuel samples

2. Object V

3. Fuel rods

4. Capsule

Fig. 4.10. Axial section of calculation geometrical model of object V for MCU computer code

During the second stage, neutrons recording are treated as surface sources. The non-uniform problem of the

neutron field distribution inside the volume V, surrounded by the black absorber, is solved using these

sources. This problem is mathematically equivalent to the original problem of the neutron distribution inside

the capsule placed in the critical reactor.

This algorithm, which provides for the calculations in two stages, allowed to reduce significantly the tally

variance and to shorten the count time.

4.22
1. Guide tube with special samples

2. Fuel rod

3. Boundary of volume V

4. Capsule

Fig. 4.11. Cross-section of the calculation geometrical model of object V for MCU computer code

1

2

3

1. Protective shroud

2. Object V

3. Capsule

5

6

4. Threc shrouds ofjactor capsule

5. Reactor core

6. Reflector

Fig. 4.12. Axial section of calculation geometrical model of IGR reactor for MCU computer code

4.23
A number of additional methods were applied to increase the count efficiency:

1. Each neutron entering the volume V was split into a number of neutrons with corresponding changes in

the weight during calculations at the second stage. The combination of the splitting method with the

single reactor calculations greatly improved the efficiency of procedure.

2. The hypothesis on the smooth nature of the neutron flux on the surface of the object V was used. This

allowed in a random manner to shift within certain limits the coordinate and the vector of the direction for

each split neutron entering the volume V. The use of this method resulted in a considerable reduction of

the estimate tally variance and in an improved efficiency of the calculations.

The practical implementation of this algorithm within the framework of the specific problem required a

series of optimization calculations with the aim of the final selection of the calculation scheme. The

following problems were solved during the optimization calculations:

a) The shape and dimensions of the object V were selected;

b) Effects of the model type of IGR reactor on the calculation accuracy were assessed;

c) Effects of the material composition and the geometry of fuel rods in the capsule on the distribution

function of the surface neutron flux at object V boundaries were assessed;

d) Splitting parameters and parameters of coordinate and the velocity vector shift, that characterize neutrons

entering the object V, were selected.

The shape and dimensions of the object V were determined in accordance with the following requirements:

" effects of individual differences in the geometry and the material composition of fuel rods on the neutron

flux at the surface of the object V should be negligible;

" dimensions of the object V should ensure the maximum reduction of the calculation result variance.

The practical implementation of these requirements allowed to obtain the following geometric characteristics

of the object V:

- the shape of the object is cylinder;

-the radius of the object is 39.5 mm;

-the height of the object is 170 mm.

The assessment of the effects of IGR reactor model on the calculation accuracy was carried out on the basis

of comparing neutron spectra at the surface of the capsule, obtained within the framework of the solution of

the stationary problem, with the reference spectrum calculated by solving the non-stationary problem.

The analysis of the effects of the material composition and the geometry of fuel rods on neutron flux

parameters at the surface of the object V demonstrates that individual features of fuel rods have practically

no effects on surface neutron fluxes (for this particular calculation model of the reactor). This circumstance

was used to develop the scheme of performing variant calculations of fuel rods.

Scheme of variant calculations and calculation results

In accordance with optimization calculation results, the following two criticality calculations of IGR reactor

were carried out within the framework of the first stage of ALIGR algorithm implementation:

" reactor calculations for the version of water filling of the capsule with fuel rods;

" reactor calculations for the version of air filling of the capsule with fuel rods.

Calculations resulted in values of surface fluxes of neutrons entering the object V.

23 calculations of IGR reactor with 23 variants of geometric dimensions and material compositions of

capsules with fuel rods of C, D, F types were performed for the second stage of ALIGR algorithm. In this

case two sets of values of surface fluxes of neutrons entering the object V, that were obtained at the first

stage of implementing the algorithm, were used as the input data.

Calculations results, presented in the table form of integral number of fissions in tally regions for each of the

main fissile isotopes, were the input data for procedures to determine energy deposition fields in each C, D,

E fuel rods, described on section 4.8. The calculations were performed for the following scheme of dividing

fuel rods into tally regions:

4.24
" number of regions along the radius - 5 (5h" region corresponds to rim layer);

" number of regions along the height - 15-20.

In addition to tables of integral number of fissions in tally regions, the integral number of fissions in the

volume of the fuel rod, the integral number of fissions in the special fuel sample and the ratio between the

number of fissions in the central fuel pellet of E-type fuel rod and in the special fuel sample were calculated

for each fuel rod. These results were also used as input data for the procedure described in section 4.8.

Calculation error

The basic error of the method is the methodological one, related to the error of assigning the neutron flux distribution at the surface of the volume V. This error is due to the fact that the neutron flux was calculated

within the framework of the above approximation on the possibility of switching from the solution of the

non-stationary problem to the solution of the stationary criticality problem. According to calculations, this

error is about 3 %.

The systematic error related to the data base on constants is 0.5 % - 1 %. The statistical error of calculating

the number of fissions in fuel rods and in special fuel samples does not exceed 2 % (one standard deviation).

The statistical error of calculating the ratio between the number of fissions in the central fuel pellet of E-type

fuel rods and the number of fissions in special fuel samples is about 2.2 %.

Verification procedures

As it has already been noted, MCU code was reliably verified on the basis of various experiments including

assemblies of different geometry and material composition. Within the framework of this work, the

following additional verification procedures were implemented:

a) The comparison of calculated and experimental values of coefficients, that connect the integral (over the

duration of the tests) number of fissions in central fuel pellets of E-type fuel rods and in special fuel samples,

was carried out.

b) The comparison of calculated and experimental number of fissions distributions in C-type fuel rods was

carried out using results of special experiments at MIR research reactor.

Verification procedure using measured number of fissions in central fuel pellet of E-type fuel rods

According to the analysis of results of comparing calculation and experimental ratios of number of fissions

in fuel rods of type E and fuel rods of type C, the average relative deviation of these values is about 4 %.

Verification procedure using MIR reactor experiment

The purpose of this work was to conduct a special experiment with fuel rods of C and E types at MIR

research reactor, to perform the calculation simulation of fission densities in fuel rods using MCU code and

to compare calculation and experimental results.

MIR reactor is a channel-type research thermal neutron reactor intended for lifetime testing of fuel

assemblies and individual fuel rods of various reactors [30, 31].

MIR reactor core is located in the water pool and consists of hexagonal beryllium blocks. Blocks are

arranged with a gap to ensure the cooling with the pool water. There are holes along the axis of the central

block and of blocks of the first four rows of the reactor core to position reactor fuel assemblies and loop

experimental channels.

Experimental channels are located in the second and the third rows of the reactor stack to ensure the

arrangement when each of them is surrounded by 6 channels with reactor fuel assemblies. The reactor fuel

assembly consists of co-axial annular fuel rods (2 mm thick, 2.5 mm space between fuel rods). The height of

the fuel rod core in the reactor fuel assembly is 1000 mm. The fuel is uranium-aluminum alloy with 90 %

enrichment in U235; fuel cladding is made of aluminum alloy. The maximum reactor power is 3.6 MW. The

power is controlled using control rods. The cartogram of MIR reactor core is presented in Fig. 4.13.

The scheme of the special verification experiment conducted at MIR reactor was as follows [32]:

1. Three C-type fuel rods and three E-type fuel rods were manufactured. C-type fuel rods were fabricated

from commercial fuel elements ## 316, 23 and 166 of fuel assembly # 1114 of NV NPP-5. The average

fuel burnup in refabricated fuel rods was 49.2, 44.4, 43.2 MWd/kg U. •-spectrometric measurements of

fuel rod activity were performed.

4.25
2. Six fuel rods of C and E types were irradiated in the experimental channel # 3-7 of MIR reactor. In

addition to fuel rods of C and D types, six fuel rod simulators (rods with steel cladding, filled with water)

were installed in the channel. Fuel rod simulators were used as activation detectors to determine the

distribution of the thermal neutron flux in the channel. The arrangement of fuel rods in the channel is

presented in Fig. 4.14.

(DI 8 Reactivity shim fiel assembly.

Operating channel with NUR fuel assembly;

Excperimental loop channel;

() special channel;

0 Compensator rod;

j Control rod.

Fig. 4.13. The cartogramn of MIR reactor core

H High bumup fuel rods

S Simulator of fuel rods

F Fresh fuel rods

Fig. 4.14. The arrangement of fuel rods In the loop channel at MIR reactor

4.26
3. Fuel rod irradiation conditions were as follows:'

" coolant temperature at the channel inlet 1820C

" coolant temperature at the channel outlet 186 0C

" coolant flow rate 5000 kg/hour

" coolant type water

" irradiation time 5 days

" MIR reactor fuel assembly power about 500 kW

4. Y-spectrometric measurements were performed after fuel rods were removed from MIR reactor, and the

axial distribution of Zrs was obtained for fuel rods of C- and E- type. Each measurement was repeated 10

times.

5. Zr" isotope concentration ratios in central fuel pellets of C- and E-type fuel rods were determined in

accordance with measurement results under item 4 taking into account corrections related to the nonuniformity of the neutron flux in fuel rod locations and differences in coefficients of gamma quanta self

absorption in fuel rods with the fresh and burnt-out fuel.

The random error in determining the concentration ratios is - 3.5% (2a).

The computer modeling of this experiment was performed using MCU code. The reactor cell containing a

loop channel surrounded with six fuel assemblies of the reactor core was used as the calculation model (Fig.

4.15).

Input data for calculations were taken from [32].

The verification procedure covered the comparison of the calculation and experimental ratio KJ, where K

characterizes the ratio between the fission density in the central fuel pellet of C-type fuel rod and the fission

density in the central fuel pellet of E-type fuel rod. Results of this procedure are presented in Table 4.5.

1. Fuel assembly of MIR reactor

2. Berilium moderator blocks

3. High burnup fuel rods

fabricated from fuel element "of #316 NV NPP 4. Simulator of fuel rods

5. Unirradiated fuel rod

Fig. 4.15. The calculation cell for MCU code

4.27
Table 4.5. Verification results of MCU code based on MIR reactor experiment

Number of fuel Fuel burnup Km as measured K, as calculated Km - K 100 (%)

rod tested at MIR (MWd/kg U) (per-unit) (per-unit) Km

reactor____________________

1 49.2 0.358 0.365 -2

2 44.4 0.388 0.392 -1

3 43.2 0.388 0.417 -7

According to verification results, the average difference between experimental and calculation results does

not exceed the statistical measurement error. Thus, the verification confirmed a high quality of the procedure

developed to determine the energy deposition in fuel rods of C-, D-, E- types.

4.8. r, z, t distribution of the energy deposition and power offuel rods

A special algorithm was developed to determine the energy deposition distribution in fuel rods of C-, D-, Etypes as a function of time and r, z coordinates [32]. The main components of the algorithm are presented

below.

Input data

The following was used as the input data:

" sets of fission values in tally regions of fuel rods of C-, D-, E- types, obtained as a result of the procedure

described in section 4.7;

" sets of integral number of fissions values in the fuel volume of fuel rods of C-, D-, E- types and in special

fuel samples, obtained according to the procedure described in section 4.7;

" values of coefficients connecting the number of fissions in central fuel pellets of E-type fuel rods and the

number of fissions in special fuel samples, that were calculated on the basis of the procedure in

section 4.7;

" experimental values of number of fissions in central fuel pellets of E-type fuel rods and in special fuel

samples, experimental values of coefficients connecting the number of fissions in central fuel pellets of Etype fuel rods and the number of fissions in special fuel samples, that were obtained on the basis of

procedures described in sections 4.3, 4.4;

" adjusted profiles of power and energy deposition in IGR reactor versus time, obtained within the

framework of procedures in section 4.6;

" geometry and material composition of fuel rods of C-, D-, E- types and of the capsule in accordance with

the data base in Appendixes C, D, E, F, Volume 3 of the present Report;

" geometry and material composition of special fuel samples in accordance with the data in chapter 2 of the

present volume.

Norming the set of calculated fission densities

The set of integral values of fission densities in tally regions of fuel rods of C-, D-, E- types, calculated using

MCU code, was obtained within the framework of solving the stationary criticality problem. In this case the

integral number of fissions characterizes the number of fissions caused by one neutron entering the volume

V (capsule with fuel rods). The procedure of switching to the set of real integral fission densities in tally

regions of fuel rods of C-, D-, E- types over the entire time of the tests was implemented using the following

ratios:

ni. = nc kmffr (1)

k,. k - m

nffr, nEffrE

4.28
km ki + k k- 2 2m for two fuel rods in the capsule,

km = kIm for one fuel rod in the capsule,

where ni. = the calculated (on the basis of experimental data) fission density in a given elementary

volume of the fuel rod for the th fissile isotope at the m ' test (fissJcm);

ni = the fission density in a given elementary volume for the ti fissile isotope at the mdi test

(fiss./cm3), that was calculated based on the procedure in section 4.7;

km = the norming coefficient (per-unit);

ff, = the temperature correction which depends on the fuel rod of type C, D, E

(see section 4.9) (per-unit);

kim = the norming coefficient for the number of fissions in the special fuel sample (per-unit);

k2m = the norming coefficient for the number of fissions in the central fuel pellet of E-type fuel

rod;

nsm = the measured number of fissions in the special fuel sample (fiss./g U2 35

);

nsc = the calculated number of fissions in the special fuel sample (fiss./g U235);

nEm = the measured number of fissions in the central fuel pellet of E-type fuel rod (fissjgU233);

nEc = the calculated number of fissions in the central fuel pellet of E-type fuel rod

(fiss./gU2 35 );

ffrs = the temperature correction for special fuel sample (per-unit);

ffE = the temperature correction for fuel rods of E-type (per-unit).

Determination of the spatial distribution of the fission rate for fuel rods of C-, D-, E- types versus time

The fission rate of each fissile isotope in a given elementary volume of a specific fuel rod as a function of

time was determined using the following formula:

R,(r,z,tk) = P(tk)nm E, '

where Ri(r,z,td) = the fission rate for the th isotope at t time moment (fiss./cm3s);

P(tk) = the reactor power in the ionization chamber measurement units at tk time moment (pA);

=nh, = the number of fissions for the th isotope over the entire test, adjusted based on formula

(1) (fiss.jcm 3

);

E, = the energy deposition in IGR reactor over the entire time of the test in the ionization

chamber measurement units (pAs).

The integral fission density for the i& isotope in a given elementary volume of the fuel rod at time moment tk

is determined on the basis of the formula:

k

n,,,,P(tk )At,

ni(tk) k =1 E

where ni(t) = the integral fission density for the i6 isotope in the time interval 0-tk (fissJcm3

);

n& = the integral fission density for the eh isotope over the entire test (fiss/cm3

);

P(td = the reactor power at time moment tk in the ionization chamber measurement units (pA);

Atk = the time step in the numeric scheme (s);

Er = the reactor energy deposition over the entire test in the ionization chamber measurement

units (pAs).

4.29
Calculation procedure to determine the energy deposition in fuel rods of C-, D-, E-tvpes

In the general case, the balance of the volume energy density in the elementary fuel volume at time moment t

can be written in the following form:

Efr(t) = Eff(t)+ Epr(t)+ EA(tj,

where Efr(t) = the integral energy deposition in the elementary volume of the fuel rod (C, D, E) at time t

(J/cm3);

Eg(t) = the energy deposition due to fission fragments of all fissile isotopes (i/cm3

);

Epr(t) = the energy deposition in the fuel due to prompt neutron and gamma radiation (J/cm3

);

E(t) = the energy deposition in the fuel due to delayed beta and gamma radiation (i/cm3

).

The energy deposition due to fission fragments in the elementary volume of the fuel rod was calculated on

the basis of the formula: 'n

Eff(tk)= ZE n,(tk),

i=l

where E#(tk) = the integral energy deposition due to fission fragments by the time moment tk (i/cm3

);

E1 = the kinetic energy of fragments in case of fission of the eh isotope [34] (J/fiss.);

n1(t) = the integral fission density for the th isotope in the time interval O-tk (fissjcm 3

);

i = the number of the isotope: for C-type fuel rod n=4 (U 23 5

, U 2 38, Pu23 9, Pu24 1

), for fuel

rods of D and E types n=2 (U235, U238

).

Values of the kinetic energy of fragments , which were used to determine energy deposition, are presented in

Table 4.6.

Table 4.6. Kinetic energy of fragments

Isotope

Energy U235 U238 pu 23 9 pU 24

'

(MeV/fiss.)

172.7 170.3 178.6 175.1

The energy deposition due to the prompt neutron and gamma radiation was calculated according to the

formula: n

Epr(tk)= EprfrT n,(tk), 1=1

where Ep,(4) = the integral energy deposition in the elementary volume of the fuel rod due to the

prompt radiation by the time moment tk (J/cm3);

Ep,, = the energy deposition due to the prompt radiation absorbed in the volume of the fuel

rod of C-, D-, E- types and normalized -per the number of fissions in the fuel rod

volume (J/fiss.);

nj(tk) = the integral fission density for the i' isotope in time interval 0-tk (fissJcm3

).

Energy deposition values due to the prompt radiation in the entire fuel volume EX were calculated using

ANISN computer code with CASK system of constants [35]. The radial distribution of the neutron density in

IGR reactor was calculated with CITATION code [36]. The obtained radial distribution of the neutron

density was used as the input data for ANISN code. The neutron radiation contribution to the energy

deposition was assessed using kerma-factors from the library of BLANC code [37]. The neutron sources

ratio in IGR reactor and in fuel rods was determined using experimental data obtained in IGR reactor.

Table 4.7 presents values of F_,5, and of their components.

4.30
Table 4.7. Energy deposition due to the prompt radiation in fuel rods of C-, D-, E- types

Energy deposition (MeV/fiss.)

C type of fuel rod

Type of E, D type of fuel rod fuel rod refabricated from fuel rod refabricated from

radiation #22 fuel element #317 fuel element

water air water air water air

coolant coolant coolant coolant coolant coolant

Neutrons from 0.007 0.02 0.01 0.04 0.02 0.06

reactor

Neutrons from 0.025 0.02 0.03 0.02 0.03 0.03

fuel rod

Gamma quanta 6.1 9.1 8.0 12.7 8.3 14.3

Total ~ 6.2 9.2 12. '8.4 14A

The power due to the delayed beta and gamma radiation was calculated as a function of time using the

following formula [38]:

ntk

PA(tk) = PR(t'fiI(tk -t') + CrI(tk -t')t',

1=1 o

Where Pp(t) = power deposited in the fuel rod due to delayed radiation at time moment tk (MeV/s);

t'= time moment when the neutron, that caused the fission, was absorbed (s);

P,(t) = fission rate atthe time moment t'(fissJs);

lj(tk-tq= power deposited in the fuel rod after the fission of the i' isotope due to delayed 13

radiation during the time interval tk-t'[ 3 8] (MeV/s.fiss.);

yj(tk-t= power deposited in the fuel rod after the fission of the idi isotope due to delayed y

radiation during the time interval tk-t'[ 38] (MeV/s.fiss.);

C fraction of 7 radiation absorbed energy in the fuel rod (per-unit);

i= number of fissile isotope.

Calculations of fuel rod power due to the delayed radiation were performed taking into account the assumption that all the energy of beta particles is deposited in the fuel rod.

Coefficient C in the formula to determine the power deposited in the fuel rod due to the delayed radiation

was determined as a result of calculations with ANISN code in accordance with the procedure used to

calculate Ej.(t,). Values of this coefficient are presented in Table 4.8. To determine the contribution of

delayed radiation the data characterizing Ei(t) are presented in the Fig. 4.16 for one of high burnup fuel rods

tested at IGR reactor.

Table 4.8. Energy fraction of the delayed gamma radiation absorbed in fuel rods of C-, D-, E- types vs.

time

Value of C coefficient (per-unit)

Coolant type E-, D- types of fuel rod fuel rod refabricated from fuel rod refabricated from

#22 fuel element #317 fuel element

Water 0.29 0.34 0.33

Air 0.36 0.42 0.44

4.31
6

8 _____ _ _______ _ _........................._____

5'

4)

S 2

0 100 200 300 400 500 600

Time (s)

Fig. 4.16. Ep(t) normalized on the one fission vs. time for fuel rod #H1T

The energy deposition in fuel rods of C-, D-, E- types due to the delayed radiation Ep(tk) was determined

using the procedure of integrating the sets of Pp'ti) values. In the final form, the set of energy deposition

values in fuel rods of C-, D-, E- types is presented in tables of Appendixes G, H, I, Volume 3, as energy per

fuel unit mass. A corresponding set of power values was determined due to the procedure of differentiating

the corresponding values of energy deposition using reactor power profile versus time.

4.9. Dependence of the number offissions in fuel rods on the temperature

As it has been noted in section 4.7, calculations of the spatial distribution of the number of fissions in fuel

rods of C-, D-, E- types with MCU code were carried out without considering the temperature changes of the

reactor core, the coolant in the capsule and fuel rods, i.e. at the initial conditions.

From the physical point of view the thermal neutron spectrum is a function of the temperature. In its turn, the

thermal neutron spectrum determines the ratio of fission densities for various fissile isotopes. It is special

importance for C-type fuel rods, i.e. for fuel rods containing isotopes of Pu239 and pu24'since there are

clearly expressed resonances for these isotopes in the energy region of 0.3 - 0.5 eV. This factor results in

changes of the fission density ratio for all main fissile isotopes U 235, Pu23, Pu' depending on the neutron

gas temperature in the capsule with fuel rods; moreover, the neutron gas temperature affects the block-effect

in fuel rods.

According to a preliminary analysis, the maximum differences in the number of fissions density in C-type

fuel rod taking into account temperature change effects does not exceed 4 % of the initial values of the

fission density obtained for the value of T0=17°C. Thus, in the final form the temperature correction was

introduced as an average in time and fuel isotopic composition. To determine it the following function was

used:

f f =1 p(t) P(t)dt,

ro

whereffr = the temperature coefficient in formula (1) in section 4.8;

4.32
ip(t) = the functional reflecting the ratio of fission densities in the fuel rod for the initial and current

temperature values (at time moment t) (per-unit);

P(t) = IGR reactor power in the ionization chamber measurement units (pA);

E, = the integral energy deposition in the reactor in the ionization chamber measurement units

(pAs).

Calculations of the functional qt) were performed using the following formulas:

't)=krtQ)

kTo

Z n. (t) ZxnrJ~.

kT(t)= k = W

1=1 1=1

where p,(t) = the functional which takes into account the ratio of fission densities in the fuel rod

for the initial temperature and the temperature at the time moment t (per-unit);

kT0, kr(t) = coefficients characterizing the ratios of the section-average fission density in the

central fuel pellet of the fuel rod and the fission density in the special fuel sample

for the initial temperature T. and temperature T, respectively (per-unit);

nTofro. nf,(t) = fission densities in the central fuel pellet for the ie isotope for the initial temperature T. and temperature T, respectively (fissJcm3

);

nfro.T, n,(t) = fission densities in the special fuel sample for the i' isotope for the initial temperature To and temperature T, respectively (fiss./cm 3

);

i = the number of the fissile isotope.

This approach to the determination of temperature corrections was implemented within the framework of the

following procedure:

1. The determination of the radial distribution of the energy deposition in IGR reactor, the fuel rod and the

coolant for critical reactor conditions (i.e. at temperature To). Calculations of the energy deposition from

fission sources were carried out using CITATION code [36].

2. The differentiation of the absolute value of the energy deposition in the reactor according to the reactor

power as a function of time. The absolute value of the energy deposition in IGR reactor Q) was

determined experimentally at the end of each test.

3. The formation of the set of energy deposition radial distributions in the reactor as a function of time,

using calculation results under item 1 and the set of integral values of the power deposition in the reactor

as a function of time obtained under item 2.

4. Calculations of the radial temperature distribution in the reactor as a function of time using the set of

energy deposition radial distributions as a function of time and the set of values of the material heat

capacity of the reactor core and the capsule as a function of time.

5. The formation of the set of temperature distribution of the fuel in the fuel rod as a function of time by

using results of the computer simulation of thermo-mechanical fuel rod behavior with FRAP-T6 code

according to the procedure described in section 4.11.

6. Determination of the set of fission densities in fuel rods of C-, D-, E- types and in special fuel samples as

a function of time (i.e. as a function of temperature) by carrying out the computer simulation of IGR

reactor, in each of the time moments t under consideration, using WIMS-4D code [39]. Sets of z,t

temperature values obtained in accordance with procedures in items 4 and 5 were used as the input data

for WIMS code.

Results of calculating temperature coefficients f are presented in Table 4.9 for C-type fuel rods. This set of

values was used in the procedure in section 4.8 during the stage of using the formula (1). Results of

4.33
calculating temperature coefficients for fuel rods of D-, E- types demonstrate that, since the main

contribution to the fission process in these fuel rods is made by isotope U235, the value of coefficient f does

not exceed 1.005. Therefore, the temperature coefficient in fuel rods of D-, E- types was not considered.

Table 4.9. Values of the temperature coefficient f for C-type fuel rods

Para- Number of fuel rod

meter HIT H2T H3T H4T H5T H6T H7T H8T B9T BlOT Bl1T B12T B13T

f

(per- 1.018 1.02 1.02 1.014 1.017 1.01 1.017 1.005 1.02 1.015 1.03 1.025 1.03

unit)

4.10. Uncerlainty analysis

This chapter covers the analysis of uncertainties related to the determination of the fuel rod energy

deposition and the power.

Errors in other chairacteristics used as incoming data to calculate the fuel rod energy deposition and the

power are presented in corresponding sections of Chapter 4.

The algorithm of the uncertainty analysis in energy deposition units contains the following sequential stages:

" determination of the random and systematic errors in the integral energy deposition in the elementary

volume of each fuel rod type (here, the term "elementary volume" is equivalent to the one in sections 4.7,

4.8);

" determination of the random and systematic errors in all types of r, z, t distributions of the energy

deposition in fuel rods.

The error assessment was performed for each fuel rod type on the basis of their specific set according to the

following scheme:

" H7T for high burnup fuel rods cooled by water,

" B9T, B13T for high burnup fuel rods cooled by air (fuel of B9T rod had the burnup of 42 MWd/kg U,

fuel of B13T rod had the burnup of 49 MWd/kg U);

" H16T for fuel rods of D, E types cooled by water,

" B20T for fuel rods of D, E types cooled by air.

The error assessment of the energy deposition in high bumup fuel rods was performed only for undamaged

sections (see Table C.2.1-C.2.3 Appendix C, Volume 3 of the Report).

4.10.1. Methodological aspects of the procedure

The analysis was based on the determination of the following characteristics of the error for an arbitrary

parameterX.

" standard deviation S, for the assessment of the random error in determining parameterX;

" boundary of the non-eliminated remainder O for the assessment of the systematic error in determining

parameter X;

* total error A, for the assessment of the accumulated error in determining parameterX.

Values S, and 0, were assessed with 95 % confidence level. The total error was calculated using the

following formula (with the same confidence level):

. =S14+ 0.

4.34
Regarding the distribution laws of assessed values, standard assumptions were made:

" all reference random values, which determine the set of values S.,, have Gaussian distribution;

" all reference random values, which determine the set of values O, have equipartition distribution.

Since the main set of reference data 'characterizing errors in measured parameters was presented in the form

of the relative error expressed in percentage, this procedure also uses values k, S,, and 0,, presented in the

relative form:

8x= 100; 8s= 100; 80, = -•100;

where ,55, , 8a-= relative total error, relative standard deviation, relative systematic error, respectively (%);

X = the sample mean of value X.

The assessment of the error in determining the value y=f(X,,X2...Xk...X,) was performed using the following

approach [40, 411:

2

8= -X (X ,).

8Sy (k) 8S(Xk),

Y Ck

k=1

x,9.

80(Xk) X 80(Xk),

8Y = + 88,

where y = the complex parameter which is a function of f type of values XI...Xk...Xm;

8s (Xk), 80 (Xk ) = random and systematic relative errors in determining parameter y due to the presence of random and systematic errors in determining the reference value Xk (%);

S,, 6 >, ,80 = total, random, systematic relative errors in parameter y, respectively, (%).

4.10.2. Energy deposition error in the elementary volume of fuel rods

Type of the functional dependence to determine the energy deposition in the elementary volume of fuel rods

of C-, D-, E- types.

As it was indicated in section 4.10.1, the error calculation for the complex parameter y (which, in this case, is

the energy deposition in the fuel rod elementary volume) is based on the differentiation on partial derivatives

of function y =f(X2..X.). Thus, combining the individual stages of the complex procedure to determine the

energy deposition (see sections 4.8, 4.9) into a single functional dependence is a necessary step in order to

analyze the energy deposition determination error. The result of such operations can be presented in the form

of the following formula:

Ef,(t) = kEff[±Eni(tk)+(EP,+, +E n (tk ,

where Ef,(t)= the integral energy deposition in the fuel rod elementary volume at time t (J/cm3);

km = the norming coefficient (per-unit);

4.35
ff, = the temperature correction (per-unit);

Ej = the kinetic energy of fission fragments per one fission event of the i9 isotope (J/fiss.);

ni(td) = the integral calculated fission density for the ith isotope in the time interval

0-tk (fiss./cm 3);

Epr~f, = the energy of prompt neutron and gamma radiation deposited in the fuel per one fission

event (J/fiss.);

E6 = the energy deposited in the fuel due to delayed beta and gamma radiation per one fission

event (J/fiss.).

Procedure to determine errors in parameters determining the type of the functional dependence for the energy

deposition in the elementary volume of fuel rods of C-, D-, E- types

A detailed description of this rather complex procedure is outside the scope of the Report, thus, only its main

principles are presented here.

The basic provisions of this procedure are as follows:

* passport data for sensors or results of metrological qualification of the method are used as random and

systematic components of the error for all measured parameters;

" random and systematic errors of computer codes are presented in the form of results of their qualification,

verification or results of implementing special standard procedures to assess the computer code errors;

" errors in parameters which are functions of a known type of measured characteristics are determined in

accordance with the requirements of the procedure in section 4.10.1;

e errors in parameters which practically cannot be presented in the form of a strict functional dependence

are assessed using the sensitivity method of calculation results to incoming parameters.

To analyze the sensitivity of calculation results to incoming parameters, a method was selected which is

based on the perturbation theory [42, 43].

In this method the sensitivity coefficient of the functional to the incoming parameter is presented in the

following form [42]:

P16, ( XI, X 2 ... XN)= lim AR/R

Ax;/x.-,O AX. / X.

where P,, = the sensitivity coefficient of the outgoing parameter R, that characterizes changes in

parameter R in percentage in case of changing the incoming parameter X,, by 1%;

XI, X 2... XN = incoming parameters;

AXA,,AR = increments in parameters X, and R;

n-= 1,2,... N.

The final purpose of this method is to determine the relative error in the outgoing parameter 8R = AR/ R

using the dependence which, for the case of the linear relation between SR and Sx., is as follows:

N

n=1

where 8 = the relative error in the outgoing parameter R,

Sx= the relative error in the incoming parameter X.(8x. = AX. / X,);

1•. = the sensitivity coefficient.

The functional to determine 5R for the case of non-linear relation between the incoming and outgoing

parameter is much more complex and is not presented here.

4.36
In practice, procedures of the sensitivity analysis of outgoing parameters (such as fission densities, etc.) to

incoming parameters (such as fuel mass in the elementary volume, bumup, nuclide composition, etc.) were

applied using computer code VWIMS-4D [39] or the same computer codes used within the framework of

procedures to calculate outgoing parameters (see sections 4.7, 4.8, 4.9).

To illustrate results of practical application of this method in the procedure of analyzing the energy deposition determination error in the fuel rod elementary volume, Table 4.10 contains sensitivity coefficients of

fission density for different isotopes.

Table 4.10. Sensitivity coefficient of the fission density in the elementary volume of fuel rod #H7T to

incoming parameters

Sensitivity coefficients of fission density for different isotopes

Incoming parameters (%)

U23 U 23 8 pu 2 3 9 pu24

Burnup -2.5 -0.54 -0.42 0.19

Fuel mass -0.21 0.5 -0.19 -0.19

U23` concentration 0.99 0.07 -0.004 -0.005

U238 concentration -0.1 1.13 -0.08 -0.09

pu2 39 concentration -0.12 0.42 0.88 -0.12

Pu24 1 concentration -0.01 0.06 -0.01 0.99

Results obtained using the procedure of determining energy deposition errors in the elementary volume of

fuel rods of C-, D-, E- types

Errors of determining the energy deposition in elementary volumes of fuel rods of C-, D-, E- types are

presented in Table 4.11 -Table 4.14.

In addition to final error values, Tables contain data on errors in all main parameters, which determine the

error in the energy deposition.

4.37
Table 4.11. Energy deposition error in elementary volume of fuel rod #H7T

Random error Systematic error

Incoming parameters 85y (X) k So(Xkd

% )( 0/0 ( 0/) 1 ( 1 1)

1.The kinetic energy of fragments (J/fiss.) 0 0 1.0 0.56

2.The energy deposition due to prompt ra- 0 0 20.0 0.86

diation per the number of fissions (J/fiss.)

3.The energy deposition due to delay ra- 0 0 20.0 0.86

diation per the number of fissions (J/fiss.)

4.The fission density in the central fuel pellet 4.4 4.4 2.1 2.1

of the E-type fuel rod as measured

(fissJg.fuel)

5.The fission density in the central fuel pellet 2.0 1.4 1.0 0.7

of the E-type fuel rod as calculated by

MCU code (fissjcm3)

6.Burnup (MWd/kg U) 5.0 4.9 3.5 3.4

7.Fuel mass (g) 4.8 0.92 1.3 0.25

8.The concentration of U235 in the fuel as 2.0 0.64 2.0 0.64

calculated by TRIFOB code (1/cm 3

)

9.The concentration of U238 in the fuel as 2.0 0.16 2.0 0.16

calculated by TRIFOB code (1/cm 3)

10.The concentration ofPu239 in the fuel as 2.0 0.72 2.0 0.72

calculated by TRIFOB code (1/cm3)

I l.The concentration of Pu24 1 in the fuel as 2.0 0.36 2.0 0.36

calculated by TRIFOB code (1/cm 3

)

12.The fission density of U235 in the fuel as 2.0 0.65 0 0

calculated by MCU code (fissJcm3)

13.The fission density of U238 in the fuel as 2.0 0.015 0 0

calculated by MCU code (fissJcm3

)

14.The fission density ofPu23 9 in the fuel as 2.0 0.95 0 0

calculated by MCU code (fissJcm3)

15.The fission density of Pu241 in the fuel as 2.0 0.38 0 0

calculated by MCU code (fissJcm3)

16.The thermal fission cross-section of U235 0 0 0.5 0.34

(cm)

17.The thermal fission cross-section of Pu239 0 0 0.5 0.24

(cm2)

18.The thermal fission cross-section of Pu24

"' 0 0 0.5 0.09

(cm2)

19.The temperature correction coefficient 0 0 3.0 0.30

(per-unit)

Total error ofenergy deposition is 12%

4.38
Table 4.12. Energy deposition error in elementary volume of fuel rod #B9T

Random error Systematic error

Incoming parameters 8 (xk) 8o I (

(%) ( _) (%) (%)

1.The kinetic energy of fragments (J/fiss.) 0 0 1.0 0.56

2.The energy deposition due to prompt ra- 0 0 20.0 0.86

diation per the number of fissions (J/fiss.)

3.The energy deposition due to delay ra- 0 0 20.0 0.86

diation per the number of fissions (J/fiss.)

4.The fission density in the central fuel pellet 4.4 4.40 2.1 2.10

of the E-type fuel rod as measured

(fissJg.fuel)

5.The fission density in the central fuel pellet 2.0 1.64 1.0 0.82

of the E-type fuel rod as calculated by

MCU code (fissJcm3

)

6.Burnup (MWd/kg U) 5.0 4.5 3.5 3.1

7.Fuel mass (g) 4.8 0.53 1.3 0.14

8.The concentration of U235 in the fuel as 2.0 0.52 2.0 0.52

calculated by TRIFOB code (1/cm 3)

9.The concentration of U238 in the fuel as 2.0 0.095 2.0 0.095

calculated by TRIFOB code (1/cm 3

)

10.The concentration of PuT3 in the fuel as 2.0 0.92 2.0 0.92

calculated by TRIFOB code (1/cm 3

)

11 .The concentration of Pu 24

1 in the fuel as 2.0 0.36 2.0 0.36

calculated by TRIFOB code (1/cm 3)

12.The fission density ofU235 in the fuel as 2.0 0.54 0 0

calculated by MCU code (fissJcm3

)

13.The fission density of U238 in the fuel as 2.0 0.026 0 0

calculated by MCU code (fissJcm3

)

14.The fission density ofPu239 in the fuel as 2.0 1.03 0 0

calculated by MCU code (fisslcm3

)

15.The fission density of Pu241 in the fuel as 2.0 0.40 0 0

calculated by MCU code (fissJcm3

)

16.The thermal fission cross-section of U2

35 0 0 0.5 0.36

(cm2)

17.The thermal fission cross-section of Pu 23 9 0 0 0.5 0.26

(cm2)

18.The thermal fission cross-section of PU24 1 0 0 0.5 0.1

(CM2)

19.The temperature correction coefficient 0 0 3.0 0.30

(per-unit)

Total error of energy deposition is 1 M

4.39
Table 4.13. Energy deposition error in elementary volume of fuel rod #H16T

Random error Systematic error

Incoming parameters & 8 N) 88 Bey (xd

.(%) (%) (%) (%)

1.The kinetic energy of fragments (J/fiss.) 0 0 1.0 0.91

2.The energy deposition due to prompt ra- 0 0 20.0 0.88

diation per the number of fissions (J/fiss.)

3.The energy deposition due to delay ra- 0 0 20.0 0.88

diation per the number of fissions (J/fiss.)

4.The fission density in the central fuel pellet 4.4 4.4 2.1 2.10

of the E-type fuel rod as measured

(fissJg.fuel)

5.The fission density in the central fuel pellet 2.0 1.44 1.0 0.72

of the E-type fuel rod as calculated by

MCU code (fissicm3)

6.Fuel mass (g) 0 0 0.5 0.36

7.The concentration of U235 in the fuel as 0 0 0.5 0.49

calculated by TRIFOB code (1/cm3 )

8.The concentration of U 2 38 in the fuel as 0 0 0.5 0.048

calculated by TRIFOB code (1/cm3)

9.The fission density of U23

" in the fuel as 2.0 2.0 0 0

calculated by MCU code (fissJcm3

)

10.The fission density of U238 in the fuel as 2.0 0.007 0 0

calculated by MCU code (fissJcm3)

11 .The thermal fission cross-section of U235 0 0 0.5 0.002

(cm2)

Total error ofenergy deposition is 8%.

4.10.3. Errors for the fuel rod power and t distribution of the energy deposition

The following functional dependencies were used to determine the power and the energy deposition of fuel

rods as a function of time (see section 4.8):

E (tk) M,

fi(t)dt

0

tk

E Ji(t)dt

E(tk)-- M

fi(t)dt

0

where P(tk) = the fuel rod power at the time tk (W);

E = the integral energy deposition in the fuel rod at the time t-oo (J/g fuel);

E(td) the energy deposition in the fuel rod at the time tk (J/g fuel);

i(td) = the ionization chamber current at the time tk (pA);

i(t) = the ionization chamber current at the time t (pA);

m = the fuel rod mass (g).

4.40
Table 4.14. Energy deposition error in elementary volume of fuel rod #B20T

Random error Systematic error

Incoming parameters &s 6sy M) 15 , ey (Xk)

(%) (%) (%) (%)

I .The kinetic energy of fragments (J/fiss.) 0 0 1.0 0.91

2.The energy deposition due to prompt radiation 0 0 20.0 0.88

per the number of fissions (J/fiss.)

3.The energy deposition due to delay radiation 0 0 20.0 0.88

per the number of fissions (J/fiss.)

4.The fission density in the central fuel pellet of 4.4 4.4 2.1 2.1

the E-type fuel rod as measured (fissig.fuel)

5.The fission density in the central fuel pellet of 2.0 1.6 1.0 0.82

the E-type fuel rod as calculated by MCU code

(fisslcm3)

6.Fuel mass (g) 0 0 0.5 0.40

7.The concentration of U235 in the fuel as 0 0 0.5 0.49

calculated by TRIFOB code (1/cm3)

8.The concentration of U 23

1 in the fuel as 0 0 0.5 0.047

calculated by TRIFOB code (1/cm 3)

9.The fission density of U235 in the fuel as 2.0 2.0 0 0

calculated by MCU code (fiss./cm3

)

10.The fission density ofU238 in the fuel as 2.0 0.011 0 0

calculated by MCU code (fiss./cm3)

11 .The thermal fission cross-section of U"5 (cm2

) 0 0 0.5 0.3

Total error of energy deposition is 8%.

4.10.4. Errors in z distributions of the energy deposition

This procedure is based on the following principles:

" the random error in the energy deposition for any axial section of the rod fuel stack is equal to the random

error in the energy deposition in the fuel rod elementary volume if the length of this axial section is equal

to the length of the axial section which forms the fuel rod elementary volume;

" the systematic error in the energy deposition in the axial section, determined by a corresponding

dimension in the fuel rod elementary volume, includes (in addition to the systematic error in the energy

deposition in the elementary volume) an additional error related to the MCU code error in calculating the

axial distribution of the neutron flux in the capsule.

According to calculations, when the additional systematic error is taken into account, the total energy

deposition error is increased not more than by 0.5 %.

4.10.5. Errors in r distributions of the energy deposition

According to the analysis, in comparison with the energy deposition error in the elementary volume, the total

error in r distributions of the energy deposition must take into account two additional factors:

" error reduction due to the averaging procedure of the energy deposition values in elementary volumes in

the volume of the radial zone;

" error increase due to the presence of an additional systematic error related to calculations of r distribution

of nuclide concentrations.

4.41
According to calculation results, both these factors practically compensate one the other, and the final errors

in r distributions agree within the accuracy of 0.2 % with the errors in the energy deposition in the

elementary volume of fuel rods of C-, D-, E- types.

Errors in parameters P(tk) and E(tk) were calculated in accordance with the procedure described in

section 4.10.1, calculation results are presented in Table 4.15, Table 4.16.

1

Table 4.15. Power error and energy deposition error vs. time for fuel rod #H7T

Power Power error Energy deposition

Time (s) (per-unit) Systematic Total error (%) Systematic Total error (%)

error (%) error (%)

0.60 0.01 5.1 12.6 4.5 12

1.90 0.05 5.1 12.6 4.4 12

2.45 0.10 5.1 12.6 4.4 12

3.10 0.50 5.1 12.6 4.5 12

3.40 1.00 5.0 12.5 4.4 12

3.70 0.50 5.1 12.6 4.4 12

4.00 0.10 5.1 12.6 4.5 12

4.15 0.05 5.1 12.6 4.4 12

5.50 0.01 15.6 24.2 4.4 12

Table 4.16. Power error and energy deposition error vs. time for fuel rod #B16T

Power Power error Energy deposition

Time (s) (per-unit) Systematic Total error (%) Systematic Total error (%)

error (%) error (%)

0.85 0.01 3.7 9.1 2.7 8

3.85 0.05 3.7 9.1 2.7 8

4.35 0.10 3.7 9.1 2.7 8

4.95 0.50 3.7 9.0 2.7 8

5.35 1.00 3.6 9.0 2.7 8

5.80 0.50 3.7 9.0 2.7 8

6.45 0.10 3.7 9.1 2.7 8

7.00 0.05 3.7 9.1 2.7 8

10.00 OM01 15.2 21.8 2.7 8

4.10.6. Summation of errors

According to the analysis of results obtained, the main contribution to the final error in determining the

energy deposition is made by experimental data (error in number of fissions measurements in central fuel

pellets of E-type fuel rods, error in the isotopic composition determination in high burnup fuel which, in its

turn, largely depends on the error in determining the burnup, etc.).

4.42
It should also be noted that errors related to the system of assumptions for the error assessment procedure

were not analyzed. This can only be carried out on the basis of special reference experiments with the aim of

qualifying this procedure.

4.11. Fuel enthalpy

Purpose and tasks of the procedure

Fuel rods of C-, D-, E- types were tested in IGR reactor under conditions when the power pulse was rather

wide (half pulse width about 700 ms). Therefore, only a part of the energy deposition was spent to increase

the fuel enthalpy, some heat was absorbed by the coolant due to the heat exchange between fuel rods and the

surrounding water. However, it is the enthalpy which is the licensing criterion determining the possibility of

fuel element damage in case of reactivity initiated accident.

Thus, the main purpose of this procedure was to determine the value set of peak fuel enthalpies for each fuel

rod of C-, D-, E- types by computer simulation of the thermo-mechanical fuel rod behavior under conditions

of capsule tests at IGR reactor. Detail analysis of this procedure, description of the computer codes used to

determine the fuel enthalpy are presented in Chapter 5.

4.43
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4.44
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[34] "Basic Physics of the Fission Process. Nuclear Fission Cross Section", Ed. by A.Michaudion, Oxford,

Pergamon Press, 1981.

[35] W.Engle. "A Users Manual for ANISN", Union Carbide Corporation, K-1693, 1967.

[36] T.Fowler, D.Vondy and G.Cunningham. "Nuclear Reactor Core Analysis Code: CITATION", USAEC

REPORT ORNL-TM-2496, Revision-2, ORNL, 1971.

[37] S.Marin, D.Markovsky, G.Shatalov. "Code for Calculations of Spatial Energy Distribution of Neutrons

in l-Dimentional Geometry (BLANK)", Rus., IAE "Kurchatov Institute", Report No. 2832, Moscow,

1977.

[38] K.Tasaka et.al "JNDS Nuclear Data Library of Fission Products", JAERI-1287, 1983.

[39] J.Askew et.al "A General Description of the Lattice Code WIMS", J. of the Brit. Nucl. Energy Soc.,

Vol.5, p.564, 1966.

[40] Under the editing of R.Vasiliev. "Metrology of Neutron Measurements at Nuclear Facilities

(Recommended information and measurement procedures) ", Vol.2, Central Scientific Research Institute

of Information and Feasibility Studies in the Field of Nuclear Science and Technology, Moscow, 1976.

[41] Himmelblau. "Process Analysis by Statistical Methods", J.Wiley and Sons, ING, New York, London,

Sydney, Toronto, 1970.

4.45
[42] V.Boliatko et.al "Errors in Calculations of Protection Versus Irradiation", Rus.,. Moscow,

Energoatomizdat, 1983.

[43] L.Usachev. "Disturbances Theory for Reproduction Coefficient and Other Ratio of Numbers for Reactor

Processes", Rus., At. Energia, Vol.15, Iss.6, 1963.

4.46
5. COMPUTATIONAL ANALYSIS OF FUEL ROD BEHAVIOR AT IGR/RIA

TESTS

5.1. Formulation of a problem

Technical requirements to the list of parameters required for the development of the data base within the

framework of the computational analysis are presented in Chapter 1 of this Volume together with a brief

characteristic of FRAP-T6 [1] and SCANAIR [2] codes that were selected as instruments for the

computational analysis.

The next stage of studies covered the applicability assessment of these codes to achieve this goal. The

consolidated list of main physical phenomena that determine the behavior of high burnup fuel rods in IGR

tests and code capabilities in describing these processes are contained in Table 5.1. According to the

analysis, none of the codes has a complete set of models required for the description of IGR test results.

Table 5.1 Physical phenomena and capabilities of codes

Code possibility to model a

Physical phenomenon physical phenomenon

FRAP-T6 SCANAIR

1. Parameters of high burnup fuel before IGR tests (at the end of No No

fuel cycle)

2. Geometry of VVER fuel rod No Yes

3. Heat transfer in fuel rod with account for heat conductance Yes Yes

through fuel-clad gap

4. Clad-to-coolant heat transfer for the following coolants:

* water Yes Yes

" air No No

5. Behavior of gas inside a fuel rod Yes Yes

6. Cladding oxidation Yes No

7. Cladding and fuel melting, chemical interaction and relocation No"• No

8. Fission product release Yes Yes

9. Fuel hoop strain due to:

" swelling No Yes

" thermal expansion Yes Yes

e plasticity No Yes

10. Plastic cladding hoop strain due to:

* pellet/cladding mechanical. interaction (PCMI) Yes Yes

* gas pressure inside a fuel rod Yes No

11. Cladding failure due to:

9 PCMI No No

9 ballooning Yes No

* melting No') No

') Code allows to predict initiation of these processes, but does not contain models, describing their evolution.

5.1
Therefore, a series of special code modifications was performed during the studies to adapt the codes to IGR

test conditions. The main attention was paid to the development of a modified data base that characterizes

material properties of VVER fuel rods. This work required the conduct of new additional experimental

studies to get original mechanical properties of unirradiated and irradiated claddings. The validation of codes,

was the final stage of studies. This procedure was implemented in two stages. The first stage included the

verification of intermediate code versions. Results of the second stage allowed to finally determine the

region of the applicability of each code and to develop the procedure of their practical use within the

framework of results presented in Volume 3 of the Report.

5.2. Assessment of required input data on VVER material properties to calculate

IGR tests with FRAP-T6 and SCANAIR codes

A specific problem of these studies was related to the fact that MATPRO-VI 1 [3] library of properties is

used in FRAP-T6 code and the original input data base is used in SCANAIR code to describe material

properties of the cladding and of the fuel. At present, MATPRO-V 1 is probably the most complete data

base characterizing physical and mechanical properties of fuel claddings made of Zircaloy 2, 4 alloys and

U0 2 fuel of PWR type. SCANAIR code library of properties combines the data base that is partially based

on MATPRO library and partially - on packages of properties developed for earlier French codes ; moreover

it includes results of special experiments conducted in France. SCANAIR library, as well as MATPRO, is

intended to describe properties of PWR fuel rods.

This is why two problems arose within the framework of the task of describing the behavior of high bumup

fuel rods during the IGR tests. The first one was the modification of libraries as applied to properties of

VVER materials. The second problem was related to the fact that the practical study of characteristics of

commercial high bumup fuel elements and their testing under RIA conditions have started simultaneously

only recently. Therefore, results of studies intended to investigate corresponding material properties have not

yet been included into the above libraries.

Thus, the validation of the approach to develop the data base with material properties for IGR tests was

conducted taking into account both problems. It should be noted that the development of a full-scale

specialized data base with VVER material properties is far beyond the scope of the present study. Therefore,

the approach based on an integrated use of the following procedure was applied:

" expert judgments of the necessity of using VVER original properties in each considered case;

" preliminary sensitivity analysis of codes to properties selected on the basis of expert judgments;

" modification of code libraries by introducing VVER original properties that have been obtained earlier

and been published;

" development and implementation of special studies to get missing data on properties.

Results of the first stage of this procedure are schematically presented in Table 5.2. It is important to

underline that the following considerations formed the basis of the obtained expert judgments. As for fuel, it

is obvious that differences in technological processes of manufacturing PWR and VVER fuel pellets result in

certain differences in their initial characteristics. Particular features of power operating cycles can cause

additional differences. However, it should be noted that quantitative differences in properties of fresh fuel are

small, and a modem data base for high burnup fuel still does not exist. Moreover, it was taken into account

that the accurate knowledge of fuel characteristics is of a principle importance during the interpretation of

RIA tests scenarios for the stage of the mechanical fuel - cladding interactions. However, a particular feature

of IGR/RIA tests is the cladding rupture of ballooning type. In other words, the failure of cladding occurs

due to gas pressure effects on the fuel cladding. In this case a significant effect from the fuel side is the heat

flux to the cladding. This is why at the stage of the expert judgment, it was decided to introduce, into

libraries, the models which characterize the thermal conductivity and specific heat of the high burnup fuel.

Regarding cladding properties, differences in the composition of Zircaloy and Zr-1%Nb alloys can result in

more significant differences in properties. Therefore it was decided to get additional information on the

relevance of the problem by conducting the sensitivity analysis of codes to material properties of the fuel and

the cladding. The sensitivity analysis was performed for the following set of material properties:

5.2
Cladding

" specific heat;

" specific enthalpy;

" thermal conductivity;

• thermal expansion;

* Young's modulus;

* Poisson's ratio;

• and other parameters of stress-strain diagrams.

Fuel

" specific heat;

" specific enthalpy;

" thermal conductivity;

" thermal expansion;

" Young's modulus;

" Poisson's ratio;

" yield stress.

Table 5.2. Material properties required to calculate fuel rod behavior in IGR test with computer codes

Material properties I Expert estimation to

correct data base for

WER cladding and fuel

1.1.

1.2.

1.3.

1.4.

1.5.

1.6.

1.7.

1.8.

1.9.

Thermal physical constants

Specific heat

Thermal conductivity

Density

Specific enthalpy

Oxidation

Emissivity

Mechanical properties

Yes

Yes

Yes

No

Yes

Yes

No

Yes

Thermal expansion Yes

2.1.

2.2.

2.3.

2.4.

2.5.

2.6.

2.7.

Thermal physical constants

Specific heat

Thermal conductivity

Density

Specific enthalpy

Emissivity

Thermal expansion

No

Yes

Yes

No

Yes

No

Yes

The objective of the first stage of research of the sensitivity analysis was comparison of the data base

characterizing the above VVER material properties with the similar data bases presented in MATPRO and

SCANAIR codes. Results of this comparison are presented in Fig. 5.1-Fig. 5.5.

5.3
1000 

600

1000 600

750

1500

250

0

400

200

0

400 800 1200 1600 2000

Temperature (K)

a)

0 500 1000 1500 200(

Temperature (K)

b)

60

.~40

120

0

0.6

0.3

0 500 1000 1500 2000

Temperature (K)

C)

0 500 1000 1500 200(

Temperature (K)

d)

Fig. 5.1. Specific heat (a), specific enthalpy (b), thermal conductivity (c), thermal expansion (d) vs.

temperature for unirradiated Zry and Zr-l%Nb

5.4
Fig. 5.2. Young's modulus (a), Poisson's ratio (b), yield stress (c) vs. temperature and ZrO2 thickness

(d) vs. time for unirradiated Zry and Zr-1%Nb

5.5
800

600

5 400

200

0 500 1000 1500 2000

Temperature (K)

a)

2500 3000 3500

12

9

S

*1~

I

6

E CANAIR

N-kTPR

3

0

0 500 1000 1500 2000

Temperature (K)

2500 3000 3500

b)

Fig. 5.3. Specific heat (a) and thermal expansion (b) for unirradiated fuel of PWR and VVER type

5.6
10

j

A

8

6

4

2

0

0 500 1000 1500 2000 2500 3000

Temperature (K)

3500

10

I

A

8

6

4

2

0

Burnup 30 U/~1

E s rCANAI

0 500 1000 1500 2000 2500 3000 3500

Temperature (K)

10

I

A

8

6

4

2

0

0 500 1000 1500 2000 2500 3000

Temperature (K)

3500

Fig. 5.4. Thermal conductivity of uranium dioxide fuel vs. temperature and burnup

5.7
Fig. 5.5. Thermal expansion (a), Young's modulus (b), Poisson's ratio (c), and yield stress (d) vs.

temperature for unirradiated fuel of PWR and VVER type

Comparative analysis of the whole batch of material properties necessary for the IGR test simulation

indicated that:

" in some cases there exist significant discrepancies in the three data bases (MATPRO-V 11, SCANAIR,

VVER);

" MATPRO and VVER databases have not been renewed for a long time;

" there exists the deficiency of the data characterizing the properties of irradiated claddings and high

burnup fuel;

" there exists the lack of the necessary scope of data characterizing material properties under fast transient

conditions;

" some of the data are missing in the data bases.

5.8
With consideration of these remarks the program for the second stage of the work on sensitivity analysis was

targeted at assessing the scope of consequences which can be caused by uncertainties of the input data on

material properties.

Sensitivity analysis was done in the framework of a very simple procedure; hence the obtained results are a

very preliminary nature.

This procedure was based on the standard perturbation by ±20% deviation in all values of each property

under consideration. The procedure was sequentially applied to each property; then the code response was

observed in accordance with the selected list of output parameters.

The set of the main output parameters included fuel enthalpy, clad temperature, clad stress. #HIT high

burnup fuel rod was selected for the study in order to perform the sensitivity analysis procedure. Evaluation

of the results obtained with the help of this procedure is presented in the report for two groups of material

properties:

" basic group includes thermal-physical properties, Young's modulus, Poisson's ratio for cladding and fuel,

yield stress for fuel;

" mechanical group includes the cladding mechanical properties to describe the stress-strain diagrams.

Results of sensitivity analysis of FRAP-T6 and SCANAIR codes to the basic group of material properties

It is important to note that the presented evaluation of the results of sensitivity analysis of FRAP-T6 and

SCANAIR codes to the basic group of material properties, obtained for # HIT fuel rod are of great value.

This fuel rod was tested under the conditions close to the failure threshold, but the threshold was not reached.

That is why, theoretically even the slight change of the input data can result in the qualitatively and

quantitatively different output parameters.

Summarizing of the results obtained by the basic group of material properties allowed to make the following

conclusions:

" Two parameters of this group are the decisive ones from the standpoint of their influence onto the output

parameters. These are: fuel specific heat, and fuel thermal conductivity.

* Response of output parameters to 20% disturbance of the other basic properties has the following values:

SCANAIR FRAP-T6

= peak fuel enthalpy not more than ±1.2% ±1.3%;

= cladding temperature not more than ±3.2% ±2.0%;

=> cladding stress not more than ±3.4% ±2.6%.

Table 5.3 contains some results characterizing response of some output parameters to the disturbances

introduced as the input for fuel specific heat and fuel thermal conductivity.

These results are graphically presented in Fig. 5.6 for specific heat of fuel.

Table 5.3. Response of output parameters of codes to the disturbance of some input parameters

Response of output parameters') (%)

Input Peak fuel enthalpy Peak clad temperature Peak clad hoop stress

parameters () 0%) (%)

FRAP-T6 SCANAIR FRAP-T6 SCANAIR FRAP-T6 SCANAIR

1. Fuel specific +20% +2.4 +4.5 -6.2 -6.9 +8.5 +5.0

heat -20% -4.5 -5.8 +5.2 +7.7 -1.4 -3.7

2. Fuel thermal +20% -1.1 -1.3 +1.3 +3.8 +10.6 +8.2

conductivity -20% -0 +1.7 -2.1 -5.5 -4.2 -12.0

I) Response was determined as relative deviation from normal value of parameter

5.9
FRAP-T6 code SCANAIR code

code SCANAIR code

I

200

150

100

50

0

ý1z

200

150

100

50

0

0 1 2 3

Time (s)

4 5

Time (s)

1200

800

400

1600

1200

400

0 0

0 1 2 3 4 5

Time (s)

0 1 2 3 4 5

Time (s)

I

I'

0

500

400

300

200

100

0

700

600

500

400

300

200

100

0

I~d q'~i ~ fi ll.

5 0 1 2 3

T7me (s)

4 5 0 1 2

Tine (s)

3 4 5

Fig. 5.6. Response of fuel enthalpy, clad temperature and hoop stress to 20% disturbance of the fuel

specific heat

5.10
On the whole analysis of results obtained for the basic group of material properties allowed to work out the

following recommendations:

" specific heat and thermal conductivity of the WER fuel are to be certainly included into the MATPRO

package and SCANAIR input block;

" adding of the rest of VVER properties to the MATPRO package and SCANAIR input block is a desirable

but not compulsory procedure;

" peak fuel enthalpy is the least sensitive output parameter; in the some cases cladding temperature and

cladding hoop stress can be sensitive enough to the uncertainties in material properties, that is why the

results of computer simulation of WER fuel rod performance are to be analyzed with consideration of

the material properties problem.

Results of sensitivity analysis of FRAP-T6 and SCANAIR codes to the mechanical group of material

properties of the cladding

The problem of sensitivity analysis of the code output parameters in respect to the set of the cladding

mechanical properties is far beyond the framework of this report because those properties depend in their

turn on a great number of factors characterizing not only the cladding composition, but also the technology

of its manufacture, irradiation conditions, loading conditions, etc. That is why only some preliminary

assessments were made during this stage.

It is also necessary to remember that this group of properties is presented in the SCANAIR input block and

in MATPRO-V1 1 package differently. Hence, the sensitivity analysis procedure was developed for each

code independently.

Input block for SCANAIR code contains three parameters characterizing mechanical properties of the

cladding. There are Young's modulus, Poisson's coefficient and yield stress. The only difference from

previous analysis was that the 30% initial disturbance was specified. Response of output parameters to 30%

disturbance of Young's modulus and Poisson's ratio does not exceed 1%. Fig. 5.7 presents the responses of

output parameters to clad yield stress disturbance.

Data presented in Fig. 5.7 indicate that sensitivity assessment of the code to the cladding mechanical

properties is not unique and universal, i.e. thermal characteristic of fuel rods reacts weakly onto the

uncertainty specified by the cladding mechanical properties. Still peak cladding hoop stress changes by (+6; -

14) % in case of 30% disturbance of the yield stress. That means that the issue is of principal importance

when prediction of parameters characterizing fuel rod failure is a part of the tasks to be solved by this

computer code. It should be additionally noted that in this case we analyzed the situation when the cladding

failure can be only due to PCMI mechanism. Physical phenomena following cladding failure of ballooning

type can be analyzed by FRAP-T6 code.

MATPRO=VI 1 code which is used by FRAP-T6 code as the input data package does not contain mechanical

properties as functional dependencies for the yield stress, ultimate strength, uniform elongation, etc.

This code operates with a number of K, n, m functionals characterizing relationship between stress and strain

not only as the function of temperature, but also with consideration of the cladding cold work, burnup,

oxidation, strain rate, fast flux. Strength coefficient K, and strain hardening exponent n allow to describe

stress-strain power law for the basic cladding strain rate, and strain rate sensitivity exponent m allows to

consider the influence of the loading conditions for different cladding strain rate. Detailed description of the

MATPRO approach in order to characterize cladding mechanical properties is presented in Chapter 6,

section 6.4.

With consideration of the above mentioned 30 % disturbance of K, n, and m functionals was performed with

the already described procedure and responses of output parameters for the fuel rod #HIT were found. These

responses are presented in Fig. 5.8-Fig. 5.10.

5.11
160

120

I

80

40

I

200

150

100

50

I

0

1600

1200

800

400

0

800

600

0 1 2 3 4 5

Time (s)

0 1 2 3

Time (s)

4 5

Time (s)

0

Il

0 1 2 3 4 5

Time (s)

1400

200

0 1 ' --I w----i i I I = 0 1 2 3 4 5

Tlme (s)

Fig. 5.7. Response of fuel enthalpy, clad temperature and clad hoop stress calculated by

SCANAIR code to the 30% disturbance

of clad yield stress

0 1 2 3 4

Tune (s)

Fig. 5.8. Response of fuel enthalpy, clad temperature, clad hoop stress calculated by

FRAP-T6 code on 30% disturbance of

strength coefficient K

5.12
I

200

150

100

50

0

2c ~-30%

/ I

200

150

100

50

0

0 1 2 3

Time (s)

4. 5 0 1 2 3

Time (s)

4 5

I

0

0 1 2 3

Time (s)

4 5

09

0 1 2 3

Time (s)

4 5

0 1 2 3 4 5

Time (s)

Fig. 5.9. Response of fuel enthalpy, clad temperature, clad hoop stress calculated by

FRAP-T6 code on 30% disturbance of

strain hardening exponent n

0 1 2 3 4 5

Tune (s)

Fig. 5.10. Response of fuel enthalpy, clad temperature, clad hoop stress calculated by

FRAP-T6 code on 30% disturbance of

strain rate sensitivity exponent m

5

5.13
Analysis of the obtained data shows that just like in the SCANAIR code the highest sensitivity to the

uncertainty of the input data is demonstrated by the cladding hoop stress, its peaking response to the 30%

disturbance being:

47% for strength coefficient;

13% for strain hardening exponent;

10% for strain rate sensitivity exponent.

That is why the following final conclusion can be made based on the results of this type of research: correct

prediction of the deformation behavior of the high burnup fuel rod under the conditions of the pellet-cladding

mechanical interaction can be assured in case we know the cladding mechanical properties very accurately.

But the codes sensitivity analysis to the cladding mechanical properties performed on the basis of the fuel

rod #H1T can not be considered sufficient because the issues connected with the cladding failure of

ballooning type were not reviewed in this case. The following procedure was developed in order to evaluate

this effect:

1. Energy deposition was artificially increased in HIT fuel rod up to the value when FRAP-T6 code

predicted cladding failure due to ballooning.

2. 30% disturbance was specified sequentially for the K, n, m functionals. The value of energy deposition

resulting in the cladding failure due to ballooning was selected for each six variants of the input data.

3. Additive effect of the cladding hardening influencing the peak fuel enthalpy was also reviewed by the

simultaneous increase of K and n by 30%.

4. Peak fuel enthalpies characterizing fuel rod failure were identified for each case.

5. Relative deviations of peak fuel enthalpies from the value reached according to item I were identified and

presented in Table 5.4.

Table 5.4. Response of peak fuel enthalpy in case failure due to ballooning onto disturbances of the

cladding mechanical properties

Input parameter disturbance (%)

Response of output K n m K, n

parameter

+30 -30 +30 -30 +30 -30 +30

Relative deviation of

peak 

peakife fuel enthalpy enthaipy of (*/) +9 -22 +7 -5.5 +5.6 -6 +21

One of the variants of this procedure is graphically presented in Fig. 5.11.

Analysis of results obtained in the framework of the developed procedure leads to the conclusion that

reliability of the computational data base characterizing WER fuel rod performance can be ensured only in

case original properties of the WER cladding are used. That is why we worked out and performed the

special cycle of the studies aimed at getting the data base with mechanical properties of unirradiated and

irradiated VVER cladding versus temperature and strain rate. Results of this work are discussed in detail in

Chapter 6.

5.14
3

2 0- ~ful etalpy (+3(P) 0

-- .. 200 -,

100

0

0 2 4 6 8 10

Time (s)

Fig. 5.11. Response of fuel enthalpy and internal gas pressure on 30% disturbance of K and n

5.3. Specific requirements for computer codes to simulate geometry of VVER fuel

rods and IGR test conditions

The central hole in fuel pellets of VVER fuel rods is the specific feature that makes its geometry different

from PWR fuel rods. According to the computer code analysis, it is possible to simulate this type of fuel rods

in SCANAIR code and FRAP-T6 codes.

The next problem was related to the fact that VVER fuel rods tested in IGR reactor had an extended upper

gas plenum that is not provided for in SCANAIR code. The neglect of this feature resulted in a principally

incorrect description of gas parameters inside the fuel rod. Thus, it will be necessary to develop special

procedures to eliminate this shortcoming.

A non-standard requirement was set for codes regarding those IGR tests when the air was used as the

coolant. Special modules were developed for both codes to calculate the fuel rod behavior in these tests.

And finally, a serious problem was related to the fact that the usual set of input data that characterizes the

fuel geometry and the material composition is not sufficient for the simulation of the behavior of high burnup

fuel under power pulse conditions. In this case it is necessary to know not only the r, z distribution of fissile

isotopes, but also the spatial distribution of fission products in the fuel after the base irradiation. The

preparation of corresponding input data for SCANAIR code was conducted using TOSUREP code [11] that

is intended for these purposes and has the coupling with SCANAIR code. FRAPCON-2 code [12] is usually

used to prepare similar data for FRAP-T6 code. Unfortunately this code was not available to the authors of

the Report. However it is known that some researches expanded the application range of FRAP-T6 code to

include calculations of fuel rod characteristics at NPP base-irradiation modes [13, 14]. Therefore, a similar

approach was used within the framework of the present work. In this case a special attention was paid to the

verification of calculational results obtained at the first stage. Verification procedures consisted of several

stages including the comparison of calculated results with both, experimental data and results of calculations

using TOSUREP, TRIFOB [15] codes. Detailed description of corresponding procedures and obtained

results are contained in subsequent sections of this Chapter.

5.15
5.4. Development of IGR/VVER version of FRAP-T6 code

5.4.1. Description of FRAP-T6 code

FRAP-T6 code was developed to calculate the behavior of LWR fuel rods during reactor transients and

accidents such as loss-of-coolant and reactivity initiated accidents [1]. The code allows to predict the fuel rod

behavior as a function of the fuel rod power, coolant boundary conditions, burnup and to simulate the

following main physical phenomena:

" heat conduction;

" heat transfer from cladding to coolant;

" elastic fuel deformation;

" elastic-plastic cladding deformation;

" creep of cladding;

" fission gas release;

" fuel rod pressure;

" cladding failure due to stress corrosion cracking, cladding-pellet mechanical interaction, ballooning.

Fig. 5.12 shows the order of the general models in FRAP-T6 code. The calculation cycle starts with the

determination of the temperature of the fuel and cladding in each calculation node of the fuel rod.

Then, the following parameters are sequentially calculated:

" gas temperature in the gas plenum;

" the stresses and strains in the fuel and cladding;

" the gas pressure inside fuel rod.

The entire calculation cycle is repeated until conditions, set in the numerical scheme, are satisfied. After that,

calculations of the cladding oxidation, cladding ballooning and fission gas release are conducted. Iterative

procedures allow to take into account the influence of calculation results in each model on other models.

In a general case the calculation of the fuel pin performance under NPP transient conditions is conducted by

coupling FRAP-T6 code with FRAPCON-2 and SCDAP/RELAP5/MOD3 (or TRAC-FI) codes [12, 16, 17].

This procedure is schematically presented in Fig. 5.13. In this case FRAPCON-2 code provides the

calculation of initial conditions for the fuel pin as a function of the burnup; SCDAP/RELAP5/ MOD3 or

TRAC-PF1 codes calculate thermal-hydraulic boundary conditions. However the structure of FRAP-T6 code

allows to set thermal-hydraulic boundary conditions independently using corresponding options of the code.

In this case there is no need in using SCDAP/RELAP5/MOD3 or TRAC-PFI codes.

It should be noted that FRAP-T6 code does not have an original data base to describe fuel rod material

properties. For this purpose MATPRO-V II is used [3]. The MATPRO-V I1 material properties package

allows to calculate thermal and mechanical properties of urani~um oxide fuel and Zircaloy-4 cladding up to

the melting temperature.

Properties of helium and fission gases are also calculated using the same code package. FRAP-T6 code has a

direct interface with MATPRO-V11 package.

Regarding the FRAP-T6 code application region, the analysis shows that FRAP-T6 code and MATPRO-VI 1

codes are well adapted and verified for steady-state and slow transient conditions. The set of material

properties and other physical correlations that take into account fast transient conditions is significantly less

complete. Thus, the analysis of fuel rod behavior by FRAP-T6 code under RIA conditions requires a special

attention and must be accompanied by special verification procedures. These comments are relevant also to

tasks related to calculations of high burnup fuel rods. Since the last version of MATPRO package was

developed in 1981, it does not contain many material properties that characterize conditions of commercial

fuel rods.at burnups of 50 MWd/kg U and higher obtained in more recent years.

5.16
New time step

Fig. 5.12. Order of general models [11

5.17
FRAPCON-2

Calculated bumup-dependent

fuel pin initial conditions

Initial values of.

* released fission gas inventory

" retained fission gas inventory

" permanent cladding strains

" cladding oxide thickness

" amount of open fuel porosity

SCDAP/RELAP5 or TRAC-PF1 FRAP-T6

Calculates primary system thermal- Steady -state case run to provide

hydraulic response, including: initial steady - state conditions

* primary system pressures, tem- for SCDAP components

peratures, void distributions

* break flow

* core thermal-hydraulics

* containment isolation signal e Initial gap conductance

timings * Initial gap gas pressure

e fuel pin ballooning and rupture e Radial temperature profile

Time-dependent tables of:

* bulk thermal-hydraulic conditions in

core nodes and core inlet and outlet

volumes

" coolant mass flux in core nodes

" fuel pin power distribution

[ ~FRAP-T6

Calculated transient

L fuel performance

Fuel pin failure timing

Fig. 5.13. Flow chart of methodology using FRAP-T6

5.4.2. Preliminary adaptation of FRAP-T6 code to analysis IGR/RIA tests

Formulation of the problem to adapt the FRAP-T6 code to IGR/RIA tests included the following working

areas:

1. Account of design features of the fuel rod and the test capsule that were not provided for in the

specification of input data, and the optimization of the calculational scheme.

2. Outline of FRAP-T6 models to calculate VVER fuel rods performance under IGR test conditions.

3. Development of new models and modification of FRAP-T6 models.

5.18
4. Outline of MATPRO-V1 1 code models required to calculate PWR fuel rod performance under IGR test

conditions.

5. Modification of MATPRO-V I1 models taking into account original material properties for VVER fuel

rods.

6. Verification of FRAP-T6 version adapted for VVER fuel rods and IGR test conditions.

In accordance with these items, the first stage of the work was implemented to adapt FRAP-T6 code and

MATPRO-VI 1 package for VVER fuel rods tested in IGR reactor. The schematic list of these activities is

presented in Table 5.5.

Table 5.5. List of codes modifications

Research position ,Set of actons'Y~

Adaptation of * Account of central hole in fuel pellet

1. calculational scheme • Account of material mass in upper gas plenum

for fuel rod Optimization of axial meshing in calculational scheme

* Heat transfer from cladding to air

S FRAP-T6imodelsf * Oxidation of Zr- 1%Nb cladding

* Correction of axial length of ballooning region in correspondent model

* Thermal physical constants for unirradiated Zr-lNb

* Thermal conductivity, specific heat, enthalpy of unirradiated Zr-I %VNb

Modification of * Poisson's ratio, Young's modulus, thermal expansion of unirradiated

3. MATPRO-V11 Zr-iNb

package

e thermal conductivity of VVER high burnup fuel

* specific heat of VVER fuel

The analysis of presented data shows that at the first stage of FRAP-T6 adaptation it was impossible to solve

one of the most important problems listed in Table 5.5 related to the modification of the data base on

material properties of Zr-lNb. This is the problem of replacing Zry mechanical properties by

corresponding properties of Zr-1%Nb, including properties of irradiated Zr-1%Nb claddings as a function of

not only the temperature, but also of the strain rate, which is important for the interpretation of IGR/RIA

tests. It was impossible to solve this problem because there is no corresponding data base available for

Zr-l%Nb claddings. Thus, a decision was made to conduct a special cycle of experimental studies to obtain

the required data. A detailed discussion of these studies is presented in Chapter 6 of this Volume. The

obtained data base formed the basis for the modification of FRAP-T6 and MATPRO at the stage of the final

adaptation of FRAP-T6 code for VVER fuel rods.

The final stage of the work cycle on the preliminary FRAP-T6 adaptation was the verification of the code

version obtained. The characteristic of the experimental data base used for the verification is presented in

section 5.9 of this Volume. Verification procedures were primarily focused on checking the correctness of

rod cladding temperature calculations. The analysis of first verification calculations demonstrated that

Bromley-Pomerantz model [18], recommended in FRAP-T6 code for the description of the heat transfer in

post-critical heat flux (post-CHF) region, lead to unacceptable results (see Fig. 5.14). This conclusion forced

us to look for an, alternative model that takes into account the subcooling effect. Modified Labuntzov model

was selected as the alternative model [19, 20]. This model takes into account the subcooling effect [21] and

is intended for the simulation of the heat transfer under film boiling conditions. The use of this model

allowed to get rather good results for the simulation of all heat transfer modes up to rewetting phase (see Fig.

5.15). The comparison of experimental and calculated results shows that Labuntzov model overestimates the

duration of the film boiling and, consequently, overestimates the cladding temperature. The rewetting phase

begins significantly earlier in the experiment.

5.19
Fig. 5.14. Comparison of the measured clad outer temperature and calculated by FRAP-T6 with

Bromley-Pomerantz model

-- Clad outer temperature (measurd

A& Clad outer temperatur (calculated)

1500

0 2 4 6 8 10

Tune (s)

Fig. 5.15. Comparison of the measured clad outer temperature and calculated by FRAP-T6 with

Labuntzov model

The next verification stage was the comparison of measured and calculated values of the cladding

temperature for tests with the air coolant. Promising results were obtained for this case. The outcome of the

preliminary adaptation of FRAP-T6 code for the behavior analysis of VVER fuel rods under IGR test

conditions was the understanding that, in order to consider the FRAP-T6 adaptation to be successful, it is

necessary to perform a serious modification of the model of the post-CHF heat transfer and to obtain

mechanical properties of Zr-lNb claddings. During subsequent studies these two problems were solved to

a significant extent and the original version of FRAP-T6 code was developed to simulate IGR tests.

5.20
5.4.3. Description of FRAP-T6 version to predict VVER fuel rod performance under IGR

test conditions

5.4.3.1. Calculational scheme

As it was noted in Section 2.1 three types of fuel rods were tested in IGR reactor:

" fuel rods with high bumup fuel and irradiated cladding (C-type);

" fuel rods with fresh fuel and irradiated cladding (D-type);

" fuel rods with fresh fuel and unirradiated cladding (E-type).

From the point of view of the geometry, the design of all three types of fuel rods was similar. Thus, a

common approach was developed for all types of fuel rods. The following assumptions formed the basis of

the calculational scheme of WER fuel rod:

" fuel and cladding are of cylindrical form and are arranged axisymmetrically;

* initial fuel diameter, cladding thickness and gap width are constant on the axial coordinate;

" there are no changes in the fuel density and composition along the fuel rod height and radius;

" only the active part of the fuel rod is simulated.

The geometrical scheme of VVER fuel rod including the meshing scheme is presented in Fig. 5.16. The

calculational scheme of the fuel rod consists of the fuel stack with the central hole, cladding, fuel-cladding

gap, lower and upper plenums and pseudo spring. The meshing scheme determines axial and radial

calculational nodes.

upper gas plenum

NZj

cladding Nz-1.

fuel-clad gap

fuel pellet

central hole.I

coolant

m axial node - radial node

lower gas plenum

Fig. 5.16. Calculational scheme of fuel rod

The optimization procedure was used to determine meshing parameters for WER fuel rod.

The sensitivity of calculated parameters to meshing conditions was used as the optimization criterion. As a

result, the following characteristics of the calculational scheme were obtained:

" axial nodes: 10

" radial nodes: 31, including

5.21
fuel: 25

cladding: 6

* time step during fast transient: 1 - 5 10.3 s

* time step during slow transient: 5 10. - 1.0 s

* accuracy parameters of the numerical

solution:

fuel temperature ±1 K

number of iterations in calculations of the gas pressure and radial 200

temperature distribution

relative difference between two

iterations (criterion to stop the 0.1%

calculation)

The design of the test capsule, in which the VVER fuel rod was placed during tests in IGR reactor, was not

simulated by FRAP-T6 code. All calculations were performed under the assumption that the fuel rod is

surrounded either by an infinite volume of stagnant water under normal initial conditions, or by an infinite

volume of air under the same conditions.

5.4.3.2. Input data to characterize the geometry of VVER fuel rods and IGR test

conditions

VVER fuel rods

The set of characteristics that were used to form the input data in FRAP-T6 code is presented in Table 5.6.

The table contains also a brief description of methods that were used to get individual input data for each

VVER fuel rod. Measured parameters for each fuel rod were taken from Appendix C, D and E of Volume 3.

Regarding the material composition of fuel rods, it was assumed that the uranium dioxide is the material of

the fuel pellet, and Zr-l%Nb alloy is the material of the cladding, and He is the gas inside fuel rod.

Other components of the high burnup fuel (fission products) were taken into account, if necessary, by using

material properties for high burnup fuel. Special input data were developed for the calculation module that

describes the fission product release. These issues are discussed in more detail in the following Section of the

Report.

IGR test conditions

In addition to initial data for the coolant, parameters that characterize the power of each fuel rod were used

as input data. These parameters allow to describe r, z, t distributions of the fuel rod power using the

following data base presented in Appendixes G, H, I of Volume 3 of the Report:

* power time history;

" axial power profile;

" radial power profile.

As it has been noted earlier, the adjustment of FRAP-T6 module that describes the radial power profile was

performed to take into account the central hole in the fuel pellet.

5.22
Table 5.6. Set of input data on fuel rod design

Parameters of fuel rod Method to determine the parameters for WER fuel rods

I. Fuel rod data

1.1. Fuel stack cold length as measured

1.2. Cold fuel rod outer diameter as measured

1.3. Cold state fuel rod temperature 293 K

1.4. Gas gap radial thickness as measured and estimated

2. Pellet data

2.1. Cold state pellet height It was calculated in the assumption that fuel stack consists

of 10 pellets

2.2. Cold state pellet dish volume It was calculated taking into account the pellet geometry

2.3. Pellet outer diameter as measured

2.4. Pellet inner diameter as measured

2.5. Pellet surface roughness estimated according to [32]

2.6. Fraction of theoretical density It was calculated taking into account the data on 2.7

2.7. Fuel density as measured

3. Cladding data

3.1. Inner surface roughness estimated according to [32]

3.2. Cladding thickness It was calculated taking into account the cladding outer

diameter, pellet outer diameter, gas gap thickness

4. Plenum data

4.1. Upper plenum volume as measured

4.2. Lower plenum volume as measured

4.3. Initial gas composition He

4.4. Initial gas pressure as measured

In-the current version of FRAP-T6 code, the integral of the relative power in the pellet area is calculated as

follows:

2xr2

f fP(r,O)rdrdO

0 =10.01,

Yr(r22 _-r2)

where P(r, 0) = normalized radial power factor at r, 0,

r = current pellet radius;

0 = azimuthal angle;

r, = pellet inner radius;

r2 = pellet outer radius.

5.23
Materials properties

MATPRO-V1 1 package was used to form input data required for the calculation of VVER fuel rod behavior

under IGR test conditions. As it has already been noted, additional original material properties of VVER fuel

rods and air coolant were developed and included into the package according to the procedures, described in

Section 5.6.

5.4.3.3. Output data

The data base that characterizes the behavior of VVER fuel rods under IGR test conditions was obtained

using the following set of output parameters of FRAP-T6 MODI code:

" time history of energy deposition, power of fuel rod, specific energy of metal-water reaction, specific

leakage of energy, fuel enthalpy;

" time-axial-radial distributions of the temperature for fuel and cladding;

" time history of heat transfer coefficient and heat flux on the cladding surface;

" time history of fuel rod pressure, gas gap thickness, ZrO2 thickness on the cladding;

" time history of cladding hoop stress;

" time history of fuel swelling, fuel hoop strain, fission gas release;

" special set of peak- and failure parameters characterizing fuel rod performance under the test condition.

5.4.3.4. Selection of FRAP-T6 models to calculate VVER fuel rod performance

FRAP-T6 MODI code contains a lot of models for predicting the fuel rod behavior under accident

conditions [1]. However the purpose of this Section is to present the list of FRAP-T6 code models from

which the user must select the required model out of several alternatives. The list of models that were

modified for VVER fuel rod is presented in the next Section of the Report.

FRAP-T6 code provides model selection for the following options:

" internal gas pressure;

" metal-water reaction;

" deformation;

* failure;

" heat conduction.

Suboption of "plenum temp" was selected to calculate the internal gas pressure in VVER fuel rod, since this

model is recommended as a preferable one in FRAP-T6 Model Selection Data Block. The option "MetalWater Reaction" in FRAP-T6/VVER code version was described using the model presented in

.Section 5.4.3.6. This is why none of FRAP-T6 suboptions was used. In accordance with IGR test conditions

and FRAP-T6 recommendations, suboptions named "FRACAS-I", "General" and "CENTRAL VOID" were

selected for options "Deformation", "Failure" and "Heat Conduction", respectively.

5.4.3.5. Approach to determine the input data characterizingfission product distribution

in the high burnup VVER fuel before IGR tests

In order to calculate fission gas release (FGR) and fuel swelling for VVER high burnup fuel under RIA test

conditions, initial distribution of fission gas products is to be known for each of high burnup fuel rods. As

was stated earlier standard procedure of calculating FGR by FRAPCON-2 code is usually performed for such

cases [12]. The final result of these calculations is spatial distribution of Kr and Xe isotopes. As the authors

of this report had no possibility to use FRAPCON-2 code, Kr and Xe spatial distribution at the end of fuel

cycle for Unit 5 NV NPP was identified by FASTGRASS model of FRAP-T6 code. Specifics of the obtained

data were confirmed later by a number of verification procedures, described in section 5.7.

5.24
Input data from Appendixes A, B of Volume 3 of the report were used to calculate performance of

commercial fuel elements during fuel cycle. Heat transfer from fuel elements to coolant was calculated with

the help of standard FRAP-T6 code models for the water coolant with the given parameters, characterizing

flow rate, inlet temperatures, outlet pressure, hydraulic diameter of the channel, etc. Real geometry of the

VVER fuel element was taken as the basis for the development of the nodalization scheme. Power history

was calculated without consideration of the transients connected with the shut downs of the reactor. The

procedure of special axial meshing of fuel elements was performed after the calculation results of the fuel

cycle were obtained. The objective of this procedure was to find the sections within the length of commercial

fuel element for which the average value of burnup is corresponded to the average value of bumup for each

of re-fabricated high burnup fuel rods within the heated length. The number of the respective fuel rod was

given to each of these sections, and FGR radial distribution within these sections was assumed as the input

data characterizing FGR in 13 high burnup fuel rods prior to IGR tests.

It is important to note that a number of modifications was made in order to get final calculational results

including:

" FSWELL model from MATPRO library was introduced to calculate the steady-state fuel swelling;

" fuel densification model from PIN-04M code [22] library was used to consider fuel radiation

densification, besides we also considered a number of original VVER characteristics;

" dependence of fuel thermal conductivity vs. burnup was considered;

" RIM effect was considered by introducing the radial coefficient of the energy density non-uniformity vs.

time.

The final set of FGR distribution contains the following data base for Kr and Xe in each of fuel rods:

" radial distribution of intragranular bubbles concentration;

" radial distribution of bubbles on grain face;

* radial distribution of bubbles on grain edges.

5.4.3.6. Modified models in FR.iP-T6 code

The list of modified models in FRAP-T6 code includes the following items:

* metal-water reaction;

" heat transfer to air coolant;

" DEFORM subroutine;

" film boiling correlations;

" BALON2 subroutine.

Metal-water reaction

Parameters that characterize the oxidation kinetics of Zr-1%Nb were obtained on the basis of experiments

conducted with samples of unirradiated claddings [7]. Tests were performed in the water steam at the

atmospheric pressure under isothermal and quasi-isothermal conditions. To describe the cladding oxidation,

the classical parabolic dependence was proposed:

W' = Aexp(-B / T)r,

where W = ZrO2 or ctZr(O) thickness (in);

T= temperature (K);

r= time (s);

A, B = coefficients.

Experimentally determined coefficients A and B allow to use the equation for the calculation of the thickness

of ZrO2 layer and of alpha zirconium layer stabilized by oxygen.

5.25
Values of A and B coefficients are presented in Table 5.7.

Table 5.7. A, B coefficients for Zr-l%Nb oxidation

Temperature. ZrO2 oaZr(O)

(K) A B A B

<1773 5.19 I07 15355 1.44 106 14088

1773-1873 17.7210-7 14680 5.16 10"s 19520

>1873 up to melting 17.72 10" 14680 1.5142 10-7 24230

Model of heat transfer to air coolant

For the above conditions heat transfer coefficient can be presented as follows:

h = h.+ h,.d,

where h,. = heat transfer coefficient due to convection;

hod = heat transfer coefficient due to radiation (the code already has this model).

Heat transfer coefficient due to convection can be determined by the system of the following equations [20]:

Nu = CRa", Ra = GrPr,

gfJ(tW -_tf )Z3 Gr=

v-a

2Nu

z

where Nu, Ra, Gr, Pr = Nusselt number, Rayleigh number, Grashof number, Prandtl number,

respectively;

g = acceleration due to gravity (m/s2 );

,6 = thermal expansion volumetric coefficient (1/K);

z = heating length (m);.

tw-= wall temperature (K);

tf= fluid temperature (K);

C, n = coefficients;

2= thermal conductivity (W/m K);

h, = heat transfer coefficient due to convection;

v = kinematic viscosity (m2

/s);

a = temperature conductivity (m2

/s).

Nu, Ra, Gr, Pr are calculated at the temperature:

(tw +tf)

2

C, n coefficients are identified according to the data of Table 5.8.

5.26
Table 5.8. C, n coefficients vs. Ra, Pr

Ra Pr C n

0.1 0.32 0.25

1.0 0.54 0.25

10 0.62 0.25

100 0.66 0.25

109 - 1013 0.15 0.333

DEFORM subroutine

DEFORM subroutine calculates the gap between the fuel and cladding. Despite the fact that FRAP-T6

declares the capability to account for fuel strain by swelling when calculating pellet/cladding gap, this

procedure is not performed automatically. That is why this effect was additionally taken into account by

DEFORM subroutine.

BALON2 subroutine

Correction of the axial length of ballooning region was made by BALON2 subroutine in order to consider

specific features of VVER fuel rods. Original version of BALON2 subroutine suggests to consider that axial

length is equal to 8 cm. But the heated length of VVER fuel rods is equal to 15 cm only. Use of the axial

length of ballooning, which exceeds the half of the fuel rod length, makes it much more difficult to interpret

the calculation results. Moreover, the results of post-test examinations of the VVER fuel rod indicated that

the actual axial length was 2-4 cm. That is why axial length in the BALON2 was decreased to 3 cm.

Heat transfer models for water coolant

FRAP-T6 code has multiple correlations to calculate the heat transfer from the fuel rod to the coolant. For

IGR test conditions, the following set of correlations was selected, that sequentially describes the change of

heat exchange regimes on the fuel rod surface in the straight and reverse directions: convection, nucleate

boiling, transition boiling, film boiling. The nature of the change of the heat flux from cladding to the coolant

for these regimes is presented in the linearized form in Fig. 5.17.

Fig. 5.17. Heat flux from cladding to coolant vs. wall temperature used In FRAP-T6 code for IGR tests

The convection regime (section a-b) was described by Dittus-Boelter correlation [23]. When the wall

temperature reaches the saturation temperature Ts the transition to the nucleate boiling takes place. Chen

correlation [24] was used for the nucleate boiling regime (section b-c). The transition from the nucleate

5.27
boiling regime to the transition boiling regime takes place when the heat flux reaches the critical heat flux

value (qhr). McDonough correlation was provided to describe the transition boiling regime (section c-d).

Calculations of heat transfer coefficients in section c-d are performed in parallel with calculations of heat

transfer coefficients using film boiling correlations. As soon as the comparison of two coefficients shows

that heat transfer coefficients for film boiling are higher than the heat transfer coefficient for transient

boiling, the transition to the film boiling regime takes place (point d). As it was noted in section 5.4.2, results

of the preliminary verification of FRAP-T6 code shows that the use of Bromley-Pomerantz model [18] to

describe the film boiling regime (section d-e) leads to a significant overestimation of the cladding

temperature. The search for an alternative model allowed to propose Labuntzov model [19] with a

subcooling factor, that takes into account particular features of the heat exchange at subcooling of water. As

it was shown in section 5.4.2, the use of this model allows to predict the cladding temperature with a good

accuracy till the rewetting phase (point f). The rewetting phase begins in IGR tests much earlier in

comparison with predictions by the original model of FRAP-T6 code. Therefore, a special model was

developed for this phenomenon and the criterial rewetting temperature Twet was proposed in order to find

point f that characterizes the reverse transition from the film boiling to the nucleate boiling regime (section

d-g). The heat flux for this section was calculated using heat transfer coefficients for which the linear

interpolation law was specified.

Thus, two additional models were introduced in FRAP-T6 code to calculate parameters of the film boiling

regime.

The first one - Labuntzov model - is described by the following expression:

aFB = 0.25(Ac (p9 Pg /)

V9

where aF = heat transfer coefficient (W/m2K);

A = steam thermal conductivity (W/m K);

c g = steam specific heat (J/kg K);

pf = fluid density (kg/in3);

pg = steam density (kg/m3

);

g = gravity acceleration (m/s2);

vg = steam kinematic viscosity (m2

/s).

To take into account the initial subcooling of water, the correction factor is introduced [21]:

(1+ 0. 1(XP. )-" A

Pg hfg

where aB = corrected heat transfer coefficient (W/m2

K);

Ai = enthalpy of fluid at saturation minus enthalpy at fluid bulk temperature (J/kg).

The second developed model - Rewetting model - is based on the hypothesis of the associative similarity of

the rewetting and reflooding regimes. The main idea of the proposed method is as follows [25]:

" the wetting rate does not depend on the rate of the fluid supplied from the outside; it depends only on the

rate of the steam bubble generation, since under these conditions a free access of the fluid to the steam

film is provided;

" the presence of axial - radial heat leakages through cold end elements of the fuel rod leads to the

generation of wetting waves at the top and bottom boundaries of the heated section of the fuel rod; and

boundaries of wetting waves gradually move to the fuel rod center.

5.28
In other words, axial heat leakages into unheated parts of the fuel rod lead to a decrease in the cladding

temperature in axial segments near unheated parts of the fuel rod. Thus, rewetting fronts occur and move

from upper and lower parts of the fuel rod to the center of the heated length.

To model processes of this type, a large number of models was developed [26-28]. In this case the original

rewetting model that takes into account specific features of IGR tests was developed. Approximate analytical

dependencies were obtained to calculate the rewetting front velocity and the time history for the temperature

distribution in the multi-layer system of the fuel rod [25].

The solution of the two-dimensional non-stationary equation of the heat conductivity in the solid with

internal heat sources formed the basis of the method:

PC 07 = - f /( I+ 1 ! ¢rA ff) q

where p = clad density (kg/m3);

cp = clad specific heat (J/kg K);

T = temperature (K);

X = clad thermal conductivity (W/m K);

q, = volume internal heat source (W/m3).

In this case, p, cp, A, k are functions of the temperature. Additionally, an axial profile of cladding

temperature is specified in the region of the rewetting front by the corresponding equations. This profile

depends on the velocity of the rewetting front. At the rewetting front the cladding temperature is equal to the

minimum stable film boiling temperature.

The solution of this equation is reduced to the solution of a system of algebraic equations with respect to the

dislocation velocity of the rewetting front.

The values obtained for the velocities of the rewetting fronts, moving upward and downward, are used to

obtain the moment of rewetting for each axial slice. Distances, covered by each of the rewetting fronts by the

time t, are found by integration:

t t LU t u (Cr D(t) = fD(rd

where t = current time (s);

L- (t) = distance covered by the rewetting front, moving upward (m);

LD (t) = distance covered by the rewetting front, moving downward (m);

tD = time at which rewetting of the lower heated part of the fuel rod starts (s);

tou = time at which rewetting of the upper heated part of the fuel rod starts (s);

u (r) = velocity of the rewetting front, moving upward (m/s);

u"D (r) velocity of the rewetting front, moving downward (m/s).

To apply the obtained model, the following logical approach was developed for FRAP-T6 code:

* till Tch-d 74 0 K, calculation are performed in accordance with the procedure sequence described for Fig.

5.17;

* then, in parallel, calculations of parameters of the film boiling regime and parameters characterizing the

rewetting front movement are conducted;

* transition from the film boiling to the transition boiling occurs simultaneously for all axial slices when

rewetting front reaches the axial slice of the fuel rod with maximum power.

5.29
5.5. Development of IGR/VVER version of the SCANAIR code

5.5.1. Description of the SCANAIR code

SCANAIR computer code is designed to model thermal mechanical behavior of LWR fuel rods under

reactivity initiated accident conditions [2]. Version 2.2 used by us was developed in the Institute for

Protection and Nuclear Safety (LPSN, France) in order to model the first stage of the accident. The models

describing cladding failure, cladding oxidation, etc. are still being developed, and thus are not present in this

code version.

The following physical processes are modeled by the SCANAIR code in order to describe fuel rod behavior

under RIA conditions:

" heat transfer in fuel, clad and in pellet-cladding gap;

" heat transfer from cladding to coolant, and from coolant to the channel wall;

" gas pressure inside fuel rod;

" fuel and cladding mechanical behavior;

" fission gas transient behavior.

Fig. 5.18 presents the logical scheme used by SCANAIR code to calculate fuel rod performance.

INPUT DATA

Fig. 5.18. Principal scheme of SCANAIR code

5.30
Temperature distribution within the fuel, cladding and coolant is calculated by the thermal dynamics model,

then the results are transferred to the model of fission gas behavior. Fission gas behavior model calculates

composition and spatial distribution of the fission gas products, and transfers the current data on the swelling

and inner gas pressure to the mechanics model. Stress-strain conditions in the fuel and cladding are

calculated by the mechanics model. Fuel hydrostatic pressure data are transferred to the model of fission gas

behavior and used to calculate gas pressure in the porous area. The whole computation cycle in the fission

gas behavior and mechanics models is iteratively repeated up to convergence in hydrostatic pressure in the

fuel. After that the value characterizing pellet-cladding gap is transferred to the thermodynamic model, and

the whole computation process is repeated up to convergence in the pellet-clad gap. Then the whole

procedure is repeated within the new integration stage.

SCANAIR can use the following set of input data in order to model an irradiated fuel rod:

" measured geometrical fuel rod parameters;

* measured or calculated power history;

" thermal-physical and mechanical properties of materials;

" parameters characterizing initial state of a fuel rod (prior to RIA).

It is important to note that the initial state of a fuel rod is characterized by geometric parameters, as well as

by composition and spatial distribution of fission gas products. Special TOSUREP code is used to calculate

this set of parameters for the required moment of a fuel cycle at the NPP [11]. Hence, all the initial geometric

parameters of fuel rods can be either measured or calculated the complex approach can also be applied.

Brief description of each of the major SCANAIR models is presented below.

Thermal-dynamics model

This model describes heat transfer in the fuel rod, thermal-hydraulic behavior of coolant and heat transfer

between fuel rod and coolant.

These are the major peculiarities of the heat transfer module:

" heat transfer in fuel rod is calculated in the radial direction only;

" radial coordinates of calculational nodes are the function of time;

" axial coordinates of calculational nodes are not the function of time;

" gas temperature in the gas plenum is equal to the gas temperature in the adjacent gas gap;

" heat transfer model for the pellet-cladding gap considers conductive and radiation components only, heat

transfer due to natural convection and the contact component are not considered.

The coolant is modeled as a single-phase flow and by one-dimensional equations of conservation of the mass

and energy. Boundary conditions are specified as the mass flow rate and the inlet temperature. Coolant

material properties and heat transfer coefficients at the cladding surface and channel wall are used as the

closure relations.

SCANAIR code assumes modeling of three typical modes of heat transfer between cladding and coolant:

" heat transfer due to convection;

" heat transfer due to nucleate boiling;

" heat transfer due to film boiling.

Two options exist for heat transfer due to convection. In the first option Dittus-Boelter law [23] is used for

forced convection. In the second option it is considered that heat transfer coefficient is equal to 100 W/m2

K.

The code automatically selects for the calculations the option, which predicts the higher value of the heat

transfer coefficient. If the cladding temperature reaches the saturation temperature the change takes place for

heat transfer due to nucleate boiling which is described by the Chen model [24]. Criterion for the departure

from nucleate boiling is based on the temperature of the minimum stable film boiling. This temperature is

calculated in accordance with the Groenveld-Stewart law [29]. Bromley law is used to calculate heat transfer

due to nucleate boiling [18].

5.31
Mechanics model

Mechanics model is based on the assumption that the fuel column and the cladding are long axial asymmetric

cylinders. Total fuel strain includes the following components: elastic strain, plastic strain, thermal

expansion, cracking strain, strain due to swelling. Cladding strain is calculated with consideration of elastic

strain, plastic strain, and thermal expansion.

Mechanics model calculates fuel and cladding displacement in the axial and radial directions, cladding

anisotropy is not considered. Elastic strain and plastic strain of the cladding is calculated on the basis of the

assumption on isotropic mechanical properties. Calculation of the stress - strain state for the cladding is done

on the basis of the assumption on the ideal elastic plastic material. I.e. elastic region is calculated by the

Hooke's law with the specified Young's modules. Hypothesis of the ideal plastic body with no strain

hardening is used to calculate simultaneous plastic strain of the cladding, flow of materials is described

according to the Prandtl-Reuss rule. Plastic strain increments are calculated for the effective stress equal to

the yield stress. Finite element technique is used to solve equilibrium equations.

It is important to note that calculation of the fuel clad local plastic strain of the ballooning type is not

possible by the mechanics model of the SCANAIR code. Neither does the code have the models for cladding

failure.

It is important that elastic and plastic strain in the fuel is not modeled if the initial fuel cracking is specified.

Model of fission gas behavior

This model describes fission gas release, fuel swelling and redistribution of the fission gas within the fuel

between three types of populations: intragranular bubbles, intergranular bubbles, porosity gas. It is assumed

that intragranular bubbles move to the grain boundary due to the temperature gradient and Brownian motion.

Temperature increase and coalescence of the intragranular bubbles lead to the growth of the gas pressure in

the bubbles and to the increase of their radius. These two effects result in their turn in the intragranular fuel

swelling. Intergranular bubbles are located at the boundaries of fuel grains. Temperature growth leads to the

intergranular fuel swelling. Besides, migration of the intragranular bubbles to the grain boundaries results in

the intergranular swelling as well. It is assumed that if gas pressure inside intergranular bubbles leads to the

pressures exceeding fuel fracture stress, this gas volume goes to the porous area.

Initial concentration of porosity gases is calculated by the TOSUREP code. Current values characterizing

porosity gases are calculated on tfie basis of the balance correlations between initial porosity gases,

additional porosity gases due to intergranular gas flow, and porosity gases migrating in the free gas volume

of the fuel rod according to the Darcy law.

5.5.2. Preliminary adaptation of the SCANAIR code to analysis of IGR/RIA tests

At this stage the major effort was directed to solving a number of standard and specific tasks. By the

standard problem we mean development and optimization of the nodalization scheme, preparation of

individual input data for 25 VVER fuel rods, etc. The set of specific tasks included the following issues:

" analysis of the SCANAIR'code representativity to calculate VVER fuel rod behavior under RIA test

conditions, and modification of some code models;

" development of an approach to consider WER original material properties;

" development of the preliminary SCANAIR version to analyze IGR tests;

" preliminary verification of the SCANAIR/VVER code version;

" working out of recommendations to develop the final version of the SCANAIR code for VVER fuel rods.

As for the code representativity the major problem is that SCANAIR code does not allow to predict cladding

failure, besides it is not designed to calculate great values of clad hoop plastic strain typical for the

pressurized VVER fuel rods tested at the level equal to or higher the failure threshold value. Considering the

fact that a significant group of fuelrods was tested below the failure threshold value, use of the SCANAIR

code to analyze such fuel rods can be justified under condition that we review special aspects connected with

the original material properties of the WER fuel rods, and some other specific features of the fuel rod

design and conditions of testing.

5.32
In accordance with the recommendations of sections 5.1, 5.2 preliminary package of the VVER material

properties was developed, and other input data and nodalization scheme were prepared. Then preliminary

stage of the verification procedure with the use of specific test data base was completed. Verification results

allowed us to find two serious problems at this stage of the study:

" non-adequacy of the SCANAIR heat transfer models for the IGR test conditions;

" necessity to correct gas pressure model.

Modification of heat transfer models

Verification procedures have indicated that the use of original Chen model to calculate heat transfer from the

fuel rod to the coolant under nucleate boiling conditions leads to the unacceptable overestimation of the

cladding temperature (Fig. 5.19).

g

I

25

Time (S)

Fig. 5.19. Cladding temperature vs. time

In order to comprehend the reasons for this overestimation it is necessary to reviewthe Chen model in more

details. Chen correlation is presented as:

a = Fa. + Sa,.b,

where a = total heat transfer coefficient;

a cm = macroscopic heat transfer coefficient due to turbulent convective flow;

anb = microscopic heat transfer coefficient due to nucleate boiling;

F = intensification factor of convective heat transfer,

S = factor of boiling suppression.

Analysis of this correlation indicates that consideration of pool-boiling conditions typical for IGR tests leads

to very small values of ac. coefficient. Besides, it was found out that suppression factor S is equal to zero,

and F factor - to 1 for the single phase flow model which is used in the SCANAIR code. In the frames of the

Chen model both of these reasons lead to a very fast departure from nucleate boiling (DNB), and as the

consequence - to overestimation of the cladding temperature. That is why the attempt was made to use Thom

correlation to calculate cladding temperature [30]. This correlation developed specifically for the sub-cooling

boiling conditions is described by the following expression:

5.33
P

qF = 2000AT2 exp( ),

4.34

AT= Tw -Ts,

where q = heat flux (W/m2

);

AT = superheating of the wall (K);

T = wall temperature (K);

T = saturation temperature (K);

P = coolant pressure (MPa).

Introducing of this correlation into SCANAIR code allowed us to obtain good agreement between the

measured and calculated temperatures for nucleate boiling (see Fig. 5.19). But the next stage of verification

procedures to test SCANAIR code under post-CHF conditions revealed a new problem. The problem is that

the transfer from the nucleate boiling to the film boiling is done by the SCANAIR code with the help of the

temperature criterion described by the following expression [29]:

Tm,= 284.7 + 4.4110-s P - 0.037210-'0 p 2 ,

where T, B = minimum temperature of the stable film boiling ('C);

P = coolant pressure (Pa).

Application of this criterion for the IGR test conditions leads to the fact that heat transfer crisis does not

occur because the cladding temperature happens to be always less than Tw (Fig. 5.20).

Fig. 5.20. Verification of SCANAIR code with Thom model for nucleate boiling and original

SCANAIR DNB criterion

That is why the above set of correlations can not be used to predict cladding temperature under post-CHF

conditions for IGR tests. So the third step in this direction was made to improve the criterion for DNB. The

selected Kutateladze model is based on the correlation for critical heat flux under pool boiling conditions

[21]:

qCF = 0.23hf,,VpF9 cg(p f -pg

where qcHF = critical heat flux (W/m2);

5.34
hfg = latent heat (J/kg);

,of = fluid density (kg/m3

);

Pg = steam density (kg/rm3

);

a = surface tension (J/m2

);

g = gravity acceleration (m/s 2

).

IGR tests are characterized by the high water sub-cooling. In this case it is recommended to increase qcHF by

the value necessary to support saturation temperature at the boundary between the nucleate boiling region

and the sub-cooled water region [21]. Account for this correction leads to the modified expression for the

critical heat flux:

q c~ r q c~ ( I + 0 . "I( _f ) 0 .7 5 A ) ,

Pg hfg

where qcHF = modified critical heat flux (W/m2

);

Ai = difference between the water enthalpy at the saturation level and enthalpy of the sub-cooled

water (J/kg).

Verification of the SCANAIR code with the modified correlations for nucleate boiling and CHF criterion,

and Bromley correlation for heat transfer in the post CHF region indicated that the Bromley correlation

overestimated the fuel cladding temperature (Fig. 5.21).

2000

IGR test 51F-16

1600 -- Clad •*::•:uto o:'::' ........... er ata = ••,e

i800-

400

0

0 2 4 6

Tune (s)

Fig. 5.21. Verification of SCANAIR code with CHF model

Therefore, the next step was made to adapt SCANAIR code to IGR test conditions.

Bromley correlation uses the equation for the heat transfer coefficient that was obtained in experiments with

horizontal tubes cooled by stagnant water under conditions of the film boiling and laminar state of the steam

film. However in IGR tests, the fuel rod was positioned vertically. Moreover, the non-stationary energy

deposition mode is a characteristic feature of these tests. Taking into account these two factors, it can be

assumed that the steam film on the fuel rod surface is in the turbulent mode already at an early boiling stage.

5.35
Thus, a decision was made to replace Bromley correlation by Labuntzov model that was developed for

turbulent film boiling modes [19]. This model is described by the following expression:

ar3= 0.25(A? cpg (pf - pg-) 911,

Vg

where a. = heat transfer coefficient for film boiling (W/m2

K);

A g = thermal conductivity of steam (W/m K);

Cpg = specific heat of steam (J/kg K);

p = fluid density (kg/n 3);

pg = steam density (kg/m3);

g = gravity acceleration (M/s2);

Vg = steam kinematic viscosity (m2/s).

Moreover, the effect of the water subcooling should be taken into account for this case, since it can affect

significantly the cladding temperature. This correction was introduced similarly to the correction for qcf

[21]:

a• = a,(I + 0.l(Pf)°- Ai),

Pg hfg

A corresponding adjustment of SCANAIR models allowed to obtain results presented in Fig. 5.22.

1600

Clad ...... ,,• ,• IGR test 50F-16

1200 A caatcdS SANMRwiLabuntzov

800

400

0f I 1

0 2 4 .6

Tune (s)

Fig. 5.22. Verification of SCANAIR code with Labuntzov model

The analysis of the results obtained shows that another problem remained unresolved at this stage. In the

experiment, the rewetting stage begins much earlier than the modified model of SCANAIR code predicts.

This results in an overestimation of the film boiling duration, and, thus, in an overestimation of the cladding

temperature at this stage of the scenario. However this problem can be a study topic within the framework of

the development of the final version of SCANAIR code for IGR tests analysis.

5.36
Modification of gas pressure model

It is obvious that the gas pressure model that calculates the gas pressure inside the fuel rod is very important

for pressurized VVER fuel rods. Thus, the verification of this model in SCANAIR code was performed on

the basis of the test data base obtained using fresh pressurized fuel rods, tested in the air coolant. According

to verification results, SCANAIR model significantly overestimates the gas pressure (see Fig. 5.23).

6- 1600

IGR test 92-0 2

1200

4- - -- Caic. original innr pes1.ssure

Nlezuredinne presure800 2-

400

0 0

0 2 4 6 8 10

Time (s)

Fig. 5.23. Verification of original gas pressure model in SCANAIR code

The analysis of causes of the discrepancy between measured and calculated gas pressures shows that

SCANAIR original model calculates the pressure in gas plenum in accordance with the assumption that the

gas temperature in the plenum is equal to the gas temperature in the fuel-cladding gap (adjacent to the gas

plenum). SCANAIR code uses the following equation to calculate the temperature in the gas plenum:

T+T=

TL = Tif + i,

2

Where TpL = temperature of gas plenum;

Tf= fuel outer temperature;

T, = cladding inner temperature;

i = index of first or last axial node.

In other words, this model does not take into account the heat exchange between the fuel rod (at the length of

the gas plenum) and the coolant in the gas plenum region. Such an assumption can be true for fuel rods with

small volumes of gas plenums and low values of the initial gas pressure. However, another model must be

used for fuel rods of VVER type tested in IGR reactor. A corresponding model was developed, and

verification procedures show that it can be used for SCANAIRVVER version (see Fig. 5.24). This model is

described in section 5.5.3.

5.37
I

0 2 4 6 8 10

Time (s)

Fig. 5.24. Verification of modified gas pressure model in SCANAIR code

5.5.3. Description of SCANAIR code version to predict VVER fuel rod performance under

IGR test conditions

5.5.3. 1. Calculational scheme

As in the case of FRAP-T6 code, a unified calculational scheme was developed to model VVER fuel rods of

three types. The geometric calculational scheme of the fuel rod, presented in Fig. 5.25, consists of fuel

pellets, cladding, fuel-pellet gap, low and upper gas plenums and coolant. Axial. and radial meshings define

the coordinates of calculation nodes where the temperature, pressure, strain, stress etc. are determined.

upper gas plenum

Nzcladding

fuel-clad gap '

fuel pellet I

central hole

coolant

m axial node - radial node

lower gas plenum

Fig. 5.25. Calculational scheme of VVER fuel rod SCANAIR code

5.38
The modeling of VVER fuel rods with SCANAIR code was performed using the following set of

assumptions:

" the fuel and cladding are of regular cylindrical form and are arranged axisymmetrically;

" there are no changes in initial dimensions of fuel pellets, cladding and gap along the fuel rod height;

" there are no changes in the fuel density along the fuel rod height;

" there are no changes in the fuel composition along the fuel rod height;

" the axial meshing is applied only at the heated length of the fuel rod.

The calculation experience obtained at the stage of the preliminary adaptation of SCANAIR code allowed to

get the following optimum parameters for the calculational scheme:

* axial nodes: 10

* radial nodes: 31, including

fuel: 25

cladding: 6

* time step during fast transient: 1 - 5 10.' s

o time step during slow transient: 5 10. - 1.0 s

All calculations were performed taking into account the assumption that the fuel rod is surrounded by an

infinite volume of stagnant coolant under normal initial conditions.

5.5.3.2. SCANAIR input data to characterize the VVER fuel rods and IGR test conditions

The main set of input data, that characterize VVER fuel rods, was specified using the data base, presented in

Appendixes C, D, E of Volume 3. This set includes parameters listed in Table 5.9.

Additional parameters were required to calculate the behavior of high burnup fuel rods with the help of the

fission gas release model. These parameters were obtained using TOSUREP code within the framework of

the procedure described in the following section of the Report. As it has already been noted, initial

parameters of the coolant were characterized by the zero flow rate and atmospheric pressure. The initial

coolant temperature was assumed to be 293 K, the coolant volume was equal to the infinity. Test conditions

in IGR reactor were described by the following set of input data:

" power history of fuel rod;

" axial power profile;

* radial power profile.

These input data were prepared individually for each fuel rod in accordance with the data base, presented in

Appendixes G, H, I of Volume 3.

Account of original material properties of VVER fuel rods was a separate study area in the development of

input data for SCANAIR code. These studies were applied simultaneously for SCANAIR and FRAP-T6, and

their results are presented in section 5.6 taking into account particular features of each code.

5.5.3.3. Input data to calculate fission gas release from high burnup fuel

In order to calculate fission gas release and fuel swelling for the VVER high bumup fuel under IGR test

conditions initial distribution of fission gas products is to be assigned for each fuel rod. It has been already

noted that SCANAIR code can not model basic irradiation conditions, that is why we used TOSUREP code

[11].

5.39
Table 5.9. Set of input data on fuel rod design

Parameters of fuel rod Method to determine the design parameters

1.1. Fuel stack cold length as measured

1.2. Cold state fuel rod temperature 293 K

1.3. Gas gap radial dimension as measured and estimated

2.1. Fuel material U0 2

2.2. Pellet outer diameter as measured

2.3. Pellet inner diameter as measured

2.4. Pellet surface roughness estimated according to [31 1

2.5. Fuel density as measured

3.1. Cladding material Zr-lNb

3.2. Cladding outer diameter as measured

3.3. Cladding inner diameter It was calculated, taking into account the cladding outer

diameter, pellet outer diameter, gas gap thickness

4. plen umi data

4.1. Upper plenum volume as measured

4.2. Lower plenum volume as measured

4.3. Initial gas composition He

4.4. Initial gas pressure as measured

TOSUREP code can model behavior of LWR fuel elements over fuel cycles at NPP. The code calculates

heat transfer in the fuel element and in the coolant, pellet-cladding mechanical behavior, fission gas products

behavior. TOSUREP considers the following main physical phenomena:

" thermal mechanical pellet-clad behavior;,

" in-pile densification;

" fuel swelling due to fission products;

" clad creep down;

" clad growth;

• gap closure;

" clad strain by PCMI after gap closure;

" fission gas generation and release;

" evolution of pressure in the free volume and plenum;

* evolution of radial power profile.

TOSCAN code [2] is used to arrange the interface between the TOSUREP and SCANAIR codes. TOSCAN

code reads the output files with the results calculated by TOSUREP code, processes this information and

prepares the input data deck for SCANAIR code.

In general, TOSUREP code calculates r, z and t distribution of the following output parameters:

" axial height (cm);

" radius of the central hole (cm);

5.40
" external fuel radius (cm);

" diametric gap size (pm);

" columnar radius (cm);

" equiaxis radius (cm);

" total pin power.(W);

" linear power rating (W/cm);

" burnup (at %);

" plenum gas pressure (bars);

" fission gas release (%);

" gas retention (cm3

);

" gap conductance (W/cm 2

/K);

" fuel temperature (C);

" cladding temperature (C);

" cladding deformation (%);

" cladding hoop strain due to irradiation creep (%);

" cladding axial growth due to irradiation (%);

* residual clad strain (%);

" contact pressure between fuel and cladding (Pa).

In order to determine initial characteristics of the fission gas products in VVER fuel elements before IGR

tests TOSUREP code calculated behavior of the VVER commercial fuel element # 317 over the fuel cycles

of Unit 5 NV NPP.

Initial data characterizing VVER commercial fuel element, coolant parameters and power history were taken

from Appendixes A, B of Volume 3. General approach to the development of the nodalization scheme and

calculations by TOSUREP was the same as for FRAP-T6 code (section 5.4.3).

The procedure for axial meshing of commercial fuel elements was performed after completion of

calculations by the TOSUREP code. Meshing of fuel elements. into the parts was performed so that the set of

average burnups for 13 selected parts corresponded to the set of average burnups for 13 refabricated high

burnup fuel rods tested in IGR reactor.

In this case the final set of input data for SCANAIR code obtained by TOSUREP code contained the

following information for each of high burnup fuel rods:

" radial distribution of fission gas products;

" radial distribution of fuel porosity;

" radial distribution of fuel burnup.

5.5.3.4. Output data of SCANA4IR code

To get theset of parameters presented in Appendixes G, H, I of Volume 3, the following output parameters

were prepared by SCANAIR code as the data base that characterizes the VVER fuel rod behavior:

* time history of energy deposition, power of fuel rod, specific leakage of energy, fuel enthalpy;

" time - axial - radial distributions of temperature for fuel and cladding;

" time history of heat transfer coefficient on the cladding surface;

" time history of fuel rod pressure, gas gap thickness;

" time history of cladding hoop stress;

5.41
" time history of fuel swelling, fuel hoop strain, fission gas release;

" special set of peak parameters, characterizing fuel rod performance under the test condition.

5.5.3.5. Selection of SCANAIR models to calculate VVER fuel rod performance

Similar to the corresponding section for FRAP-T6 code, this section will present only those models that were

either modified or added to SCANAIR code, or selected by the user out of several options provided for in the

code.

Selection of original models of SCANAIR code

TM-COUPLING option provides for the selection of the numerical method of the coupling between the heat

transfer and mechanic models in the fuel rod. Two suboptions are intended for this purpose. Suboption

"implicit" is recommended for slow power ramps. Suboption "explicit" that provides calculations of the heat

transfer for the explicit geometry is recommended for RIA conditions. The latter suboption was used for

WER calculations. CRACKS option has two alternative models to calculate the mechanical behavior of the

fuel pellet. Both these models were used for this series of calculations. The behavior of high burnup fuel was

calculated using the model that assumes that fuel pellets had cracks before IGR tests, and therefore, the

calculation of elastic-plastic strain was not performed for them. The alternative model was used for the fresh

fuel. In this case the elastic-plastic strain was calculated by SCANAIR code.

The next STICKING option allows to take or not to take into account the sticking effect between the fuel and

the cladding under PCMI conditions. In accordance with the code developers recommendations, calculations

were conducted based on the assumption that there is no sticking.

PORO-EQ option is used to calculate the fuel swelling. The option allows to change the fuel porosity during

the calculation in order to take into account effects of the grain boundary saturation or grain boundary

failure. However, in a general case it is recommended to calculate the fuel swelling at constant porosity of

the fuel, thus, this variant was used for VVER calculations.

FLUID-CALC option provides for the selection of method to simulate the coolant behavior. Suboption "no"

was used to calculate parameters of stagnant and high subcooled water.

Additional and modified models for SCANAIR code

To predict the behavior of VVER fuel rods tested in the air coolant, a special program module was added to

the thermal dynamics model of SCANAIR code.

Correlation ratios that were used in this module are in full agreement with correlations described in

section 5.4.3.6 for FRAP-T6 code.

In accordance with results of the preliminary adaptation, the calculation of the temperature in the gas plenum

was modified in the gas pressure option according to the following expression:

TPL = CO CO + ,

S +Sf

where TpL = temperature of gas in gas plenum;

T,, = coolant temperature;

Tf= average temperature of fuel pellet, adjacent to the gas plenum;

S,, = area of gas plenum surface in contact with coolant;

Sf= area of fuel pellet, adjacent to the gas plenum.

As it has already been noted, the preliminary adaptation of SCANAIR code shows that heat transfer models

must be seriously modernized to be able to describe IGR tests. The final stage of this cycle of the work

covered the development of an original heat transfer model to calculate the transition from the film boiling

on the cladding surface to the rewetting phase of the fuel rod (see Fig. 5.26). A special rewetting model was

developed within the framework of unified requirements for FRAP-T6 and SCANAIR codes. A detailed

description of this model is presented in section 5.4.3.6.

5.42
In general, the entire complex of the work in this area can be summarized in the form of idealized schematic

diagram that characterizes the logical sequence of using individual heat transfer modules and criteria to

calculate the heat flux from the cladding to the coolant (see Fig. 5.26).

q,

b

a

T. T. T.. T, T.

Fig. 5.26. Wall to coolant heat flux vs. wall temperature used in VVWERIGR version of SCANAIR code

The calculation starts with the section a-b of diagrams. Dittus-Boelter correlation [23] is used to calculate the

heat flux for the convection regime. The transition from the convection to the nucleate boiling regime takes

place when the wall temperature reaches the saturation temperature Tr. Thom correlation [30] is used for the

nucleate boiling regime (section b-c). Point "c" is the point of the departure from nucleate boiling. Critical

heat flux (qchf), that is calculated using Kutateladze correlation [21], defines the coordinates of this point.

Section d-e of the diagram characterizes the turbulent film boiling regime. Labuntzov correlation [31] with

subcooling factor [21] is used for this regime.

The heat flux for point "d" is determined using Labuntzov correlation at the wall temperature Tmf, that is

equal to the minimum stable film boiling temperature calculated using Groenveld-Stewart correlation [29].

Section c-d characterizes the transient boiling regime. The heat flux for this regime is calculated using the

linear interpolation for heat transfer coefficients in points "c" and "d". The reverse transition from the film

boiling to the nucleate boiling takes place when the wall temperature becomes equal to the rewetting

temperature T,,. The heat flux at the transition section from the film boiling to the nucleate boiling

(section f-g) is calculated using the linear interpolation for the heat transfer coefficient.

It is necessary to note that one more problem was met after implementation of mechanical properties of Zr1%Nb in the SCANAIR code. This problem is that the SCANAIR code does not have a model to calculate

cladding plastic deformation induced by inner gas pressure. When the clad temperature reaches the value at

which inner gas pressure causes cladding plastic deformation, disconvergence of inner mechanical iterations

occurs in the SCANAIR code. That is why the moment of initiation of cladding plastic deformation induced

by inner gas pressure was chosen as a criterion to stop calculations by the SCANAIR code. By this reason

only initial stage of fuel rod behavior can be simulated with the SCANAIR code for large group of tested

fuel rods. To extend the possibilities of the SCANAIR code a model was proposed in which calculation of

the cladding mechanical behavior was stopped after the above-mentioned criterion was reached. It is done by

making inner gas pressure equal to coolant pressure, stresses in the cladding become equal zero. At the same

time, thermal dynamics model, fission gas behavior model and fuel mechanics model continue to work. The

calculational analysis has shown that this model is valid for fuel rods not failed in the tests (for example,

#HIT, #5OF-16).

Besides, a model allowing to account for influence of clad strain rate on clad yield stress was included in the

mechanics model of the SCANAIR code (for more details see section 6.4.2 in Chapter 6).

5.43
5.6. Input data on material properties offuel rods and coolants

The integrated list of material properties included into MATPRO package contains the following items:

" thermal conductivity, specific heat, temperature conductivity, dynamic viscosity, density for air;

" thermal physical constants of Zr-lNb alloy;

" specific heat of Zr-I %Nb and WER fuel;

" specific enthalpy of Zr-lNb and VVER fuel;

" thermal conductivity of Zr-lNb cladding and WER fuel;

" thermal expansion of Zr-l%Nb alloy and VVER fuel;

" mechanical properties for Zr-lNb cladding:

=* Young's modulus and Poisson's ratio;

=> stress-strain diagrams;

=• anisotropy coefficients for strains and stresses;

= mechanical limits and failure criteria;

* mechanical properties for VVER fuel:

Young's modulus;

Poisson's ratio;

yield stress.

The analysis of the representativity and sufficiency of the existing data base on material properties is

contained in section 5.2. The following paragraphs of this Section describe specific correlation dependencies

that were added to MATPRO and SCANAIR package to characterize conditions of IGR/RIA tests.

Thermal properties for air coolant

Thermal physical properties of the air coolant are proposed to be calculated using the following correlation

set [32]:

= 24.407 + 7.978.10-2. t - 3.1541O-I V t 2 + 0.802-10-. t

3 ,

cP = 1004.16-9.761-10- 3 -t + 55.229.10- 5 _t2 -36.275.10- .t 3,

a = 10-6 .(18.788 + 13.484-10-2 t + 13.959.10-5. t2 -4.654.I0-. t3),

p =10-6 .(17.162+49.894-10-3 .t-2.935.10-5 .t 2 +1.133.10- .t 3

),

p = -2.883 -10- 3 + 355.06/(t + 273) + 353.527/(t + 273)2,

where X = thermal conductivity (W/m K);

c~p =specific heat (J/kg K);

a = temperature conductivity (m2

/s);

p = dynamic viscosity (Pa/s);

p = density (kg/m3);

t = temperature (*C).

Thermal physical constants of Zr-I %N-b

Thermal physical constants for unirradiated material of VVER cladding are presented in Table 5.10 [5].

5.44
Table 5.10. Thermal physical constants of Zr-l%Nb

:~Pazixncter U.Jnit VALIe

Melting temperature K 2133

Specific temperature J/g K 210

Temperature of the beginning of a-P3 phase transition K 883

Temperature of the end of a-P3 phase transition K 1153

Density kg/M3 6550

Thermal physical properties of the Zr-l%Nb alloy

The set of Thermal physical properties of the Zr-l%Nb alloy is characterized by the specific heat, specific

enthalpy, thermal conductivity and thermal expansion. At present all the data base on these parameters is

available only for unirradiated material. However it should be assumed that, for all cases when an additional

oxidation and hydration of the fuel rod cladding during the power operating cycle is small, this data base

certainly can also be used for irradiated material.

It should also be noted that the specific heat and specific enthalpy for Zr alloys suffer a perturbation in the

region of a-P3 transition (see Fig. 5.1 of section 5.2). In this case the perturbation scale depends on the

cladding temperature increase rate. However, taking into account results of the sensitivity analysis of fuel rod

parameters to these properties, this effect was ignored. Thus, in this case the correlation is of the following

form [4]:

for temperature region up to 1050 K:

cp = 2.375 -10-' + 15.91.-10-' -T,

HT - H 293K = -74.53 + 2.375-10-'. T + 7.955-10-5 . T 2 ,

for temperature region from 1200 K to 1600 K:

cP = 1.997.10-' + 12.3 64-10-'- T,

HT - H 293K = 4.125-10-' + 1.997-10-' .T+ 6.182-1 0-.T 2,

where cp = specific heat (J/kg K);

H= specific enthalpy (J/g);

T = temperature (K).

Experimental data obtained in [4] for 1100-1200K were processed and presented in the form of interpolation

Table 5.11.

5.45
Table 5.11. Specific heat and specific enthalpy for tempera-ture region 1100 - 1200 K

1100 412 1000 242.5

1110 420 1050 262.5

1120 480 1113 307.6

1134 600 1133 322.0

1142 1000 1153 336.3

1150 1400 1173 350.6

1155 1600 1200 370.0

1161 1400

1168 1000

1177 600

1180 400

1190 360

1200 348

The thermal effect of a-P phase transition for Zr-I%Nb alloy is about 48 J/g [4].

The following data set [5] was used to describe the thermal conductivity of Zr-lNb alloy:

273K<T5373K 2 =9.5.10- 3.(T-273)+17.01,

373K< T5 673K

673K< T• 1273K

T= 1273K

T= 1473 K

2 = 10.3848. (T - 273)0 '"7 . exp(-0.115.10-3 .(T - 273)),

2 = 167.88. (T - 273)-0.42 9 .exp(1.16910-3 . (T - 273)),

2 = 27.8,

T= 1573 K 2 =31.0,

where 2 = thermal conductivity (W/m K);

T = temperature (K).

The thermal conductivity of Zr-l%Nb at temperature above 1773 K was described by the extrapolation

dependence:

X = 15.0636. exp(0.46181- I -3. T).

The thermal expansion of the LWR cladding is usually characterized by a system of two coefficients for

axial and circumferential directions since zirconium alloys have obvious anisotropy of properties. The

existing data base for unirradiated Zr-l%Nb was obtained for temperature up to 923 K, inclusively, and is

presented in Table 5.12.

Table 5.12. Thermal expansion coefficients for Zr-l%Nb cladding

. in axial and radial directions [5j

Parameter Unit Value

Temperature K 293-393 393-573 573-773 773-923

a2 .106 1/K 5.3 5.4 5.5 5.6

a,,.10 6 1/K 5.7 5.9 6.3 6.8

Taking into account the fact that the thermal expansion of Zircaloy in ct-13 region have a step-like changes,

the following approach was used to get Zr-I %Nb data base for the temperature above 923 K. The

temperature region was divided into two sections:

5.46
923 - 1153 K (a-P region)

above 1153 K (P region).

The linear interpolation was applied to each section. The slope of curves at each section in "temperature -

thermal expansion" coordinates corresponded to the slope of curves for Zircaloy taken from MATPRO'

package. The obtained set of correlation dependencies is presented in Table 5.13.

Table 5.13. Thermal expansion for Zr-l%Nb alloy for temperature region above 923 K

Temperature (K) Thermal expinsian (%)

e=-I 7 .

9 5 + 0.0549 T - 5.4 10" T 2 + 1.74 104 T3

923 -1153 9 1=-17.28 + 0.0533 T- 5.3 10"' T2 + 1.72 10- T3

0=-0.8 86 + 9 .

7 104 T

above 1153 _ _ _-1.038 + 9.7 104 T

Mechanical properties of Zr-I %N-b cladding

To describe the cladding deformation, two main models are used in FRAP-T6 and SCANAIR codes:

1. Hooke's model for the region with elastic strain.

2. Model of elastic - plastic body for strain region above the yield point.

The first method requires the data base that characterize Young's modulus and Poisson's ratio. Therefore the

following correlation dependencies were added to MATPRO package and SCANAIR code for unirradiated

Zr-l %Nb alloy [5]:

E = 1.121.10" -6.438-107 -T, for273 < T < 1073K,

E=9.129-1W0 °-4.500-10 7 .T, forT>1073K,

u = 0.42628-5.556.10-' .T,

where E = Young's modulus (Pa);

p = Poisson's ratio (per-unit);

T = temperature (K).

A corresponding data base for irradiated Zr-l%Nb does not exist, however results of the sensitivity analysis

of FRAP-T6 and SCANAIR codes to these parameters show that even a high level of their uncertainty

affects little the calculation results obtained using FRAP-T6 and SCANAIR codes.

The second model of the FRAP-T6 code is based on the approximation of real stress - strain curves by

power law of the following form:

where a = true effective stress (Pa);

e = true effective plastic strain (per-unit);

= strain rate (11s);

9o = basic strain rate (1/s);

K = strength coefficient (Pa);

n = strain hardening exponent (per-unit);

m = strain rate sensitivity exponent (per-unit).

Thus, the set of coefficients (K, n, m) is the actual data base for MATPRO package. In their turn, these

coefficients are determined using the data base that characterizes the yield stress, ultimate strength and

5.47
uniform elongation. The preliminary experience of applying FRAP-T6 and SCANAIR codes and the

sensitivity analysis of the codes show that original properties of Zr-l%Nb cladding are a necessary condition

to get acceptable calculation results for VVER fuel rods under IGR test conditions. Thus, a special research

program was implemented to develop a corresponding data base for unirradiated and irradiated claddings. A

detailed description of this research cycle is presented in Chapter 6. It contains also final results that

characterize K, n, m coefficients as a function of the burnup, temperature, strain rate etc.

Fuel properties

As it has been noted earlier, the thermal conductivity for fresh and high burnup VVER fuel was additionally

introduced into MATPRO-V1 1. To determine the thermal conductivity of VVER fuel, the ratio of the

following type was proposed [101:

AB =2o KIK 2,

where A. = thermal conductivity of fuel for current burnup (W/m K);

Ao = thermal conductivity of fresh fuel (W/m K) [9];

K, = coefficient accounting for dependence of thermal conductivity on fuel composition;

K2 = coefficient accounting for dependence of thermal conductivity on fuel porosity.

In its turn, the thermal conductivity of the fresh fuel with a given density p is determined using the following

correlations:

A. = 2.158.4.95 ,

32.91 -p

-10.95 100 +1.1.10-4T+I.01.10-" .T 3 -exp(7.2-10-4 -T),

0.0258T + 3.77

where %095 = thermal conductivity (W/m K) for fuel with relative density = 0.95;

p = density of fresh fuel (g/cm3);

T = temperature (K).

Coefficients KI, K2 are determined on the base of SIMFUEL thermal conductivity [33, 34]:

0.053+2.210-4T

K, = 0.053+1.7110- 3b+(2.2-5.3310-4b)10-4T' K2 = 1- 0.001cb,

c =5.31-3.4210- 3T+4 lO-7T2forT < 1773K,

c = 0.5forT > 1773K,

where K,, K2 , c = coefficients (per-unit);

b= burnup (MWday/kgU);

T= temperature (K).

Regarding the specific heat for VVER fuel, results presented in section 5.2 show that, firstly, output

parameters of FRAP-T6 code are rather sensitive to this parameter, and, secondly, the initial data base

characterizing the specific heat of VVER fresh fuel is very different from corresponding data for PWR fuel.

Therefore, an original data base with specific heat for VVER fuel was prepared in accordance with data in

Table 5.14 [8].

Table 5.14. Specific heat of VVER fresh fuel vs. temperature [8]

Parame- Temperature (K)

ter 300 500 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 2900 3100

Specific

heat 270 287 302 310 314 319 320 328 340 364 '390 426 470 520 594

(J/kg K)

5.48
5.7. Validation of IGR/VVER versions of FRAP-T6 and SCANAIR codes

5.7.1. General principles of validation

Verification procedures were the main basis to test and validate these versions of codes. The complex of

original in-pile and out of pile tests and research was performed in order to get the data base for verification.

But the obtained results were not enough to check the quality of modeling of each physical phenomena

presented in Table 5.1 (section 5.1). Besides, at this stage this was not the main objective of the code

validation.

The main objective was to verify reliability in predicting of as much as possible of the calculated parameters

presented in Appendixes G, H, I of Volume 3 as the integral elements of the data base on the behavior of the

VVER fuel rods under IGR/RIA test conditions.

That is why the specific approach was developed to verify FRAP-T6 and SCANAIR codes in the framework

of this task. The approach schematically described in Fig. 5.27 consists of several stages of verification of

the calculated results. Each of the stages contains the integral check procedure and the procedures to check

the separate physical phenomena. Cladding temperature versus time is the basic verification criterion for the

integral check procedure. Practical experience indicates that the cladding temperature is very sensitive to the

quality of the models used in the codes. That is why the adequacy of the calculated and measured cladding

temperature is a reliable guarantee that the main set of other output parameters characterizing fuel rod

behavior will be determined correctly. Still, it is important to note that the model of heat transfer from

cladding to coolant is often the main reason of discrepancies between the predicted and actually measured

cladding temperature.

Fig. 5.27. Scheme of verification for FRAP-T6 and SCANAIR

5.49
So three sequential stages of verification procedures were planned:

1. Code validation for simple boundary conditions of heat transfer at the cladding surface (heat transfer to

air coolant).

2. Code validation for test conditions with the water coolant and test modes before departure from nuclear

boiling (DNB).

3. Code verification for test conditions with the water coolant and test modes after departure from nuclear

boiling.

It is important to note that serious complications arose during the analysis of representativity of the test data

base for the integral check of codes. The main problem was that this test data base was obtained for the fresh

WER fuel rods tested at IGR reactor.

That is why we also performed the procedures to check the specific phenomena for high burnup fuel rods.

These procedures intended to compare the calculated and measured parameters characterizing the following

processes:

* fission gas release;

* clad hoop strain;

" clad failure.

Besides checking of the separate phenomena was done to validate the code models used for prediction of the

ballooning type cladding rupture and cladding oxidation.

5.7.2. Assessment of verification results

5.7.2.1. Assessment of integral check results

As it has already been noted, the first stage of the verification was carried out using fresh fuel rods tested in

the air coolant. The verification base consisted of five fuel rods. Calculated and measured time history of the

cladding temperature for one of fuel rods is presented in Fig. 5.28. In general, obtained results demonstrate

that both computer codes predict rather adequately the cladding temperature. In its turn, this allows to

conclude that both codes describe correctly the set of all physical phenomena that influence the fuel rod

cladding temperature.

1200

IGR est 92-03

900 -

600 - 0_______ o.mpemture.(measured) cie 

300

0 5 10 15 20 25 30

Tune (s)

Fig. 5.28. Measured and calculated cladding temperature for air coolant

5.50
The following verification stages were intended to assess the quality of both codes for water-cooled fuel

rods.

These procedures were provided for two characteristic modes of the heat exchange on the fuel rod surface. In

the first case the heat flux from the fuel rod to the coolant did nct exceed the critical heat flux. In the second

case the verification was performed for fuel rods in which modes of the transient and film boiling were

reached. It was difficult to select representative fuel rods for these procedures, since the analysis of many

results of the fuel rod temperature measurements for modes with the surface boiling shows that the

temperature distribution in the axial and azimuthal directions is largely non-uniform. This non-uniformity is

of a random nature caused, probably, by the formation of the socalled hot spots on the cladding surface.

Naturally, methodological errors of thermocouples that were used for temperature measurements also

affected the final measurement results. Taking into account above mentioned factors, the following approach

was developed to select representative measurements:

* comparative analysis of temperature measurement results for a group of fuel rods that were rather similar

in test conditions;

" selection of measurements that demonstrate the maximum values of temperature vs. time for this group of

fuel rods.

Thus, a possible measurement error due to the thermocouple installation method, thermocouple dimensions

and its position was minimized.

Verification results of FRAP-T6 and SCANAIR codes for the nucleate boiling regime and film boiling

regime are presented in Fig. 5.29, Fig. 5.30.

The analysis of verification results of FRAP-T6 and SCANAIR codes in these regimes shows that certain

issues remain unresolved. In all cases under consideration, both codes predict an earlier beginning of the

nucleate boiling in comparison with the experiment. Moreover, both codes provide some overestimation of

the maximum cladding temperature for the film boiling and the cladding temperature for the transition from

the film boiling to the nucleate boiling.

However, in general it is possible to conclude that for this type of fuel rod cooling modes, results of integral

checks demonstrate a good agreement between measured and calculated temperatures. This allowed to begin

the following stage of the code validation with the aim of checking separate effects.

Fig. 5.29. Measured and calculated cladding temperature for nucleate boiling regime

5.51
1600 

500

1600 500

1200 A clad outer temperature (mesured) 375

gZ power of fuel red (mneasured')______

800 250

400 125

0 0

0 2 4 6 8 10

Time (s)

Fig. 5.30. Measured and calculated cladding temperature including post-CHF regimes

5.7.2.2. Assessment of results of separate phenomena check

Various test data bases were used to verify separate phenomena at each stage shown in Fig. 5.27.

Summarized results of these studies were grouped individually for each of the phenomena and are presented

in this section.

Fission gas release

From the point of view of code verification, this physical phenomenon is of a principal value only for the

high burnup fuel. In this case the optimum verification variant must include two levels:

" verification of calculation methods for the fission gas release during the base irradiation of VVER

commercial fuel elements;

" verification of results of fission gas release calculations during the IGR transient tests.

The first verification level allows to obtain results characterizing the quality of the preparation of input data

on fission gas distribution in VVER fuel rods before, IGR tests. As it has already been noted, this type of

calculations was performed using FRAP-T6 and TOSUREP codes. In this case the fuel cycle of one of fuel

elements of 5he unit NV NPP was modeled by each code. Within the framework of the verification procedure,

the same calculation was performed using TRIFOB code [15], that is described in detail in Chapter 4. For

this case, TRIFOB code calculated 8 main fission products (Xe', Rh'05, Sm' 49, Sm'51 , Pm' 49

, Pm'51, Cd 13 ,

Cd'5 ), 4 effective fission products for U 23 , Pu239, Pu2 with their precursors and 8 isotopes Kr and Xe (Kr83

,

Kr84 Kr85 Kr 6

, Xe 31

, Xe 32, Xe'34 Xe'36). TRIFOB code took into account an additional release of nuclides

Kr and Xe through the following channels: Kr83(nY)Kr 4 , Xe'31(n,y)Xe132

, Xe' 35(ny)Xe'3 6. The radioactive

decay of Kr 5 was also taken into account.

As a result of the verification procedure, results obtained using three independent codes were compared.

Comparative results presented in Fig. 5.31 demonstrate a good agreement in fission gas generation predicted

by the codes. Although results are somewhat different from each other, nevertheless this difference is not of

a principle nature for parameters such as the fission gas release. The verification of the radial distributions of

fission gases was performed in a similar procedure scheme; it is results are presented in Fig. 5.32.

5.52
Fig. 5.31. Specific fission gas generation vs. burnup calculated by FRAP-T6, TOSUREP, TRIFOB

computer codes for fuel elements #317 during the fuel cycles of NV NPP

Fig. 5.32. Radial distributions of fission gas generated in fuel calculated by FRAP-T6, TOSUREP,

TRIFOB computer codes for fuel element #317 at burnup 48 MWd/kg U

Unfortunately, this stage of the codes validation was not confirmed by a corresponding test data base.

However the next verification level has a test data base that is sufficient for the assessment of not only results

of the fission gas release during the IGR transient tests, but also calculational results of this phenomenon as a

whole.

The data base described in Appendix G of Volume 3 characterizes the fission gas release and Kr

concentration in the fuel grains after the IGR tests for four VVER fuel rods. Corresponding calculations

using FRAP-T6 and SCANAIR codes were conducted for these four fuel rods and summarized results are

presented in Table 5.15. TRIFOB code was used to calculate Xe-to-Kr connection ratio.

5.53
The analysis of results in Table 5.15 allows to make the following conclusions:

" FRAP-T6 and SCANAIR codes predict correctly Kr concentration in the fuel after IGR test. This

confirms the fact that the entire scenario of Kr formation (during base irradiation and during IGR

irradiation) is calculated by these codes with a good accuracy;

" the fission gas release is predicted by both codes with a satisfactory accuracy for this class of physical

phenomena; however a tendency to underestimate the fission gas release for modes with relatively low

fuel temperatures is obvious.

In general verification results demonstrate that both codes can be used for the development of the data base

on fission gas release.

Table 5.15. Comparison of measured and calculated parameters of fission gases

Number of fuel rod Parameter HIT H4T H6T H8T

" FRAP-T6 2681 2313 1920 1489

" SCANAIR 2593 2229 1813 1386

" measured 0.13 0.13 0.14 0.16

" calculated by FRAP-T6 code 0.15 0.15 0.15 0.13

" calculated by SCANAIR code 0.17 0.19 0.20 0.20

" measured 1.39 1.01 0.59 0.49

" calculated by FRAP-T6 code 2.26 1.34 0.65 0.10

" calculated by SCANAIR code 2.48 0.59 0.31 0.36

" measured 13.02 9.71 5.4 4.05

• calculated by FRAP-T6 code 13.53 8.06 3.29 0.80

* calculated by SCANAIR code 14.89 3.51 1.86 2.16

Cladding oxidation

Unfortunately, SCANAIR code contains no model to calculate cladding oxidation. As for FRAP-T6 code,

original correlations for Zr-lNb alloy were used to describe the phenomenon of cladding oxidation with

water coolant under IGR test conditions. Special measurements of the oxidation thickness were performed

with the cross-sections of VVER fuel rods tested in IGR reactor. Results of these measurements are

presented in Appendixes G, H, I of Volume 3. Description of the measurement procedure is presented in

section 3.4 of Volume 2. This data base was used to verify the respective model of FRAP-T6 code.

Results of comparison of the tested and predicted values for ZrO2 thickness are listed in Table 5.16.

5.54
Table 5.16. Measured and calculated ZrO2 thickness for VVER fuel rods with water coolant

Number of fuel rods Parameter--- ---

HIT H2T H4T H5T H6T H7T H8T H14T H15T H16T H17T HI8T H6C

State of cladding before IGR

tests:

" irradiated + + + + + + + + + + + + -

* unirradiated . . . . . . . . . - - - +

Calculated peak

cladding outer 1149 1231 437 1212 432 1221 426 417 1301 433 428 425 1415

temperature (K)

Region of

measured ZrO2 5 8-18 5 10-17 5 5 5 5 5 5 5 5 5

thickness (un)

Calculated peak

value ofZrO2 5.29 5.5 5 5.31 5 5.32 5 5 5.73 5 5 5 7.07

thickness (pm) I I I I I I I

Fuel rod #H3T was excluded take into account melting of fuel and cladding

Analysis of the results presented in Table 5.16 indicates that there exists underestimation of ZrO2 thickness

for fuel rods ## H2T and H5T, and some overestimation of ZrO2 thickness for fuel rods ## HIT, H7T, HI 5T,

H6C. That is why the question arises whether the calculation of the time history for the cladding temperature

was accurate enough, and as the consequence, whether the initial data characterizing energy deposition in

fuel rods were accurate. Detailed review of these issues will be done in section 5.8. As for the verification

problems, the main issue is the analysis of the consequences of the cladding oxidation underestimation with

the help of the used oxidation correlation (see the results for fuel rods ## H2T, H5T). Consequences of the

possible overestimation of the cladding oxidation (fuel rods ## HIT, 117T, H15T, H6C) will in any case be

disappearingly small, and besides, it is possible to state with great confidence that overestimation of ZrO2

layer thickness (up to 14 %) in this case is caused by high level of uncertainty of the initial value of ZrO2

thickness before IGR tests and by insufficient representativity of the measured ZrO2 thickness (one crosssection for each fuel rod of this group).

Analysis of the consequences of the underestimation of the cladding oxidation was done by artificial 15 time

increase of the oxidation rate in the used kinetic correlation. This new correlation was used to calculate fuel

rod #112T with the same initial energy deposition. The calculations indicated that thickness of ZrO2 layer for

this specific case will be 19 pm, i.e. it will be approximately equal to the maximum measured value of ZrO2

thickness for the fuel rod #H2T. In this case the peak cladding temperature increases by 25 K and peak fuel

enthalpy increases by 4 callg fuel. The obtained results indicate that the impact of the error (because of

underestimation of the cladding oxidation) onto the other parameters is insignificant. The other problem

connected with the use of this version of FRAP-T6 code to calculate fuel rods cooled with air was: on the

one hand it is known that the oxidation rate of Zr alloys in the air exceeds several times their oxidation rate

in the steam, on the other hand, the data characterizing oxidation kinetics of Zr-INb in the air were never

published. Hence, calculations of oxidation were not performed for those fuel rods by FRAP-T6 code.

Evaluation of potential errors in predicting cladding temperature and fuel enthalpy in the framework of this

approach leads to approximately the same results as for the fuel rods cooled with water.

Thus the verification has indicated that:

" understanding of the oxidation kinetics for Zr-liNb claddings for transients should .be improved in the

future;

* majority of the predicted results characterizing oxidation of fuel rods cooled with water is in good

agreement with the test data base;

" lack of oxidation models in the SCANAIR code and oxidation model for the cladding cooled with air in

FRAP-T6 code do not practically influence the other calculation results.

5.55
Mechanical behavior of fuel rods

Test data base characterizing internal gas pressure vs. time, time of cladding failure and cladding residual

hoop strain was used to verify mechanical behavior of VVER fuel rods under IGR test conditions.

Internal gas pressure vs. time is an important parameter influencing the deformation behavior of the cladding

of the VVER pressurized fuel rods. Verification of the respective models was done with fresh fuel rods

equipped with pressure transducers (Chapter 4 of this Volume). Verification results for two fuel rods

characterizing time history of the pressure for the failed fuel rod with the air coolant and time history of the

pressure for the failed fuel rod with water coolant are presented in Fig. 5.33 and Fig. 5.34. Calculation of

internal gas pressure by SCANAIR code are presented up to ballooning initiation, because SCANAIR code

does not predict the fuel rod behavior under these conditions and does not calculate the time of the cladding

rupture.

2.1 1500

1.4 - 0 ~ l~ mrdg- wt? I pre:ssur , ( c Calcu lated by. FRAP) 1 0 1

-* internalg3pc! kr (ca cultdby SCNAIR) - clad outer t. pcratuw. (measur.d) .. 500

~0.7 initrw4I gas press6urc (measured)

0.0 , .... 0

05 10 15 20 25 30

Tune (s)

Fig. 5.33. Calculated and measured internal gas pressure vs. time for failed fuel rod cooled with air

3.6 - 2100

IGR test 96-0 9

~2.4 4wa 'A1400

Ima gas pressuxu (calulated1 by FRAPMl

1.2 -- clad ouert emprature(mcasured) 700

0.0 .. 0

0 1 2 3 4 5

Time (s)

Fig. 5.34. Calculated and measured internal gas pressure vs. time for failed fuel rod cooled with water

5.56
Analysis of the presented results confirms the fact that calculation of internal gas pressure by this version of

FRAP-T6 code is done correctly enough. Results obtained by SCANAIR code demonstrate good agreement

with the test up to the ballooning stage. Still evident problems arise if we try to use SCANAIR code to

calculate internal gas pressure under ballooning conditions, because the fuel rod geometry changes greatly in

this case, and the cladding rupture occurs. That is why the decision was made not to use SCANAIR code to

calculate this parameter for the respective test conditions in the framework of the computational data base

development.

The next item in the verification procedure for mechanical behavior of VVER fuel rods was the failure

conditions of the cladding. This verification stage was done for FRAP-T6 code only. In fact BALON2

subroutine with the original VVER mechanical properties was subject to verification.

Detailed checking of BALON2 subroutine was done with the help of the test data base obtained for fresh fuel

rods equipped with the cladding thermocouples and pressure transducers (see Fig. 5.33 and Fig. 5.34). The

checking has indicated that the predicted and measured failure parameters were in good agreement.

Results presented in Fig. 5.33 indicate that there exist a discrepancy between the calculated and measured

failure time equal to 1.4 s. But this does not practically influence any of the other output parameters, because

all of these parameters are the quasi steady-state ones in this time interval. The indirect confirmation to the

fact that the developed version of FRAP-T6 code predicts failure conditions adequately enough is the

comparison of the actual and predicted cladding rupture for all the 25 fuel rods presented in the data base of

Volume 3. This comparison indicates that FRAP-T6 code was always correct in predicting the presence or

absence of the fuel rod failure.

The last stage in the verification procedure for mechanical behavior of fuel rods was checking of the

cladding hoop strain calculations. The checking was performed for two different end states of the fuel rods:

" unfailed fuel rod;

" failed fuel rods due to ballooning.

Thus, the first group of fuel rods allowed to check the quality of predicting the cladding hoop strain before

ballooning phenomenon. The second group ensured checking of the prediction of the limiting values of the

cladding hoop strain typical for the cladding failure of the ballooning type. It is obvious that SCANAIR code

was checked for the first group of fuel rods only. Though the fuel rods of the first group are characterized by

insignificant residual strains, analysis of their behavior is very useful to understand the initial stage of the

cladding plastic deformation. Wide verification data base characterizing these processes exists for fresh and

high burnup fuel rods. But the most useful are the comparative results of the profilometry before and after

IGR tests for high burnup fuel rods. Such results exist for four fuel rods ## HI T, H4T, H6T, H8T. Still in the

three of them measured residual hoop strain is equal to zero, that is why fuel rod HIT was used to check the

measured and calculated residual hoop strain of the cladding vs. axial coordinate. Results presented in Fig.

5.35 demonstrate the real and predicted cladding residual hoop strain obtained mainly at the stage of the

pellet-cladding mechanical interaction (PCMI). Comparative analysis indicates that both codes predict

average strain along the length of the fuel rod well enough, though FRAP-T6 code has some tendency to

overestimation of the clad strain. Besides, the obtained results illustrate that deformation of the cladding of

the standard fuel element is determined by the effects, which are not considered in the existing code models.

Hence this stage of verification allows to make a conclusion that it is expedient to calculate weighted mean

values of the cladding hoop strain only.

The focus of the next verification stage was targeted at checking of the quality of the peak clad hoop strain

calculations for the fuel rods that had failed due to ballooning. This type of the cladding deformation is

modeled by BALON2 subroutine driven by FRAP-T6 code.

5.57
5

4.

2

0 08.

0.00 0.04 0.08 0.12 0.16 0.20

Elevation of fuel rod (in)

Fig. 5.35 Calculated and measured cladding residual hoop strain vs. axial coordinate for fuel rod

#H1T

It is important to note that the special cycle of experimental research necessary to adapt BALON2 subroutine

for the VVER cladding was performed in 1997. The major part of results of this research, which are

described in details in Chapter 6 is already included into the input data for BALON2, but the final analysis

and generalization of the data were done after completion of verification procedures. Hence it was assumed

that some certain additional modification of BALON2 subroutine could be done in the future.

Verification data base necessary to check the peak clad hoop strain predicted by BALON2 subroutine was

developed on the basis of both the results of testing VVER fuel rods presented in this report, and on the

results of earlier IGR tests. Comparative data characterizing the measured and predicted hoop strain are

presented in Fig. 5.36.

water coolant [ ir coolat] ubr Nme 50 Number Numbrr

of of

position IGR test

40 O measured irradiated F I 103F-17

c ealculated Cladding 2 103F-14

measured 1 unirradiated 3 56F-29

calculated n 4 103F-10

305 5OF-6

6 103F-7

7 50F-7

20 8 103F-16 • •9 ••' 103F-18

10 103F-22

10 I I 103F-4

12 103F-6

0

0 1 2 3 4 5 6 7 8 9 10 11 12

Number of position

Fig. 5.36. Measured and calculated peak clad residual hoop strain for ballooning area (original

approach)

5.58
Obtained results indicate that FRAP-T6 code systematically underestimates peak clad residual hoop strain

for the ballooning area. It is even more evident for the fuel rods cooled with air when the values of clad hoop

strain are of 20 % and higher. An analysis of models used in the BALON2 program was performed to

understand causes of a considerable difference between experimental and calculated data.

BALON2 belongs to a group of codes that allow to calculate the asymmetric cladding deformation in time.

For this purpose the assumption on the azimuth non-uniformity of the cladding temperature is used during

the initialization of the BALON2 program. In this case, temperature variations significantly affect the value

of the circumferential elongation. The effect of the elongation decrease with the increase in the temperature

non-uniformity was intensively studied in experiments that simulate LOCA [35, 36]. According to

experiments, this effect is a key factor that influence the cladding elongation. Parametric calculations using

the FRAP-T6/BALON2 code also demonstrated a significant sensitivity of the circumferential elongation at

burst to the azimuth variation of the cladding temperature (Fig. 5.37).

80

60

40__ _ _ _ __ _ _ _

20~ _ _ _ _ _ _

0

0 50 100 150 200 250 300 350

Temperature variation (K)

Fig. 5.37. Calculated cladding circumferential elongation at burst vs. azimuth variation of temperature

IGR test results do not allow to quantitatively estimate the azimuth variation of the cladding temperature and,

thus, to verify the calculation model of the asymmetric temperature field in the fuel rod. Nevertheless, it is

possible to make important qualitative conclusions based on post-test studies:-

* fuel rods tested in the water coolant are characterized by a considerable temperature non-uniformity along

the azimuth. This is confirmed by a low level of the circumferential elongation at burst and the local

necking of the cladding in the area of the burst tear;

* in case of the air coolant, the azimuth non-uniformity of the temperature field in the fuel rod is

considerably lower. As a consequence, the uniform deformation of the entire middle line of the cladding

takes place, that leads to much larger circumferential elongations at burst in comparison with watercooled fuel rods.

This is why two different approaches were used to describe the fuel rod behavior in the air and water coolant.

An original approach of the BALON2 to simulate the asymmetric temperature field in air-cooled fuel rods

resulted in unrealistic predictions of the cladding deformation at burst. To solve this problem, the BALON2

program was modified as follows. For the determination of cladding dimensions during the ballooning, the

assumption on the cladding bending in the axial plane is used, that leads to a relative offset of the fuel pellet

and the cladding till the time of the contact. At the time of the contact of the fuel and the cladding a sharp

surge of the cladding temperature is predicted in the contact zone. The use of the bending model for fuel rods

under consideration would be unjustified. Therefore, this model was disabled during calculations of aircooled fuel rods.

5.59
On the other hand, the bending model was used in BALON2 calculations for water-cooled fuel rods. It

should be noted once more that it was difficult to verify the model since there were no data on the azimuth

variation of the temperature. However taking into account the statistic nature of the film boiling and the

presence of the geometric eccentricity in the real fuel rod, the prediction of the fuel and cladding contact

during the ballooning can be considered as a simplified approach to the simulation of the "hot spot" on the

cladding under DNB conditions.

Calculation results of the peak deformation of failed fuel rod claddings were in a satisfactory agreement with

experimental data (see. Fig. 5.38).

70 ater- coolarn t I 0 H iN u 0Of mbe[ N um ber of IGR

position fuel rod

60 1 H5T

2 H15T S50 caculated o 0 3 1-2T 0 0 4 H7T

o 5 H6C ~40 6 BlOT

0 7 B9T

30 8 B22T

9 B21T

0 O 10 B20C 2 11 B20T

o 0

0 a , p a a p

0 1 2 3 4 5 6 7 8 9 10 11

Number of position

Fig. 5.38. Measured and calculated cladding residual hoop strain for ballooning area (modified

approach)

At the same time the calculation experience using the BALON2 subroutine demonstrated that for more

adequate deformation calculations during the ballooning under RIA conditions, it is necessary to develop

more accurate fuel rod thermal models that allow to reduce uncertainties and get adequate estimates of the

mechanical behavior of fuel rod claddings.

5.8. Main provisions of the procedure to obtain calculation results by FRAP-T6

and SCANAIR codes

The developed versions of FRAP-T6 [37] and SCANAIR codes [38] were used to calculate the behavior of

25 VVER fuel rods tested in IGR reactor under RIA conditions. These calculation results are presented in

Appendixes G, H, I of Volume 3. Taking into consideration specific features of the codes, as well as specific

features of three different types of fuel rods, the following approach was developed to get the computational

data base done:

" main set of parameters characterizing fuel rod behavior was calculated for axial coordinate corresponding

to the peak axial power in each fuel rod;

" SCANAIR code was not used to calculate cladding oxidation parameters of the fuel rods, and FRAP-T6

code was not used to calculate cladding oxidation parameters for the fuel rods cooled with air;

" calculations characterizing fission gas behavior in the fresh fuel were excluded out of the data base, as

they represent no practical interest;

5.60
" taking into consideration that in SCANAIR code there is no model characterizing cladding deformation of

the ballooning type, and the models predicting failure of fuel rods, calculation results obtained by

SCANAIR code are to be presented in the data base up to the fixed time of initiation of clad plastic

deformation due to inner gas pressure. As described in section 5.5.3.5 thermal dynamic calculations for

HIT fuel rod were obtained and presented for the whole time period:

pellet-cladding gap reopened;

= cladding stress achieved yield stress;

" calculations are completed and calculation results are not to be presented into the data base starting with

the fixed time moment for which the condition of the peak fuel temperature reaching the fuel melting

temperature is observed.

Detailed description of the specific features characterizing computational data base presented in Volume 3 is

given in Chapter 1 of Volume 3.

5.9. Data base to verify FRAP-T6 and SCANAIR codes with respect to thermal

parameters

Special instrumented fuel rods were used to verify computer codes. Fig. 5.39 presents the view of such a fuel

rod.

Upper plenum thenrocouple ] I Fud thennmouple I

Fig. 5.39. View of the instrumented VVER fuel rod

Generally, it was possible to measure the following parameters with the help of instrumented fuel rods:

* gas pressure inside the fuel rod;

" gas temperature in the upper plenum;

" fuel temperature;

" cladding temperature.

5.61
All instrumented fuel rods were fabricated of unirradiated materials so that the active part of the

instrumented fuel rods was the same as of the traditional unirradiated fuel rods. The only difference was that

from two to six thermocouples were located on the cladding surface.

It was noted earlier that two measured parameters were used to verify FRAP-T6 and SCANAIR codes:

" gas pressure inside the fuel rod;

" cladding temperature.

It was not an easy task to develop instrumentation methods to measure these parameters under IGR/RIA test

conditions. For example, two contradicting requirements were drawn to the gas pressure detector:

" high quality of the transfer function for the system consisting of the pulse tube, pressure detector,

amplifier, etc.;

" low sensitivity to irradiation taking into consideration that during these tests neutron flux density in IGR

reactor reached 1.0 1016 n/cm2s.

Therefore the special detector was designed on the basis of the inductive type pressure detector. The time

constant of the pneumatic line of this detector was 0.01 s, and the measurement error - 7 % in the dynamic

mode if the pressure shock duration was 0.01 s. There were many problems connected with designing of

detectors to measure cladding temperature under RIA conditions. In this case it was necessary to satisfy the

following main requirements:

" to ensure that the temperature measured by thermocouple is the temperature of the cladding, and not

something intermediate of the cladding and coolant temperatures;

" to have the minimum possible dimensions of the thermocouple hot junction, so that the dynamic

measurement error under transient temperature mode is acceptable;

" to locate thermocouples on the cladding in such a way that the azimuth temperature distribution can be

controlled.

The main effort of the final cycle of the research was focused to these issues. Description of the research

work and its results is beyond the frames of this Report. It is necessary to state, though, that two main types

of thermocouples were chosen to measure cladding temperature:

" W/Re or chromee-alumee thermocouples in the protective shroud with the typical dimension of about 0.4

mm, located in the grooves made on the cladding, fixed by welding;

" W/Re thermocouples with the open hot junction welded to the cladding surface.

RRC "Kr' was the program manager of the investigations targeted at the designing of the instrumented fuel

rods. Different Russian Institutes participated in the designing of these fuel rods at different stages of the

program. Initial stage of the work is described in [39]. Results of the other stages of work have not been

published. The greatest contribution to the development of the instrumented fuel rods was made by Dr. V.

Nalivayev, and the experts of the "Technoluch" Division headed by him of the Scientific Industrial

Association "Luch" (Podolsk, Russia).

Measurement results of the gas pressure inside fuel rods used as the data base to verify FRAP-T6 and

SCANAIR codes were obtained by the pressure detectors developed at the same organization. Some part of

the used temperature measurements was also obtained owing to the efforts of the same team of experts. Still,

the measurement results based on the procedures described in [39] were also used for the verification.

Selection of the verification test data base was performed very carefully. The main problems were connected

with the choice of the representative measurements of the cladding temperature for the test modes, when

departure from the nucleate :boiling took place. Two circumstances could significantly influence the

measured history of the cladding temperature:

* systematic measurement errors (bad contact of the thermocouple and the cladding, imperfection of the

thermocouple design, etc.);

e high degree of non-uniformity of the r, 0, z temperature distributions under crisis of the boiling

conditions.

5.62
We believe, there is no need to describe the importance of the first issue in detail. The data presented in Fig.

5.40 will allow to understand the degree of importance of the second issue.

Fuel pellet

Fig. 5.40. Cross-section of the VVER fuel rod after IGR test

We selected the fuel rod that was tested under peak fuel enthalpy higher than the failure threshold, because in

this case oxidation of the cladding during film boiling reaches clearly expressed values. Cross-section of this

fuel rod was made, and the photograph of the cladding microstructure was made for four azimuth angles. The

data presented in Fig. 5.40 state that there was significant temperature non-uniformity in this cross-section,

because in the two cross-sections significant ZrO2 layer and the layer of a-Zr stabilized by oxygen were

formed, but those effects were completely absent in the other two cross-sections. That is why even if the

cladding temperature would have been measured with the absolute accuracy in each of those positions, the

measurement results would still have been different by no less than 200-250 K in the point of the

temperature maximum. If we analyze both of the above problems, we can notice that:

1. any systematic measurement error leads to underestimation of the cladding temperature;

2. if the cladding temperature is measured in several points, then it is always possible to chose such a

measurement (out of the series of the similar type measurements), which most accurately reflects the

temperature scenario for the hottest part of the cladding.

Therefore, if for the given level of the peak fuel enthalpy we select (of the measured mass of temperature

histories) the history with the maximum temperature, and perform verification of the computer code just for

the cross-section with the peak enthalpy, we can assume with good confidence that the used test data base is

representative. This was the approach used to prepare the data base for verification of FRAP-T6 and

SCANAIR codes.

5.63
5.10. Analysis of the computational data base to characterize VVER fuel rod

performance under IGR test conditions

The main objective of this analysis was directed to:

" reveal such specific differences in the calculated parameters, of fuel rods which are caused by the

corresponding differences in the mathematical models used by FRAP-T6 and SCANAIR codes;

" compare calculated and measured results, and to assess reliability of the obtained computational data

base.

Decomposition of the tested scenario can be done in the framework of the following approach in order to

review the complex of physical phenomena which determined WER fuel rod performance under IGR test

conditions:

1. The stage when there exists the open gap between the fuel and cladding.

2. The stage when the gap disappears, and mechanical interaction between fuel and cladding takes place.

3. The stage when the gap reopens, and the cladding is loaded with the gas internal pressure.

Specific features of the change of parameters of all types of fuel rods for each of these stages of scenarios are

reviewed later, and analysis of the data base for peak fuel enthalpy and the data base for cladding failure was

emphasized as a separate issue.

5.10.1. Analysis of the scenario first stage

Some group of representative parameters was selected to analyze the calculated behavior of the three typical

fuel rods (Fig. 5.41):

* high burnup fuel rod tested in the water coolant (#H1T);

, high burnup fuel rod tested in the air coolant (#B9T);

• fuel rod with fresh fuel and irradiated cladding tested in the water coolant (#Hl6T).

Analysis of the data presented in the figure demonstrates that both of the codes predict practically identical

thermal parameters of different types of fuel rods, tested in different coolants. The main problem that was

revealed during this type of scenario was caused by the fact that FRAP-T6 and SCANAIR codes predicted

different time histories for the gas gap in high burnup fuel rods. If we take into consideration the fact that

there are no differences in the prediction of time histories for the cladding temperature and cladding hoop

strain, then it becomes evident that the discrepancy between time histories for the fuel total hoop strain can

be the reason caused the discrepancy between time histories for the gas gap. The data presented in Fig. 5.41

confirmed to this conclusion. Still, total hoop strain of high burnup fuel includes two components:

" hoop strain due to thermal expansion;

" hoop strain due to fuel swelling.

In order to check the adequacy of calculations of the first component calculated results of the total hoop

strain were compared for fuel rod #1H16T. This fuel rod had the fresh fuel, and thus it was possible to assume

that the swelling component was equal to zero. It is demonstrated in Fig. 5.41 both codes calculated fuel

hoop strain caused by thermal expansion completely adequately. It is evident that the models describing fuel

swelling were the source of discrepancy between the codes. Analysis of the respective results has

demonstrated that FRAP-T6 code predicted much higher values for fuel swelling than the SCANAIR code.

Unfortunately, it is impossible to verify these code models using WER/IGR test data base. Therefore,

additional effort will be made to assess reliability of each of these results during the stage of preparation of

the Final Report.

5.64
Fig. 5.41. Parameters of some fuel rods for the first stage of IGR tests

5.65
5.10.2. Analysis of the scenario second stage

Three fuel rods were also selected to assess the results of this stage of scenario (Fig. 5.42):

* high burnup fuel rod tested in the water coolant (#H4T);

" high burnup fuel rod tested in the air coolant (#B9T);

" fuel rod with fresh fuel and irradiated cladding tested in the water coolant (#HI6T).

This stage of scenario is characterized by the situation when the PCMI occurs after the gas gap is closed, and

high cladding hoop stresses can occur due to PCMI effect. Cladding failure can occur during this stage of the

scenario, therefore it is extremely important to assess the calculated results for the group of representative,

parameters.

It has already been noted that different calculated time histories for the radial component of fuel swelling,

and accordingly for the fuel total hoop strain resulted in the situation that FRAP-T6 code predicted earlier

gas gap closure, than SCANAIR code for two high burnup fuel rods. This leads to the situation that the

typical process of the abrupt increase of the cladding stress started according to the FRAP-T6 scenario by 0.5

s earlier than according to SCANAIR scenario (for the high burnup fuel rod cooled with water). Besides,

FRAP-T6 code predicted a little higher level for the maximum cladding hoop strain during PCMI stage. Still,

taking into account complexity of physical phenomena, determining the dynamics of the process, it is

possible to consider that agreement of the results, predicted for the cladding hoop stress in the high burnup

fuel rod cooled with water, is satisfactory. Calculated results for the cladding hoop stress in the high burnup

fuel rod cooled with air differ much more, because this fuel rod has demonstrated the case when FRAP-T6

had predicted gap closure and PCMI stage, and SCANAIR code had predicted that the gap would not be

closed, and no PCMI stage would take place. That is why time histories for the cladding hoop stress

predicted by two codes differ in principal. This also confirms to the earlier made conclusion that in the future

special attention is to be paid to the problem of fuel swelling. As for the fuel rod with fresh fuel, this stage of

the scenario is not important to analyze reliability of predicting cladding hoop stress, as the gas gap remains

open, and the PCMI effect does not take place in this type of fuel rods.

One more issue was revealed during the comparative analysis of the results obtained over this phase by two

codes. Significant discrepancies were revealed between time histories predicted by the codes for the

following thermal parameters in the fuel rods cooled with water:

" fuel temperature;

" fuel enthalpy;

" leakage of energy.

It is evident that two main reasons can lead to these discrepancies:

" different models are used in SCANAIR and FRAP-T6 codes to describe heat transfer from the fuel rod to

the coolant;

" SCANAIR and FRAP-T6 codes predict time histories of the gas gap width differently, and assess gas heat

conductance through the gas gap differently.

Theoretically both reasons can take place. Therefore, the first one was analyzed at first. During the first stage

we assessed behavior of the fuel rod #B22T cooled with air. This fuel rod was chosen as the referenced one,

because it had the minimum peak fuel enthalpy of the group of air cooled fuel rods, and therefore,

SCANAIR code ensured its analysis up to the maximum parameters. Besides, completely the same models

were developed for SCANAIR and FRAP-T6 codes to calculate heat transfer to the air coolant. Results of

calculations for the fuel rod #B22T are presented in Fig. 5.43.

The obtained results demonstrate that despite the fact that the same models were used to describe heat

transfer from the fuel rod to the air coolant, FRAP-T6 code predicted a little higher values for the

temperature of the fuel central line. Discrepancies between FRAP-T6 and SCANAIR codes obtained for this

fuel rod and other fuel rods cooled with air are not of the principal value, but those discrepancies indicate

that the heat flux from fuel to cladding is the reason for disagreement of the results. In order to review

individual aspects of this problem for the fuel rods cooled with water in more details, it is useful to analyze

the stage of the gas gap reopening as well.

5.66
Fig. 5.42. Parameters of some fuel rods for the second stage of IGR tests

5.67
1600 

1.00

1600 1.00

1200 - FRAP-T6 0.7

800 E0 ftiel-clad gap width 05

800 5••• : fuel:•i centre netem rat .- 0.50

400 0.25

0.00

0 2 3 4 5

Time (s)

Fig. 5.43. Time histories of some parameters for the fuel rod #B22T

5.10.3. Joint analysis of the second and third stages of scenario for unfailed fuel rods

cooled with water

Results obtained for #H4T and HI6T fuel rods were used as the basis for the analysis (Fig. 5.44).

This analysis has started with fuel rod #H16T with fresh fuel. It is also important to note that the discrepancy

between the predictions by FRAP-T6 and SCANAIR codes for time histories of thermal parameters for this

one and other fuel rods of the similar type is insignificant. Therefore, it is possible to consider that both

codes predict the behavior of this group of fuel rods well. Still, this is just the fuel rod that allows to clearly

illustrate the influence of the gas gap parameter onto the main tendencies determining time histories of

thermal parameters. Besides, it is important that gas gap size can decrease up to zero (just as presented in

Fig. 5.41, Fig. 5.42, Fig. 5.44) only in the frames of mechanical models of both codes. As for the thermal

models, then both codes assume that even in case of fuel-cladding mechanical contact some effective thermal

gas gap, which is due to roughness of the fuel and cladding surfaces, still remains. Moreover at the same

input data on the surface roughness (fuel roughness is 2 pum, and cladding roughness is 2 pim) FRAP-T6 code

predicts that the effective gas gap width will be 0.012 mm, at the same time SCANAIR code assesses this

value as 0.004 umm. In order to understand how it influences the fuel rod thermal parameters, it is expedient

to review the data presented in Fig. 5.45.

These data demonstrate that thermal parameters predicted by FRAP-T6 and SCANAIR codes start to vary

from ti time point. This time point characterizes such a state of the fuel rod after which the gap starts to

decrease, and then increases in the time range t, - t2 according to the logic of SCANAIR code, while FRAPT6 code assumes that the gap remains constant in the t, - t2 time range. The size of this gap is equal to the

effective width of 0.012 mm. The data presented in Fig. 5.45 indicate that the gas heat conductance

calculated by SCANAIR code exceeds significantly the. corresponding heat conductance calculated by

FRAP-T6 code due to the difference in the sizes of gas gap. This in its turn, leads to the fact that energy

leakage from the fuel to cladding and from the cladding to water takes place more intensively than for

SCANAIR option. Starting with the time point t2 agreement of results in prediction of thermal and

mechanical behavior of fuel rods by both codes is good. Some small discrepancy that exists is caused by the

fact that the fuel rod cooling process occurs starting with different initial fuel temperatures, registered by

both codes in the time point t2. At first sight it is not very clear, why approximately the same case leads to

more serious discrepancies of the fuel parameters in fuel rod #H4T at the stage of the open gap (Fig. 5.44).

5.68
#H4T #1116T

#H4T #H16T

I

L

Time (s) Time (s)

-FRAP-T6 ---- SCANAIR

Fig. 5.44. Calculated parameters of some fuel rods for the second and third stages of IGR tests

5.69
100-

50

0

0 2 4 68 10

Time (s)

20000- 0.100

~'15000 -0.075

10000-- 0.050

500 s. ta t (effeie gas gap width) 0.025-- 

0 =- - -r - ...... c Liv------with 0.000

0 2 4 6 8 10

Time (s)

Fig. 5.45. Time history of fuel enthalpy, leakage of energy from fuel rod, gap heat transfer coefficient

vs. gas gap width

In order to understand it we should first pay attention to the fact that FRAP-T6 code predicts significantly

larger size of the gas gap for the stage of the gap opening (5 - 10 s). As the consequence this code predicts

low energy leakage, higher fuel enthalpy, and higher fuel temperature. In order to understand the reason of

the great discrepancy between the codes in predicting the gas gap width it is expedient to compare time

histories of the cladding hoop strain presented in Fig. 5.44. Comparative analysis of the two curves obtained

by FRAP-T6 and SCANAIR codes indicates that FRAP-T6 code predicted not only much higher level of the

cladding hoop strain, but it also predicted cladding plastic deformation. It means that as soon as the fuel

starts to cool down, the gap size is determined not only by the decrease of the radial dimensions of the fuel,

but also by the residual hoop strain of the cladding. On the whole it is probable that these are the

consequences of discrepancies in the fuel swelling models revealed by the analysis of the first stage of

scenario. Still in this case, there was the possibility to check the values at the cladding hoop strain predicted

by FRAP-T6 and SCANAIR codes using the respective test data base. Outer diameter of the cladding versus

5.70
fuel rod length was measured for fuel rod #H4T using profilometry before and after IGR tests. Results of

these measurements were processed in accordance with the following procedure:

" average outer diameter of the cladding versus fuel rod length was determined by the results of

profilometry for the states both before and after test;

" -the difference of the average diameter versus axial coordinate was determined by deduction of the file of

the average diameters before test out of the file of average diameters after test.

The sign of the obtained difference characterizes presence and absence of the cladding residual hoop strain

for the fuel rod #H4T. Results of this procedure are presented in Fig. 5.46.

0.10

0.05

0.00

-0.05

-0.10

30 50 70 90 110 130

Axial coordinaft (nm)

150 170

Fig. 5.46. Measured results to estimate cladding residual hoop strain for fuel rod #H4T

These results clearly demonstrate the random spread of the measurement results around zero. I.e this

conforms to the fact that residual hoop strain is absent for the fuel rod H4T. Comparative data for the

cladding residual hoop strain are also listed in Table 5.17.

Table 5.17. Data base to characterize cladding residual hoop strain for fuel rod #H4T

Calculated and measured results

Parameter Experiment SCANAIR code FRAP-T6 code

Cladding residual hoop strain (%) 0 0 1.7

Thus, the presented data indicate that SCANAIR code predicts cladding strain for this fuel rod reasonably,

while FRAP-T6 code overestimates this parameter. Similar results were also obtained for the fuel rod #HIT

(Fig. 5.35).

Summarizing results of the analysis it is possible to conclude with the delicate confidence that FRAP-T6

code overestimates fuel swelling for high burnup fuel rods, and that leads to overestimation of the fuel hoop

strain and cladding hoop strain, and finally results in overestimation of the fuel enthalpy and fuel temperature

at the stage of cooling down of the fuel rod.

5.71
5.10.4. Analysis of the third stage of scenario for the failed fuel rods

This stage of analysis was performed for FRAP-T6 code only, because SCANAIR code does not contain any

models to predict fuel rod failure. Typical options of the scenario, that lead to the cladding failure of the

ballooning type are presented in Fig. 5.47 for two types of fuel rods:

" high burnup fuel rod #H5T cooled with water;

" high burnup fuel rod #B22T cooled with air.

Fig 5.47 shows time dependencies of key parameters at the failure stage for fuel rods H5T, B22T.

A key feature of this stage is the transition to the estimates of the local plastic deformation according to the

ballooning mechanism. As it has already been noted, during the PCMI the cladding temperature increases to

the level of 1100 - 1200 K. In this case its strength is reduced to the degree when its further deformation

takes place as a result of the internal pressure. When the plastic deformation reaches the value of the uniform

elongation, the calculation of the asymmetric deformation using the BALON2 subroutine is initiated in a

corresponding axial cross section. The subroutine uses the nodalization scheme that is independent from the

FRAP-T6 and consists of 16 azimuth and 16 axial partitions. The BALON2 predicts the cladding failure

when in any element the circumferential stress reaches the local burst stress. It should be noted that both the

uniform elongation, and the failure criterion for unirradiated and irradiated Zr-1%Nb claddings were

obtained on the basis of experimental studies described in Chapter 6. In this case the local burst stress

criterion is not a result of direct measurements, and was obtained under a number of assumptions (the

procedure to obtain this criterion is presented in section 6.4.1). After the failure the internal pressure is set

equal to the coolant pressure, and further changes in the cladding geometry (and fuel geometry) depend only

on the temperature expansion.

From the practical standpoint it is necessary to review two main issues while analyzing this stage of the

scenario:

" to estimate reliability of the peak cladding hoop strain prediction;

" to check reliability of the burst temperature and burst pressure prediction.

The first of these issues was actually reviewed in Chapter 5 during the stage dedicated to verification of the

FRAP-T6 code. Special burst tests were performed to verify the prediction validity of burst temperatures and

pressures. The comparison of experimental and calculated basic parameters of the failure (pressure and

temperature) is of interest from the point of view the integral verification of the analytical calculation model

and a corresponding failure criterion. Fig. 5.47 shows pressures and temperatures of IGR fuel rod failure,

that were predicted by the FRAP-T6, and results of burst tests (see. Chapter 6). For a more adequate

comparison, results of burst tests are presented in the form of a region that covers the range of pressure

increase rates 0.1 - 1.0 MPa/s. In accordance with calculation estimates, this range of pressurization rates is

characteristic for fuel rods tested under IGR/RIA conditions. Moreover, temperatures at the failure time

predicted by the main thermal model of the FRAP-T6, that uses the assumption of the axisymmetric

temperature field in the fuel rod, were considered as calculated failure temperatures. In this case such an

approach to the interpretation of calculation results seems to be justified since conditions of burst tests

assumed the azimuth uniformity of the specimen temperature. Therefore, a direct comparison of burst tests

results with BALON2 predictions, that are based on the assumption of the cladding failure in the "hot spot",

might be not quite adequate.

Thus, as it can be seen in Fig. 5.48, calculated burst pressures are in a good agreement with burst tests resuits. The chart also shows the predicted peak pressure and temperature of the intact HIT fuel rod cladding,

that are below the threshold region. Other intact fuel rods, according to calculations, did not reach the DNB,

and corresponding peak parameters are below the failure region obtained in burst tests. The comparative

analysis allows to make conclusions on a good reliability of predicting fuel rod cladding failures under

IGR/RIA conditions.

5.72
1~111ST 

~D2~T 9 15 9 B22T

IJ

I

I

Ij

I

I

1500 ue a

- - & atlballooning t

1400 at failure

1300

1200

1100!....

120 240 Azimuthal angle (dog)

Time (s)

360

Time (s)

Fig. 5.47. Parameters calculated by FRAP-T6 code for fuel rods ##HST, B22T vs. time

5.73
16

FRAP-T6 calculations of IGR tests :

12 12 I -4-

0.I

A failed

A intact

._NSI-RIAR burst tests

(dP/dt = 0. 1 - 1.0 MPa/s)

8-

f _ H15T, B22T B9T

ITH2T C

0 *1 I I'

1000 1100 1200 1300 1400 1500

Temperature (K)

Fig. 5.48. Comparison of FRAP-T6 results with burst test data

5.10.5. Analysis of peak fuel enthalpies at the cladding failure

It is the peak fuel enthalpy that is currently used as the criterion determining failure threshold of fuel rods

under RIA conditions. This is the reason why assessment of reliability of this parameter calculation is very

important. From the practical standpoint the most important group of the tested WER fuel rods is the group

with the peak fuel enthalpy close to the failure threshold or less than the failure threshold. In this case

comparison of the calculated results of the peak fuel enthalpy by the two preliminary verified codes was used

as the initial data base for the analysis (Fig. 5.49).

It has already been noted in section 5.10.3 that the differences in some of the models used by FRAP-T6 and

SCANAIR codes lead to the situation when FRAP-T6 code somehow overestimates the value of peak fuel

enthalpy in comparison with SCANAIR code. Average relative deviation of peak fuel enthalpies calculated

by these codes is about 3 %. Further attempts will be made to adjust the code models and to diminish the

deviations.

.0

0.

4)

4)

04

160

120

H14T H8T H18T H6T H17T H4T H16T HIT

Fig. 5.49. Comparison of peak fuel enthalpies calculated by FRAP-T6 and SCANAIR codes

5.74
5.10.6. Analysis of fission gas release calculated by FRAP-T6 and SCANAIR codes.

In the chapter describing verification procedures it is shown that satisfactory agreement of calculated and

experimental data on the integral release out of fuel and relative concentration of Xe and Kr in the free

volume of the fuel rod, as well as on the pressure inside the fuel rod after irradiation in the cold state was

obtained in the regime of pulse heating of fuel. To analyze dependence of Xe and Kr release out of fuel

versus temperature on the basis on the results of gas composition inside the cladding, it is necessary to take

into account the volume of gas mixture in the fuel rods. For instance, gas volume for fuel rods H8T, H6T,

H4T, HIT under normal conditions is 97, 123, 106, 107 cm3 (Table 5.15). Hence, for interpretation of the

calculated and experimental results of fission gas release we will use the absolute and not the relative volume

of the released fission gas, considering that experimental fuel rods have reached approximately the same

burnup (46 - 49 MW day/kg U).

Fig. 5.50 presents dependencies of calculated and experimental summarized release of Xe and Kr stable

isotopes out of fuel into the fuel rod free volume versus the peak enthalpy of fuel rods of 103F series.

Experimental data on the fission gas volume converted into normal conditions were obtained due to

processing of experimental data listed in Table 5.15. Calculated data were also converted into normal

conditions. Analysis has indicated that calculated results are very sensitive to the grain size. Hence, Fig. 5.50

presents the correlations corresponding to the average fuel grain size (6 pm), which was determined in the

course of pre-test examination, it also presents the region boundaries for the whole range of the average grain

size (4 - 8 pm). It is important to note that distribution of the initial grain size in the fuel is of a bimodal

character. Still, FRAP-T6 and SCANAIR codes use the averaged parameters of the grain size. Hence, the

range of experimental data on the average initial grain size listed in Table A. 1 (Volume 3) was used to

calculate sensitivity.

Calculation results indicate that fission gas release in the course of the pulse heating greatly depend on the

fuel peak enthalpy (temperature). Peculiar feature in modeling behavior of gas phase in the fuel during its

fast heating (up to the melting temperature) is that fission gas release out of fuel is mainly determined by the

amount of gas located along the grain boundaries and in the intergranular space. Gas release due to the

mechanism of thermo-activation diffusion out of the grain is insignificant. Hence, to calculate fission gas

release in the pulse regime it is necessary to know gas distribution in the fuel grains and in the intergranular

space by the end of the basic irradiation mode. TOSUREP [11] and FRAP-T6 codes were used to calculate

fission gas distribution over the basic irradiation mode. According to calculations by FRAP-T6 and

TOSUREP codes some 15 - 20 % of atoms and gas bubbles are localized in the intergranular space by the

.end of the quasi-state mode of operation of fuel rods.

As it was expected the greatest discrepancy of calculated and experimental results was obtained for the

relatively low fuel temperatures, and low values of fission gas release. Along with the growth of the fuel

temperature agreement of calculated and experimental results on the fission gas release becomes better.

Taking into account complicated mechanism of the described processes, agreement of the calculated and

experimental results can be considered satisfactory. Still, it is necessary to note that both FRAP-T6 and

SCANAIR codes underestimate fission gas release for IGR pulse mode in the enthalpy range up to 120 cal/g.

Similar data were obtained in [13], where experimental data on fission gas release in the fuel rods of TS

series (NSRR reactor) were studied. Experimental data were compared with the calculated ones by FRAP-T6

code in the range of fuel peak enthalpy from 60 to 180 cal/g.

Calculated results indicate clear dependence of fission gas release versus fuel temperature. Still, the curve of

fission gas release versus peak enthalpy calculated by FRAP-T6 code has more clear dependence versus

temperature, than the similar curve obtained by SCANAIR code for low fuel temperatures. This is due to

difference in the models of gas release. The model in SCANAIR code predicts fission gas release for lower

fuel temperatures than FRAP-T6 model, because it takes into account additional flow of intergranular gas

inside the net of interconnected channels due to the temperature drop along the fuel radius. In the future it

will be necessary to correct the models of fission gas release to be able to get higher values of integral fission

gas release out of the fuel typical for IGR tests.

5.75
79

25

20

15

10

5

0

60 80 100 120 140

Peak fuel enthalpy (cal/g)

160

Fig. 5.50. Calculated and measured Xe and Kr volume inside the fuel rod free volume vs. peak fuel

enthalpy

Fig. 5.51 presents the results of comparative analysis of fission gas release obtained by FRAP-T6 and

SCANAIR codes. Fission gas release is represented as the relative fraction of the volume of the fission gas

released out of the fuel to the amount of fission gas generated in the fuel over the basic irradiation mode.

Deviations of the calculated data obtained with the change of initial grain size - 4-8 Wm are also presented

there. SCANAIR calculation results were obtained for the tight fuel rods only (HIT, H4T, H6T, H8T),

because calculation of behavior of fuel rods with higher peak enthalpies is beyond the capabilities of the

code.

70

60 112T

50 -. FR.AP-T6 resuls T -~-SCANAIR restilts

40

3 0 -H 

T1 T

20 - - T T

H6T

H8T ___- 10 - - - - g-- - - -- - - --- - - - -- - 10

40 80 120 160 200 240

Peak fuel enthalpy (cal/g)

Fig. 5.51. Comparison of the FRAP-T6 and SCANAIR results on FGR for IGR fuel rods

5.76
A little lower gas release was predicted for H7T fuel rod than for the H5T one despite the higher peak

enthalpy. This in particular can be explained by the higher burnup of the fuel of H5T fuel rod (49

MW d/kg U) if compared to H7T fuel rod (47 MW d/kg U). Still, the difference in the calculated data is

sufficiently small, and is within the corridor of deviations caused by the difference in the technological

parameter. Abrupt increase of the fission gas release in H2T fuel rod is caused by the fact that the fuel

temperature has reached the melting point; for this situation 7 % of the pellet's melted area was predicted.

It should be noted that description of the main mechanisms of fission product behavior in fuel, implemented

in the above models, indicated that it is necessary to know physical and technological parameters of fuel,

micro constants of the irradiated grain, diffusion parameters of gas bubbles, etc. in order to determine fission

gas release. This set of parameters is not usually clearly determined and has a significant spread. That is why

calculation of behavior of the gas phase in the fuel is based on some effective (averaged) value of this or that

parameter, which does not necessarily lead to the adequate description of the gas circulation and release.

Besides, this can introduce uncertainty into the calculated value of fission gas release. Hence, analysis of

sensitivity of the data on fission gas release to the initial grain size of the fuel matrix was performed to

demonstrate potential uncertainty of the calculated data.

Sensitivity analysis of the calculated fission gas release versus grain size indicated that the value of the

calculated fission gas release could change up to 1.5 times in the range of the specified grain diameters - 4-8

pm. This testifies to great uncertainty in predicting gas release out of fuel, and to the influence of the fuel

technological parameters onto calculated results. While reviewing the behavior of the full-scale burnt fuel

element, it is necessary to note that even in case of low values of the fission gas release (-10 %) its

contribution into the pressure under the cladding can be very sufficient. In case of the maximum burnup of

-50 MW d/kg U, approximately 1800 cm3 if converted to normal conditions are generated in the fuel

element of the VVER reactor. Initial concentration of the technological gas (He) is approximately 640 cm3

(n.c.). If over the period of an accident some -10 % of the fission gas is released (180 cm3), then the pressure

inside the fuel element will increase by the following value: 180/640 s 0.3 (- 30 %).

Hence, analysis ofthe calculated results allowed to make the following conclusions:

" Both codes underestimate fission gas release in the range of fuel peak enthalpies up to 120 calg. In the

future it is necessary to correct the models of fission gas release in order to get higher values for the

integral fission gas release out of the fuel in this range of peak enthalpies;

" Experimental results indicate practically linear increase of the fission gas release versus fuel enthalpy.

Calculated results obtained by FRAP-T6 code have the similar trend. Calculated curve obtained by

SCANAIR code shows exponential dependence versus temperature. The greatest discrepancy of the

calculated and experimental results is in the range of the fuel peak enthalpies up to 120 calg;

" Sensitivity analysis has indicated significant uncertainty in predicting gas release out of the fuel

depending on the initial grain size.

5.77
5.11. References

[1] L. Siefken, Ch. Allison, M. Bohn, S. Peck "FRAP-T6: Computer Code for the Transient Analysis of

Oxide Fuel Rods" NUAEG/CR-2148 EGG-2104, May 1981.

[2] F. Lamare, J.C. Latche, "SCANAIR. A Computer Code for Reactivity Initiated Accidents in LWRs",

Rapport Technique SEMAR 95/01

[3] D.L. Hagrman, G. A. Reymann, R.E. Mason "MATPRO-Version II (revision 1): A Handbook of Material

Properties for Use in the Analysis of Light Water Reactor Fuel Rod Behavior", NUREG/CR-0497 TREE1280, Rev I, February 1980.

[4] V.E. Ljusternik, V.E. Peletski, I.I Petrova. "Experimental research of zirconium reactor materials thermal

properties. E-11O alloy" M, J. High Temperature Thermal Physics. v. 31, N4, 1993.

[5] B.Yu.Volkov et. al. Material property library for H-1 alloy cladding, Report IAE-4941/11, 1989 (rus).

[6] G.P.Kobyliansky, A.N.Novoselov, "Behavior of Zirconium and Its Alloys under irradiation. Guide Book

on Reactor Materials". Edited by V.A.Tsycanov. GNC RF NIIAR, Dimitrovgrad, 1996 (rus).

[7] N.B. Sokolov et. al. "Kinetics of interaction between VVER core materials" (Recommendations for

application in the frame of International Standard Problem on CORA-W2 experiment), Report ASRIIM.

N8068. October 1993 (rus).

[8] Material properties of VVER-1000 fuel rod clad and pellet. State Committee on Atomic Energy, 1983

(rus).

[9] V.I. Kolyadin et. al. Heat conductance of uranium dioxide. Journal Atomnaya energiya, 1974, v. 36(3), p.

59 (rus).

[10] A.S. Scheglov et. al. Simulation of WER-440 high burnup fuel rod behavior (on example of the 3-th

unit of Cola NPP), Journal Atomnaya energiya, 1996, v. 81(4), p. 254-261 (rus).

[ 11] F. Lemoine, TOSUREP Documentation, Note Technique SEMAR 97/43, May 1997.

[12] G.A. Berna, M.P. Bohn, W.N. Rausch, R.W. Williford, and D.D. Lanning. "FRAPCON-2: A Computer

Code for the Calculation of Steady State Thermal-Mechanical Behavior of Oxide Fuel Rods".

NUREG/CR-1845 (January 1981).

[13] T. Nakamura, M. Yoshinaga, Boiling Water reactor fuel behavior at burnup of 26 GWd/tonne U under

reactivity-initiated accident conditions. J Nuclear Technology v. 108(1), 1994.

[14] T. Fujishiro, K. Ishijima, NSRR experiments to study the effects of burnup on the fuel behavior under

reactivity-initiated accident conditions, Trans. of 22-nd Water Reactor Safety Information Meeting,

Bethesda, Maryland, USA, October 24-26.1994.

[15] M.A.Vostrikov, B.P.Kochurov. "TRIFOB - The Code for Calculation of Isotopic Composition Changes

in a Cylindrical Reactor Cell Taking into Account Neutron Spatial-Energy Distribution", Report, ITEP106, Moscow, 1981.

[16] SCDAP/RELAP5/MOD3.1 Code Manual. NUREG/CR-6150 EGG-2720, 1993.

[17] "GE SBWR Preliminary stability analysis using TRAC-BFI time domain code" ANS transaction. New

Orlean. June 19-23, 1994.

[18] A. Bromley, "Heat Transfer in Stable Film Boiling" Chemical Engineering Progress. 46. (1950) pp.

221-227.

[19] A. Labuntzov. Teploenergetika. 12 (1959). pp. 19-26 (rus).

[20] V.P. Isachenko, V.A. Osipova, A.S. Sukomel Heat Transfer. - M Energoizdat, 1981 (rus).

[21] S.S. Kutateladze. Fundamentals of Heat Transfer Theory, M, Atomizdat, 1979 (rus).

[22] PIN-micro: User's Guide for the Computer Code, 1991, Rez UIV-9515-T.

[23] F.W. Dittus, L.M.K. Boelter, "Heat Transfer in Automobile Radiators of the Tubular Type", University

of California Publications, 2 (1930) pp. 443-461.

5.78
[24] C. Chen, "A Correlation for Boiling Heat Transfer to Satdiated Fluids in Convective Flow", Process

Design Development. 5. (1966) pp 322-327

[25] G.N. Poletaev "Analytical equations for approximate analysis of fuel rod rewetting in reactivity initiated

accidents", Report IAE-6090/5, 1998.

[26] C.L.Tien and L.S.Yao, Analysis of conduction-controlled rewetting of a vertical surface, J. Heat

Transfer 97, 161-165 (1975).

[27] J.G.M.Andersen and P.Hansen, Two dimensional heat conduction in rewetting phenomenon. Report No

NORHAV-D-6. Danish Atomic Energy Comission Research Establishment, Riso, Denmark (1974).

[28] S.S.Dua and C.L.Tien. A generalized two-parameter relation for conduction-controlled rewetting of a

hot vertical surface, Int.J. Heat Mass Transfer, vol.20, pp. 174-176.

[29] D.C. Groenveld, J.C. Stewart, "The Minimum Film Boiling Temperature for Water During Film Boiling

Collapse", Proc. VII Internat. Heat Transfer Conf Munich 1982. Vol. 5 (1982). p. 393

[30] J.R.S. Thorn et. al. "Boiling in Subcooled Water During Flow Up Heated Tubes or Annuli" Proceedings

Instrumentation of Mechanical Engineers. (London). 180 (Part 30 (1966) pp. 226-246.

[31] K. Lassmann, et. al., "Transuranus Calculation on Experimental WER Fuel Rod", Proceedings of the

Second Int. Seminar VVER Reactor Fuel Performance Modeling and Experimental Support, pp. 156-161,

April 1997, Bulgaria.

[32] P.L. Kirillov, Yu.S. Yuryev, V.P. Bobkov. Thermohydraulic Analysis Handbook (Nuclear Reactors,

Heat Exchangers, Steam Generators). -M., Energoatomizdat, 1990 (rus).

[33] P.G. Lucuta, H. Matzke, R.A. Verrall, H.A. Tasman Thermal conductivity of SIMFUEL. J. Nucl.

Mater., v. 188, p. 198-204. 1992.

[34] P.G. Lucuta, H. Matzke, R.A. Verrall Modelling of U0 2 based SIMFUEL thermal conductivity. The

effect of the burnup. J. Nucl. Mater. v.217, p. 2 7 9 -

2 8 6 . 1994.

[35] H.M. Chung and T.F. Kassner, Deformation Characteristics of Zircaloy Cladding in Vacuum and Steam

Under Transient-Heating Conditions: Summary Report, NUREG/CR-0344, ANL-77-3 1, July 1978.

[36] K.Wiehr, F.J. Erbacher and H.J. Neitzel, Influence of Thermohydraulics on Fuel Rod Behavior in a

LOCA, Proceedings of the CSNI Specialist Meeting on Safety Aspects of Fuel Behavior in Off-normal

and Accident Conditions, Helsinki, Finland (1980) 59-73.

[37] A.Shestopalov, K.Lioutov, L.Yegorova, G.Abyshov, K.Mikitiouk, Modification of US NRC's FRAP-T6

Fuel Rod Transient Code for High Burnup VVER Fuel, Report of RRC "Kr', RRC KI 2180, 1999.

[38] K.Mikitiouk, A.Shestopalov, K.Lioutov, L.Yegorova, G.Abyshov, Modification of IPSN's SCANAIR

Fuel Rod Transient Code for High Burnup VVER Fuel, Report of RRC "Kr', RRC KI 2181, 1999.

[39] L. Yegorova et. al. "Analysis of capsule dynamic tests with VVER fuel rods at IGR and GIDRA

reactors", Report of RRC "Kurchatov Institute"', N 30/694186, Moscow, 1986 (rus.).

5.79

6. TEST PROCEDURES TO OBTAIN THE MECHANICAL PROPERTIES OF

ZR-1 %NB CLADDING AND DEVELOPMENT OF THE ORIGINAL INPUT

DATA FOR MATPRO-V11 AND SCANAIR CODES

6.1. Formulation of the problem

It is important to stress that in the framework of the research work presented in this report there was never an

objective to get the universal data base characterizing mechanical properties of the VVER cladding as the

function of the manufacture technology, basic irradiation conditions, and accident conditions. Development

of this program in order to study mechanical properties of the VVER cladding is based on the approach,

which can be characterized by the following provisions:

1. Analysis of specific features of unirradiated and irradiated Zr-1%Nb cladding is to be preliminary

performed and the results of this analysis are to be considered in the course of the program development

in order to measure mechanical properties of Zr-lNb cladding.

2. Assessment of MATPRO and SCANAIR data bases with mechanical properties of PWR claddings is to

be done and used in order to define the set of requirements to the data base with the original mechanical

properties of Zr-1%Nb cladding.

3. There should be enough measured mechanical properties of Zr-l%Nb cladding in order to be able to use

FRAP-T6 and SCANAIR codes for the development of computational data base characterizing VVER

fuel rod behavior under IGR test conditions.

The complex of research was performed for each of above items. Results of the work are presented in

succession in the respective sections.

6.1.1. Peculiarity analysis of unirradiated VVER claddings

Zr-lNb alloy is used for the claddings of fuel elements of the VVER reactor type. The data listed in

Table 6.1 allow to compare chemical compositions of VVER and PWR zirconium alloys [1].

Table 6.1. Concentration of doping elements in zirconium alloys

Doping element Type of alloy

(% by weight) Zr-lNb Zry-2 Zry-4

Nb 0.9-1.1 - -

Sn - 1.5 1.5

Fe 0.05 0.15 0.2

Cr 0.02 0.1 0.1

Ni 0.05 0.007 0.007

Fe+Cr+Ni 0.12 up to 0.3 up to 0.3

02 0.11 0.1-0.14 0.1-0.14

Comparative analysis of those compositions allows to see that the difference of two types of the claddings

from the standpoint of their chemical compositions is that niobium was chosen as the basic element for

doping of zirconium in the alloy for VVER reactors, and tin was the element used for the same purpose in

PWR reactors. The purpose of doping in both cases was the desire to improve strength and corrosion

parameters of the fuel element claddings. The choice of Zr-l%Nb alloy as the cladding material for VVER

reactors was caused by the fact that Zr-l%Nb alloy just slightly yields to Zry-2 alloy in the sense of

corrosion when oxidized in the pure water and steam, but in this case Zr-l%Nb alloy absorbs 5-10 times less

hydrogen generated when the cladding is oxidized by water [1].

6.1
Currently the tubes manufactured of zirconium fabricated by the electrolysis method are used for the VVER

claddings. Cladding tubes are manufactured by the rolling method, after that they are subject to thermal

processing. Annealing of the VVER tubes is done under the temperature of 580'C within 3 hours. This

process leads to complete recrystallization of the tube material. At the same time cladding tubes of the PWR

reactors are annealed till the state of partial recrystallization.

Procedure of the chemical etching and anodizing of the fuel claddings is the last stage of the technological

cycle for the VVER fuel elements. The objective of this procedure is to remove the impurities and to make

the protective 1-3 Wm thick ZrO2 layer.

The whole complex of differences in the chemical composition and in manufacture of VVER and PWR

claddings results in the differences of the initial mechanical properties of fresh claddings. It is necessary to

note that both here and after only short-term mechanical properties are considered, because these are the

properties important to interpret IGR/RIA tests. Fig. 6.1 illustrates the difference of properties of unirradiated

Zr-lNb and Zry as the function of temperature.

1600o oo100

-Z,- tzl(NATiT'o) [21 r radiate Z4, 57 M'd/kgU [4]

e -tmjrndiati7,y(MIATPRO) [2) 80 aildZ-'Nb SMdq 3

1200- - uniiaadiatcdZrY [4)

E]-~ 3 cP1I,, uniriiaedarWoa 

. 60

T 0

5 40 20

0- 0

200 600 1000 1400 200 400 600 800

Temperature (K) Temperature (K)

Fig. 6.1. Mechanical properties of Zry-4 and Zr-l%Nb vs. temperature

Analysis of the data presented in Fig. 6.1 allows to make the following conclusions:

* difference between the absolute values of mechanical properties of these alloys decreases along with the

temperature growth;

" both alloys have similar tendencies of the change of properties as the function of temperature.

In other words, general character of dependencies of mechanical properties versus temperature is determined

by zirconium properties. Doping elements and manufacture technologies influence the absolute values and

define the bending points of the presented curves. Analysis of the total influence of the physical phenomena,

which cause similarity and difference in mechanical properties of two types of the claddings, leads to the

necessity of review of the following separate effects in order to understand their influence onto mechanical

properties:

" temperature;

" strain rate;

" oxygen concentration in cladding;

" mechanical anisotropy;

6.2
" dynamic strain aging;

" annealing;

" phase transformation and superplasticity.

Mechanical properties vs. temperature and strain rate

Data presented in Fig. 6.1 indicate that knowledge of the dependencies of mechanical properties versus

temperature is the most important part for the respective data base, because strength of all Zr alloys

decreases abruptly along with the temperature growth. Besides, analysis of the temperature dependencies for

strength and ductility of the material indicates that worsening of strength and increase of ductility are not

monotonic temperature functions. Hence in order to get the data base describing those parameters with good

accuracy it is necessary to correctly select the pitch of the temperature variations.

Strain rate is a separate issue when the data base on mechanical properties intended to analyze fuel rod

behavior under RIA conditions is reviewed. Unfortunately, there exists very little published data in order to

characterize this aspect of the problem.

It is considered that zirconium alloys are very sensitive to the change of strain rate. In case of strain rate

increase strength properties are improved, but the plastic ones decrease greatly. Measurements of

dependence of strength and elongation versus strain rate in the axial direction indicated that the change of

cross-head velocity from I mm/min to 16 mm/min leads to the decrease of the total elongation of Zr-l%Nb

alloy by 10 - 12 %, in this case ultimate strength increases by approximately 9 %, main change of the alloy

properties being in the interval 1 - 8 mm/min. It is also noted that for cross-direction tests strain rate increase

leads to increase of the yield stress and ultimate strength, total elongation in this case does not change [1].

Oxygen concentration in the cladding

Presence of small amount of oxygen in zirconium alloys leads generally to the improvement of their strength,

while good plastic properties are preserved. That is why oxygen was considered as the doping element for

Zr-l%Nb alloy [1]. Table 6.2 lists the respective data characterizing oxygen influence onto mechanical

properties of Zr-1%Nb VVER tubes.

Table 6.2. Mechanical properties of VVER tubes vs. oxygen concentration at 20'C 11]

Oxygen Ultimate strength (MIPa) Yield stress (MPa) Total elongation (%)

concentration Axial Cross Axial Cross Axial Cross

(%) direction direction direction direction direction direction

0.05 400-430 350-360 240-270 290-310 45-50 35-38

0.13 520-530 - 330-350 - 40-42 -

Comparison of the data listed in Table 6.2 indicates that the oxygen influence onto mechanical properties of

Zr-1%Nb is approximately the same as for Zircaloy (fully recrystallized state of tubes) [1].

-Analysis of these and other published results shows that strength parameters depend a lot on the oxygen

concentration, hence this factor is to be considered when measuring mechanical properties of specific

claddings.

Anisotropv of zirconium alloys

It is well known that mechanical properties of materials can significantly differ depending on the direction of

measurement of these properties. This phenomenon is known as anisotropy of mechanical properties.

Zirconium is a typical example of an anisotropic material. Technology of fabrication of zirconium items

influences the material texture and this also influences differences in mechanical behavior for axial and

cross-directions. camphase is the basis for Zr-l%Nb alloy, that makes the alloy closer to zirconium from the

standpoint of the texture and anisotropy [1]. It is important to note that plastic deformation of a-zirconium

occurs in two different ways depending on the crystal axis to which the load is applied. In one case the

deformation takes place by slipping, in the other case - by twinning [1]. WER tube texture is such that its

axial tension occurs mainly by slipping. Cross-tension leads to the situation, when part of the grains is

6.3
deformed by slipping, and part - by twinning. These differences result in differences in yield stress for

different directions. Yield stress in the cross-direction exceeds significantly the yield stress in the axial

direction. Other results characterize ultimate strength. Analysis indicates that the stage of necking and burst

is characterized by the fact that the slip mechanism of strain is the main one for the material tension in both

axial and cross- directions. That is why ultimate strength depends less on the direction. Study of the

influence of anisotropy onto the material elongation parameters is a separate problem. In the work [1] it is

shown that the results of measurement of the relative elongation, done in the cross- and axial directions, are

not only the function of the property anisotropy, but of the test conditions as well. That is why we should

treat interpretation of experimental data characterizing material elongation ratio in the axial and crossdirections very carefully. That is why in order to assess anisotropy parameters for Zr-l%Nb alloy Table 6.3

lists only the parameters of the alloy strength.

Table 6.3. Parameters of mechanical anisotropy for Zr-l%Nb alloy [11]

Temperature of test (°C)

20 350-380

Material e 2) 0-0 1) 0~a.02 2 0.

0o e

KB - B K02 KB gI- 02 =

C0.2B0.2

Zr-INb tube for 0.9 1.33-1.38 0.95 1.5-1.7

VVER reactor

1ae, cq - ultimate strengths in the cross- and axial directions, respectively;

2) 0.2 , 

C0.2 -e -yield stresses in cross- and axial directions, respectively.

The data listed in Table 6.3 indicate that anisotropy of Zr-IlNb alloy is to be certainly considered for the

calculations of the fuel rod deformation.

Dynamic strain aging

Dynamic strain aging is an important phenomenon influencing the profile of strength parameters versus

temperature. For zirconium alloys this phenomenon is determined by the fact that in the certain temperature

range atoms of gas impurities, such as oxygen atoms, start preventing dislocation movement [5]. In this case

stabilization of the material strength parameters versus temperature occurs, and worsening of the material

parameters characterizing its elongation. This effect disappears completely as the temperature increases

further (see Fig. 6.2).

This phenomenon was registered for both Zr-l%Nb alloy and Zircaloy. Quantitative parameters of the

dynamic strain aging depend on the great number of factors and according to the published data this effect is

most vividly revealed in the range of 440 - 770 K [6, 71.

Annealing

Heat treatment of the cladding tubes determines greatly their mechanical properties. Annealing is the main

kind of heat treatment of the cladding tubes for both VVER and PWR reactors.

Material recrystallization takes place during the process of annealing, this leads to better plasticity and

worsening of strength. It was mentioned above that cladding tubes for VVER reactors are delivered in the

fully recrystallized state (T = 580 K, t = 3 hours), at the same time Zry tubes are manufactured differently;

tubes in the partially recrystallized state are used most often. That is why it is always important to remember

that mechanical properties for one and the same material can differ greatly depending on the annealing

procedure.

6.4
400 

200

400 200

300 150

ar20 of strain aging

200 .100

100 50

0 ---T0

200 400 600 800 1000 1200 200 400 600 800 1000 120C

Temperature (K) Temperature (K)

Fig. 6.2. Demonstration of dynamic strain aging effect for Zr-1%Nb alloy

Phase transformation and superVlasticity

Zirconium and its alloys are allotropic materials. Low temperature a-phase has a hexagonal lattice. As the

temperature increases phase transformation point is reached and the material is transformed into 13-phase,

which is characterized by the cubic volumetrically centralized lattice. Phase transformation for zirconium

takes place when the temperature reaches 1135 K.'Presence of impurities in zirconium alloys leads to the

situation when two zirconium phases are present in the certain temperature range. At the bottom boundary of

this range all the material is in the a-phase, and starting with the top boundary of this range the material is in

3--phase, respectively (see Table 6.4). Impurities present in the alloys are responsible for the stabilization of

a- and O3-phases in the transition temperature range, which is not typical for pure zirconium [8].

Table 6.4. Parameters of allotropic transformation for Zry and Zr-1%Nb alloys

Parameter _Temperature (K)

Zr [1] Zr-lNb [1] Zry [8]

Initiation of a-f3 1135 883 1090

transformation

End of a-3 1135 1163 1255

transformation

Phase transformation of zirconium alloys has an important effect on mechanical property. In particular

abnormal change of elongation of these materials was observed in the number of tests [8, 1, 9]. Due to this

effect known as the effect of superplasticity relative elongation up to 200 % was registered in the tests. Still

detailed study of this phenomenon has not been arranged yet, despite the potential importance of this effect

from the standpoint of mechanical behavior of the fuel claddings under accident conditions.

6.1.2. Analysis of peculiarities of irradiated VVER cladding

Experimental studies performed in order to validate the data base with mechanical properties of irradiated

zirconium alloys has indicated that irradiation under reactor conditions leads to improvement of strength and

worsening of ductility of the fuel rod claddings. Combination of the following main phenomena leads to

those results:

" radiation damage and micro-doping with transmutants;

* corrosion;

6.5
e hydrating.

The works performed earlier in order to study the influence of irradiation onto mechanical properties of the

fuel claddings lead to the fact that fluence of fast neutrons was generally used as the key parameter. Fig. 6.3

presents the data characterizing influence of irradiation onto mechanical properties of the fully recrystallized

Zry'4.

70 24

60 16 _ 

S50 8

40 0

0 1 2 3 4 5 0 1 2 3 4 5

Neutron fluence (E>1MeV, 1--54 C) (10" 1/cm2) Neutron fluence (E>1MeV, T=54 C) (10" 1/cmi)

Fig. 6.3. Mechanical properties of Zry-4 vs. neutron fluence [11]

The presented data allow to assess the scope of effects connected with improvement of the material strength

and worsening of its ductility in the process of irradiation. Besides, the data demonstrate that all the radiation

effects are formed quickly enough, i.e. strength parameters change insignificantly after the neutron fluence

reaches 1019 n/cm2.

Research performed with Zr-I %Nb alloy allowed to find out that the transition process characterizing the

change of Zr-lNb mechanical properties as the function of irradiation under the temperature 300-400*C

takes place quickly. Comparative tests indicated that mechanical properties of the claddings tested in MR research reactor (RRC KI) up to the fluence of 1020 V/cm 2 (1>0.5 MeV) and mechanical properties of the claddings of commercial fuel elements irradiated at NV NPP up to 102 I/cm 2 (E>0.5 MeV) do not practically

vary [10, 11].

It is worth to review the two effects mentioned above in connection with the analysis of the irradiation

impact onto mechanical properties:

" dynamic strain aging;

" annealing of irradiation damages.

It was shown in section 6.1.1 that the dynamic strain aging effect is present in the certain temperature range,

this effect being valid for both Zry and Zr-l%Nb alloys. The research indicated that irradiation either

suppresses this effect, or reduces it significantly, because interstitial atoms of oxygen are captured by

radiation defects [5].

Annealing of irradiation damages is the other effect, which is very important for development of the data

base with mechanical properties of irradiated claddings vs. temperature. This is the data base, which allows

to analyze behavior of fuel elements under accident conditions.

The numerous tests allowed to state that initial mechanical properties of the alloy are recovered if the

irradiated claddings are heated up to the temperature higher than 800 K. The rate of this process is the

function of temperature and time and can be described by the corresponding equation [12]. Fig. 6.4 presents

the set of solutions for this equation for Zry-2 alloy.

6.6
1.0 I I -

I I

0.8 Isothermal•: hcain t.ini -

' "'

0.24

0.0

500 600 700 800 900 1000 1100

Isothermal temperature (K)

Fig. 6.4. Recrystallization rate of Zry-2 vs. temperature

Study of the influence of irradiation annealing onto Zr-l %Nb alloy has revealed approximately the same

effects. Annealing of the irradiated material under the temperature of 600'C allows to recover its mechanical

properties, so that they become the same as of the unirradiated material [1].

The above listed effects do not complete the list of phenomena which worsen the mechanical properties of

the fuel claddings in the process of their irradiation in the commercial reactor, Oxidizing and hydrating of the

claddings is to be reviewed separately in order to have complete information about those processes.

Oxidation of fuel claddings takes place over the fuel cycles as the result of chemical interaction of the fuel

claddings and water coolant. This process results in the formation of ZrO2 layer on the surface of the claddings and to the increase of oxygen concentration in the cladding material. It was noted in section 6.1.1 that

reasonable oxygen concentration in the cladding is the useful factor, and oxygen is specially planned by the

technological process as the doping element. Still, further increase of the oxygen concentration leads to embrittlement of the fuel claddings. Currently there exist no published data characterizing the influence of this

effect onto the irradiated claddings, still certain conclusions can be made about the importance of this phenomenon on the basis of the analysis of results obtained for irradiated Zr-l%Nb tubes. Tube specimens were

preliminary oxidized, then cut down, and the mechanical properties of them were determined in the crossdirection. Fig. 6.5 presents the results characterizing dependence of total elongation vs. temperature and

weight gain of oxygen [13].

Hydrating of fuel claddings is another important effect, which is capable to influence mechanical properties

of the claddings under irradiation. The reaction of zirconium oxidation in the water coolant is the source of

hydrogen, which causes hydration of the cladding. Under the operating temperature hydrogen is present in

the claddings partially in the form of solid solution and partially in the form of hydrides. Under normal

conditions the total amount of absorbed hydrogen is in the form of hydrides. Hydride inclusions oriented

along the cladding radius can provoke crack propagation, especially under low temperatures. On the whole,

hydrating of the claddings of all zirconium alloys leads to improvement of strength and to worsening of

ductility. This effect is significantly reduced if the temperature increases, but it is not fully eliminated under

high concentrations of hydrogen (Fig. 6.6) [1]. It is also important to note that the presence of the

temperature gradient at the fuel claddings leads to the situation that the major part of hydrides is concentrated

on the outer surface of the cladding. This annular hydride layer influences the embrittlement of the cladding

more actively than in case there takes place uniform hydrating of the cladding.

6.7
140 n

120 A uoxidd zid

[] 93-96 mgtchn'

100 - <C 67-195 rrJg'na

80 .

40

20 ___

0 200 400 600 800 1000

Temper•tue (C)

Fig. 6.5. Total elongation of Zr-l%Nb specimens vs. temperature and oxygen weight gain

Fig. 6.6. Total elongation of Zr-l%Nb alloy (a) and hoop strain of pressurized zircaloy tubes (b) vs.

hydrogen concentration and temperature

Hydride orientation is another principal issue to understand the influence of hydrogen onto the mechanical

properties of claddings. It has already been noted that radial oriented hydrides significantly reduce the

cladding ductility. This effect can be described with the help of the hydride orientation coefficient F., which

is identified as the ratio of the amount of radial oriented hydrides to their total amount. Fig. 6.7 illustrates

this effect for unirradiated Zr-l%Nb tubes [1].

6.8
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Coefficient of hydride orientation

Fig. 6.7. Hoop strain of pressurized Zr-l%Nb tube vs. coefficient of hydride orientation

So analysis of the data obtained in the frames of separate effect tests has the logical connection to the

question about the actual characteristics of the claddings of commercial fuel elements irradiated at NV NPP

up to high burnup level. This is important for correct development of the approaches to measure their

mechanical properties. Preliminary comparison of the PWR and VVER claddings (oxidation and hydrating

levels) indicates that the parameters differ significantly.

Numerous data characterizing PWR claddings have been published recently. These data allow to characterize

oxidation and hydrating of this cladding type as the function of burnup. Analysis of these data demonstrates

that those parameters depend a lot on both type of alloy (Zry-2, Zry-4) and on the initial concentration of tin

in the alloy. As an example we can review the parameters for commercial fuel elements of PWR type. Those

fuel elements were used to fabricate fuel rods, which then were tested in NSRR (Japan), and in CABRI

(France) reactors under RIA conditions. This example reflects certain tendencies, which can not though be

generalized.

The published data are listed in Table 6.5 in accordance with the numbers of tests performed in NSRR and

CABRI reactors [14, 15].

Table 6.5. Parameters of oxidation and hydriding for irradiated fuel rods of PWR type before CABRI

and NSRR tests

Reactor CABRI NSRR

Test No Rep-Nal Rep-Na3 Rep-Na4 Rep-Na5 HBO-I" HBO-2" HBO-3" HBO-4"

Burnup 64 53 62 64 50.4 50.4 50.4 50.4

(GWd/t)

Oxide

thickness 80 40 80 20 43 35 23 19

(Ptm)

Hydrogen

concentration - - - 190 150 145 90

one mother element was used for refabrication of fuel rods

- no data

6.9
Analysis of the data demonstrates that, in the first place, there exists great spread between the characteristics,

and, in the second place, that significant oxidation and hydrating of the claddings occurs over the fuel cycles.

That is why we can expect that mechanical properties of he claddings will trace those tendencies.

A representative number of WER type commercial fuel elements irradiated up to 50 MWd/kg U has been

studied by now.

Post-test examination of those fuel elements has demonstrated that ZrO2 film thickness on the surface of the

cladding does not exceed 8 pxm, hydrogen concentration is in the range of 3-6 10-3 % (by weight), the

hydrides having random or tangential orientation [16].

Mechanical properties of ring specimens fabricated of the Zr-1%Nb claddings were also measured in the

cross-direction. The respective data are presented in Table 6.6 [3].

Table 6.6. Mechanical properties of irradiated and unirradiated VVER claddings

Temperature (C)

Reactor t Burnup 20 350-380 (MWd/kg U)

oB (MPa) 002 (MPa) Stot (%) oB (MPa) C02 (MPa) 8U. (%)

24.2 580-610 460-535 16-20 360-430 325-375 16-20

36.8 520-595 468-545 10-16 310-380 274-320 18-21

WER-440

46.2 595-614 550 14 361-426 329-395 18-30

48.2 543-603 476-578 19-26 369-425 337-391 18-26

36.7 590 435-520 12-27 316-400 270-340 16-26

40.4 540-598 485-535 13-23 348 325 18-26

VVER-1000

44.7 585 460-530 13-19 380 344 20-28

46.2 595 535 13 357-395 312-362 12

WER cladding 0 370-465 310-410 29-40 190-210 160-195 30-41

The data listed in the table demonstrate the following:

* improvement of strength and worsening of ductility of the irradiated VVER cladding takes placp despite

of the low level of oxidation and hydrating;

" ductility of Zr-l%Nb alloy is preserved well enough;

" there exists spread of mechanical properties in the studied set of claddings.

In general, the presented data demonstrate that it is expedient to get the mechanical properties for irradiated

VVER claddings in wide range of the temperature and other parameters in order to use the computer codes to

model behavior of these fuel elements under RIA conditions.

6.1.3. Assessment of approaches developed in MATPRO and SCANAIR codes to

characterize the data base with mechanical properties of cladding

In order to work out main provisions of the research program aimed at the measurement of mechanical

properties of WER claddings for computational analysis of IGR/RIA tests, it is necessary to analyze the set

of parameters, which characterize these properties in computer codes. As was already noted in Chapter 5 two

computer codes were used for calculations:

* FRAP-T6 code;

" SCANAIR code.

6.10
Specific feature of FRAP-T6 code is that the MATPRO package is used to introduce the input data

characterizing material properties of fuel rods into FRAP-T6 code. SCANAIR code has its own data base to

describe mechanical properties of the claddings. The features of data bases will be described in the further

sections.

6.1.3.1. MATPRO package

MATPRO package is the complex multipurpose data base to analyze the behavior of LWR fuel elements

under steady-state and transient conditions. This package was developed at the beginning of 80' and

contains material properties of LWR fuel elements with the claddings of Zry-2 and Zry-4 up to the fuel

burnup of 40 MWd/kg U. In the framework of this task MATPRO package proposes to describe parameters

of elastic/plastic strain of the cladding as the function of:

" temperature;

" strain rate;

" cold work of the as received cladding;

" fast neutron fluence;

" oxygen concentration;

" annealing of irradiation and cold work effects;

" anisotropy coefficients versus temperature.

Besides, the parameters characterizing fuel element cladding failure due to ballooning are also included into

MATPRO package. Local hoop burst stress is used in MATPRO as such a criterion. This is an empirical

criterion and it was obtained with the help of great number of tests with pressurized tubes. The following test

data are necessary to obtain the data base characterizing this criterion for the WER cladding material not

included into the MATPRO package:

" pressure and temperature at burst;

" axial radius of cladding curvature at burst;

" cladding peak circumferential elongation at burst;

" cladding thickness at burst.

Unfortunately, analysis of the MATPRO package indicates that it can be used to describe mechanical

behavior of irradiated commercial claddings with great caution. This is caused by the fact that the respective

correlations considering the influence of the base irradiation onto mechanical properties were mainly

obtained from the research reactors, and the requirements to similarity of irradiation conditions were not

always satisfied. There has not been any reassessment of the data base for a long time. Hence, specification

and renew of the data characterizing mechanical properties of the claddings is an urgent task.

6.1.3.2. Input data base for the SCANAIR code

Models used in the current version of SCANAIR code to describe mechanical behavior of the claddings

under RIA conditions are intended to calculate stress-strain state of cladding during the PCMI stage of an

accident. Besides, as it was already noted this version of the code has no models to predict cladding failure.

That is why the simplified stress strain law without consideration of strain hardening was used to model

elastic and plastic behavior of the cladding. Young's modulus and Poisson's ratio are necessary to calculate

elastic strain, and this part of mechanical properties has been already described in Chapter 5. SCANAIR

code uses only yield stress versus temperature to describe cladding plastic strain. This dependence was

obtained from the special tensile tests with irradiated PWR claddings under strain rates up to I I/s.

6.11
6.1.4. Justification of the program main provisions to obtain the data base with

mechanical properties of Zr-i %Nb claddings for FRAP-T6 and SCANAIR codes

Justification of the research program is to be based, in the first place, on the analysis of peculiarities of the

mechanical behavior of the claddings under IGR/RIA conditions. Analysis results demonstrate that two

characteristic types of thermal mechanical behavior are of the key importance from the standpoint of

deformation and failure of the cladding:

" pellet-cladding mechanical interaction (PCMI) stage;

" cladding ballooning and consequence rupture.

In order to understand specific parameters characterizing each of these stages in IGR tests it is possible to

review time histories of some parameters obtained by FRAP-T6 and SCANAIR codes for the following

types of VVER fuel elements tested in IGR reactor:

" unfailed high burnup fuel rod #H1T;

" failed high burnup fuel rod #H7T.

These time histories are presented in Fig. 6.8 and Fig. 6.9 in accordance with the data of Appendix G

(Volume 3 of the Report).

So, scenario of mechanical behavior of the cladding of the fuel rod #HIT is characterized by 3 phases:

1. Closing of the gap.

2. PCMI stage.

3. Reopening of the gap.

Low stresses in the cladding are typical for the first phase, because those stresses are caused only by gas

pressure inside the fuel rod. But the fuel temperature grows significantly over this phase, thus causing fuel

expansion, which finally results in the situation when fuel-cladding gap disappears, and the PCMI stage of

the scenario comes. The specific feature of this stage is that it consists of two parts too. The first is

characterized by the continuous growth of the fuel temperature, and as the consequence, the fuel tends to

increase its dimensions, but the cold cladding prevents this process. That is why abrupt increase of the hoop

strain takes place in the cladding. In this connection it is necessary to mention three principal aspects:

" peak stress in the cladding of this fuel rod is just by 20 % less than the ultimate strength for this

temperature;

" peak strain rate is 0.05 us;

" loading in the cross-direction is the key factor of this process.

The second part of the PCMI stage is characterized by the growth of the cladding temperature due to

departure from the nucleate boiling, and the stresses in the cladding start to exceed the yield stress. Both of

these factors lead to the beginning of the cladding plastic strain, thus the cladding stress decreases quickly.

Phase of the gap reopening is initiated by the cladding plastic deformation due to internal gas pressure.

Besides, if the criterional correlations determining the conditions necessary to initiate cladding strain of

ballooning type are not realized, the cladding cools down step by step and the accident scenario is completed.

Still, if the conditions necessary to begin ballooning of the cladding are realized, the further development of

the phase of the gap reopening occurs according to the scenario presented in Fig. 6.9 for the fuel rod #H7T.

Special BALON2 subcode starts to calculate time history of the cladding strain and other parameters in the

local ballooning area. If, as in this case, local hoop stress is reached, the code predicts burst of the cladding.

6.12
FRAP-T6 code

2000

1600

1200

800 P

400

0

0 2 4

"Mle (s)

500

400

300

200

100

0

0 2 4

Time (s)

0.06

SCANAIR code

pressure

6

strain

ress

6

Reopening

of gap

6

3.0

2.4

1.8

1.2

0.61

0.0

4.0

3.2

2.49.

1.61

0.8

0.0

I.

I

2000

1600

1200

800

400

0

500

400

300

200

100

0

0.06

pressure

0

0

-I--

2 4

Time (s)

6

3.0

2.4

1.2

0.6J

0.0

4.0

3.2

2.4.

1.61

0.8

0.0

2 4 6

Time (s)

0.04

0.02

0.00

0 2

g 0.04

0 .02

0.00

4 0

Time (s)

2 4

Time (s)

6

Fig. 6.8. Time histories of thermal mechanical behavior of fuel rod #H1T calculated by FRAP-T6 and

SCANAIR codes

6.13
I

2000

1600

1200

800

400

0

0

500-

400

300

200

100

0

0

0.4 -

FRAP-T6 code

I',l

2

Time (s)

4

2.5

2.0

1.51

1.0

0.5j

0.0

6

15

12

"9

3

0

.1

2 4 6

Tune (s)

0.3

0.2

0.1

0.0

0 2 4 6

Time (s)

Fig. 6.9. Time history of thermal mechanical behavior of fuel rod #H7T calculated by FRAP-T6 code

6.14
Summarizing all the above mentioned we can formulate the following requirements to the mechanical

properties of the claddings in order to predict the most important stages in the accident scenarios by

computer codes:

" mechanical properties of the cladding material versus temperature and strain rate in the cross-direction up

to 500 K are to be studied well in order to predict peak hoop stress during PCMI stage;

* mechanical properties of the cladding material versus temperature and strain rate in the cross-direction in

the range of 500 - 1300 K are to be studied well in order to predict peak hoop stress during ballooning

stage;

" experimental data base with gas pressure and cladding temperature for the burst of ballooning type is to

be defined for the given material, and the criterion for the local burst stress is to be checked and specified.

Results of this analysis were used as the basis to justify the program of measuring mechanical properties of

the WER fuel rod claddings tested in IGR reactor, because it is evident that the development of the

universal data base considering the whole complex of phenomena discussed in sections 6.1.1 - 6.1.4 is far

beyond the frames of the specific task. That is why along with the conclusions made in the process of

analysis of mechanical behavior of high burnup fuel rods ## HIT, H7T it was considered that only two types

of the cladding were actually tested in IGR reactor:

* unirradiated claddings fabricated of commercial WER tubes;

* irradiated claddings fabricated of the claddings of VVER-1000 commercial fuel elements irradiated at

Unit 5 of NV NPP up to the average burnup of 48 MWd/kg U (average burnup in the sections used for

refabrication).

That is why many of the phenomena influencing mechanical properties of the claddings can be inherently

considered, if specimens fabricated of this type of fuel elements are used for measurements. Besides,

analysis of the data shows that the problem number one to have the correct data base is to measure

mechanical properties in the cross-direction. But, measurement of only this set of characteristics is not

enough to get the parameters necessary for prediction of the ballooning strain and cladding failure of

ballooning rupture. It is evident that to solve this problem it is necessary to perform testing of the

corresponding pressurized specimens of claddings.

All the aspects of the problem were summarized taking into account of experimental equipment possibilities

and the following provisions of the testing program were developed:

" it is necessary to measure such mechanical properties of the VVER claddings as yield stress, ultimate

strength, uniform elongation, and total elongation;

" it is necessary to perform tests in the cross-direction using ring specimens fabricated of the standard

VVER tubes, and irradiated claddings of commercial fuel elements from Unit 5 of NV NPP;

" it is compulsory to perform reassessment of the earlier obtained data base with mechanical properties of

unirradiated WER tubes, to compare the results with the results of current measurements, and to develop

the combined data base;

" measurement of mechanical properties with the help of ring specimens is to be performed. versus

temperature - up to 1300 K and strain rate - up to 0.5 L's;

* it is necessary to define the parameters characterizing ballooning and cladding failure due to ballooning

using burst tests with pressurized tubes fabricated of irradiated WER tubes and irradiated claddings of

commercial fuel elements from Unit 5 of NV NPP;

" it is necessary to perform burst tests in the temperature range of 1000 - 1500 K.

The final stage of research to formulate requirements to the program of tests was directed to the development

of the procedure to use the obtained data base of the MATPRO package and SCANAIR code. General

principles of this procedure and brief justification of the respective stages are listed in Table 6.7.

6.15
Table 6.7. General principles to determine mechanical properties of Zr-l%Nb cladding for FRAP-T6

and SCANAIR codes

1. Initial state of cladding (type

of material, cold work, heat

treatment e.t.c)

VVER claddings of standard

No initial state will be tested

2. Parameters of stress-strain

state vs.:

2.1.temperature Yes Two states of cladding will be

2.2.strain rate Yes considered:

2.3.fast neutron fluence Yes -unirradiated;

2.4.oxygen content Yes - irradiated (-48 MWd/kg L9

3. Anisotropy No Test will be performed in cross

direction. Anisotropy coefficients

of Zry will be used.

4. Annealing of irradiation Yes Annealing is assumed to be

damage completed during test procedures.

5. Cladding ballooning and rup- Yes Burst tests ofgas pressurized

ture, failure criteria (pressure, cladding specimens will be

temperature, burst stress etc.) performed

6.2. Measurements of mechanical properties of Zr-il%Nb cladding by using simple

ring specimens

6.2.1. Measurement procedure

6.2.1.1. Main provisions of the procedure of testing simple ring specimens

Mechanical properties of Zr-1%Nb cladding in the cross-direction were determined by tensile tests of simple

ring specimens. This testing was arranged with the help of special machines equipped with semicylindrical

mandrels. For each testing ring specimen was located around the mandrels, then the mandrels were drawn

apart with the set cross-head velocity (V), thus ensuring tensile loading (P) of ring specimen (see Fig. 6.10).

Tensile loading of specimen was performed till the rupture of the specimen. During the test the following

parameters were registered:

" temperature;

" cross-head velocity;

" tensile load;

" displacement of mandrels.

Testing of simple ring specimen was performed in the air environment under low temperatures, and in

vacuum environment under high temperatures. Two types of simple ring specimen were tested:

" unirradiated;

" irradiated.

6.16
ring sample mandrels I--

Fig. 6.10. Cross-section of mandrels with simple ring specimen and general view of simple ring

specimen after the test

Unirradiated ring specimens were made of the standard tubes intended for VVER-1000 type fuel elements.

Irradiated ring specimens were made of the cladding of the commercial fuel element, taken out of the core of

Unit 5 NV NPP with the average burnup 48 MWd/kg U (within the section used for fabrication of ring

specimens).

6.2.2. Methodological aspects of the tests with simple ring specimens

The objective of this type of tests was to determine mechanical properties of the cladding in the crossdirection. It is well known that measuring of mechanical properties with the help of ring specimens allows to

determine yield stress and ultimate strength of material accurately enough. Still significant problems arise

when it is necessary to determine uniform and total elongation. These two parameters are characterized

respectively as:

" residual elongation of the material at maximum tensile load;

" residual elongation of the material after the rupture.

In practice these parameters are determined with the measured load-displacement diagrams. Fig. 6.11

presents the schematic view of such a diagram.

0

ý4

Displacement

Fig. 6.11. Schematic view of load-displacement diagram

6.17
The following expressions are correct for the specimen of material subjected to tensile loading up to the

rupture:

where a. = uniform elongation;

st = total elongation;

Al., A/, = absolute uniform and total elongation, respectively;

1, = initial length of the specimen.

Certain methodological problems arise when the attempts are made to determine uniform and total

elongation with the help of simple ring specimens. The main reason is that the tensile load caused by displacement of mandrels is not uniform along the perimeter of the simple ring specimen. Friction between

the mandrels and the specimen makes the additional contribution into this effect. The epure of deformation

distribution within the specimen semi-perimeter has the view presented in Fig. 6.12.

PT residual elongation

Fig. 6.12. Schematic view of azimuth profile of residual elongation for simple ring specimen

Thus, it is evident that tensile loads, non-uniform within the perimeter, lead to displacements non-uniform

within the perimeter. Degree of non-uniformity decreases as the distance from the axis, along which the

mandrel displacement takes place, increases. From the standpoint of procedure this effect can be considered

in two ways:

" selection of the shape of machined ring specimen in order to concentrate the stress and elongation within

well specified area (see Fig. 6.13);

" performance of special scoping tests allowing to empirically chose correlations that can correctly identify

elongation parameters.

PT

Fig. 6.13. Schematic view of machined ring specimen and azimuth profile of elongation for its

6.18
The historical background is that both approaches have been developed and used in practice in different

countries. For example, the first method is being used in ANL (USA) and IPSN/CEA (France). The second

method is in use in Russia. As the implementation of the new approach into practice is always an expensive

and time consuming procedure, the second approach was used to understand the summary of main

mechanical properties of the VVER cladding important for computational analysis of IGR/RIA tests.

Simultaneously the specialists of NSI RRC KI (Russia), RIAR (Russia), ANL (USA), LPSN/CEA (France)

made an effort to compare the results presented by each of these approaches. The approach developed in

Russia is based on the fact that some effective length of the simple ring specimen, which is called gauge

length, is used instead of the specimen length (Is) in the procedure to calculate uniform- and total elongation.

This length is defined by the following expression:

1

g = "- K w- , 2 2

where Ig = gauge length of ring specimen;

= average diameter of specimen;

dm = diameter of mandrels;

K = empirical coefficient.

This expression allows to account for effects of non-uniformity of elongation with the help of empirical

coefficient, which defines the effective specimen portion subjected to deformation.

A number of years ago special tests were performed at RRC KI to determine the value of K coefficient. The

values of this coefficient were determined depending on the mandrel diameter. Recommended values for this

case are K=0.85, di=4 mm. Besides, the special study was arranged in RIAR with the same objective, and a

slightly corrected formula was obtained for Ig. Still, considering the importance of this problem, analysis and

justification of the approach to define the value of gauge length were additionally performed in the

framework of this research.

6.2.3. Program of research to obtain the data base characterizing mechanical properties of

the VVER cladding tested in IGR reactor

In accordance with the main objective of the research it was necessary to obtain the data base characterizing

mechanical properties of the claddings for the VVER fresh fuel rods, and fuel rods irradiated up to

48 MWd/kg U. As was mentioned in section 6.1 the respective parameters were to be defined as the

functions of temperature and strain rate. As the time given for the work was not enough, it was decided to do

it using the following main principles:

1. To arrange maximum use of the existing data base characterizing mechanical properties of unirradiated

claddings.

2. To perform checking of the methods used to obtain data base for item 1. To perform some tests with the

WER unirradiated claddings in order to be sure that these results agree with the results obtained for

iteml, and to compare the methods for measuring mechanical properties of LWR fresh claddings together

with the specialists of ANL (USA) and IPSN/CEA (France).

3. To measure mechanical properties of irradiated claddings fabricated of the commercial fuel element from

Unit 5 of NV NPP.

Three stages of research were performed in accordance with the presented principles.

Reassessment of the data base with mechanical properties of the VVER fresh cladding

Numerous measurements of mechanical properties of different claddings were performed by VNINM

(Russia) and RIAR (Russia), and presented in [3]. In the framework of this research we reviewed mechanical

properties of Zr-lNb simple ring specimens with 9.15 mm OD diameter fabricated of the annealed tubes

(T = 580°C, t = 3 hours). Reassessment of individual measurements of mechanical properties of the

respective specimens was done by Dr. Kobyliansky, and the necessary initial data were transferred by the

6.19
author to those performing this work. The mentioned data base contains 65 measurements of mechanical

properties of fresh claddings as the function of temperature (293 - 1273 K).

Comparative tests with unirradiated Zr-l%Nb ring specimens and additional tests with unirradiated

Zr-l%Nb specimens

Considering the fact that measurement of mechanical properties of the LWR claddings is an important

problem, specialists from Russia, and specialists from ANL (USA) and IPSN/CEA (France) decided to

compare the methods to measure those properties. That is why the section of Zr-ilNb tube was cut into

three parts, each of them was sent to either RIAR, ANL, or IPSN/CEA. It was planned for this testing

program to measure mechanical properties of the tube for two temperature levels 20 - (350 - 400)°C under

different strain rates. The Russian part of the program was a little wider in order to simultaneously get the

information to compare it with the earlier obtained data base.

The generalized analysis of results of comparative experiments and of comparisons between new data and

the available data base allowed to develop a number of improvements of the procedure to process diagrams

of the simple ring specimen deformation.

Program to obtain data base with mechanical properties of irradiated cladding

For this part of research program it was necessary to measure mechanical properties of irradiated claddings

as the function of temperature and strain rate. As was previously mentioned, the approach had been used to

reveal the influence of mainly temperature and strain rate onto mechanical properties. In other words the

problem of representativity of results obtained for one commercial fuel element irradiated up to 48 MWd/kg

U at Unit 5 of NV NPP was not the subject of research, because in order to perform computational analysis

of fuel rods tested in IGR reactor it was necessary to have the data base with mechanical properties of the

cladding of just such a fuel element.

Hence only two parameters varied in the framework of these tests:

" temperature (293 - 1223 K);

* strain rate (2 10. -0.5 l/s).

Selection of the range to vary the loading rate was dictated by the capabilities of the test machines. Preliminary analysis was performed to develop the requirements assuring optimal accuracy of the statistical methods

used to process the measured results. This analysis has indicated that the optimal temperature measurement

step can be starting with 40-150 degrees up to different temperature levels. However, after the completion of

these stages, the necessity of conducting additional studies in the following areas became obvious.

New measurements of mechanical properties of unirradiated claddings in the entire temperature range

The existing and generalized in [3] data base on unirradiated claddings was obtained using old equipment

with analogue recording systems. The adjustment of this data base, performed at the first stage, did not allow

to fully eliminate systematic differences with data obtained within the framework of the present work using

modem equipment and a digital recording system. Moreover, since deformation diagrams are not fully

available for all specimens, the procedure adjustment, taking into account modifications, is possible only

using correction coefficients for the entire data base rather than individually for each specimen. Since the

purpose of the present work is to create the data base to be used in computer codes, requirements on the

relative accuracy of correlations developed on its basis is of a special significance. Thus, a decision was

made to perform new measurements of mechanical properties of unirradiated claddings in the entire

temperature range using the same equipment and procedures that were applied to irradiated claddings.

Special experiments to validate the new modified procedure

The use of diagram processing procedure upgrades that were proposed at the first stage confirmed their

efficiency, and taking into account their future application prospect, it was appropriate to develop, on their

basis, a new modified procedure. It is obvious that special experiments were required for a careful validation

and confirmnation of this modified procedure.

6.20
Additional experiments with irradiated claddings to adiust mechanical properties, primarily, in the area of the

superplasticity

A strong alternating dependency of the total elongation on the temperature in the range of 800 - 1200 K and

a large data spread required additional experiments to adjust the nature of studied dependencies and to

improve the accuracy of correlation ratios.

6.2.4. Parameters of simple ring specimens used for tests

Two groups of simple ring specimens were used to obtain measurements results:

* specimens of unirradiated VVER tubes;

" specimens of irradiated VVER cladding.

Detailed characteristic of the tube sections and claddings used for this purpose is presented in Appendix J of

Volume 3. Unirradiated specimens were fabricated of the fully recrystallized VVER tube (t = 5800C,

, = 3 hours). Thickness of the ZrO2 layer on the tube's surface did not exceed I pm, hydride orientation

coefficient was 0.42. Measurements of the diametric tube dimensions were performed in two directions with

the axial pitch of 7.5 - 8.5 umm. Accuracy of the measurements was 2 pm for the outer diameter, and 10 PM -

for the inner diameter. The following results were obtained:

" VVER tube outer diameter 9.136 - 9.149 mm;

* inner diameter 7.72°'°s8 mm.

Commercial fuel element #165 of the fuel assembly #4108 irradiated in the reactor of Unit 5 NV NPP was

used to fabricate simple ring specimens of the irradiated cladding. The following parameters were measured

for this section of the fuel element #165:

" outer diameter - by profilometry;

" cladding thickness and ZrO2 layer thickness - by using of 5 metallographic cross-sections;

" hydrogen concentration, hydride orientation and burnup - according to the procedures described in

Chapter 3.

The measurement results have indicated that this section of the fuel element is characterized by the following

parameters:

* burnup - 47 - 48 MWd/kg U;

* average outer diameter - 9.066 mm;

* cladding thickness - 0.69 + 0.15 mm;

* hydrogen concentration in fuel elements - 0.049 - 0.058 % (by weight);

* hydride orientation coefficient- 0.36 - 0.42;

" ZrO2 thickness on the cladding outer surface - 3 - 5 prm;

" ZrO2 thickness on the cladding inner surface is less than I pm.

Both types of specimens were fabricated by cutting either VVER tube or VVER cladding. The height of

simple ring specimens was 2.7- 2.8 mm, individual height measurements for each specimen were performed

with the accuracy of ±0.01 mm.

6.2.5. Types of procedures to obtain mechanical properties

The following expressions are generally used to define mechanical properties when testing simple ring

specimen:

Pm= x or PO2

=2ht' = 2ht'

6.21
8, =--100, A/ 10010 5, = 10

lg lg

where a = ultimate strength;

P. = maximum test loading of the specimen;

h = height of the specimen;

t = thickness of the specimen;

= yield stress;

Po.2 = load corresponding to residual strain equal to 0.2 %;

Al. = absolute uniform elongation;

lg = gauge length of the specimen;

Al/ = total displacement.

So the analysis of the expressions presented above indicates that two different groups of parameters are to be

measured to determine the set of mechanical properties for each test:

* geometrical dimensions of specimens and mandrels (h, t, Do, din);

" loading parameters (Pm, P0

o, Al, Alt).

Besides, the specimen temperature is to be measured in each test.

In framework of present studies the loading parameters are defined by computer processing of the measured

load-displacement curves. Previously obtained data base on unirradiated Zr-l%Nb was developed by manual

processing of such curves. As one of the tasks of the program was to reassess the previously obtained results,

then both approaches are to be reviewed in this case. Fig. 6.14 presents the main principles used in both

methods.

600 - 1 2

500 - ___

400 - ___ ___ ___ ___

100_. ___.___ _ _ _

0 / ,j 1.. 

-10 -5 0 5 10 15 20 25 30

Elongation (%)

Fig. 6.14. Processing of stress-strain curve obtained with simple ring specimen of Zr-l%Nb

Processing of load-displacement curve starts with its transformation into the stress-strain. Then the curve

slope angle is fixed in order to characterize the region of elastic strain, and thus to determine the beginning

of coordinates in the elongation axis (0 %). This and other procedures are currently performed in RIAR by

special computer tool. After that the line, parallel to the straight line fixing the region of elastic strain, is

drawn through the point in the x-coordinate equal to 0.2 %. The point where this straight line crosses the

stress-strain curve determines the yield stress value. Furthermore, the currently existing method of the curve

6.22
processing can identify point marked with "1", to which the maximum stress value, i.e. the ultimate strength

corresponds. In accordance with the theory the line, parallel to the straight line fixing the elastic strain

region, is drawn through this point, and the point where it crosses the elongation axis determines the value of

the uniform elongation (Su). The last stage of the method suggests the similar set of procedures to define

total elongation (8t). In this case the respective straight line is drawn through the point where the rupture of

specimen occurred.

The manual method of processing differed from the one described above by the procedure of So

determination. Uniform elongation (&a) was then determined with the help of the straight line drawn through

the point marked with "2" in Fig. 6.14. The rule stated that this point is the point where one could start

visually observe deviation of the curve from horizontal drawn through curve maximum. It is evident that this

method always resulted in the overestimation of 58. For example, processing of the curve presented in Fig.

6.14 by this method indicated that 64/8u ratio was about 1.3. Hence practical application of the earlier

obtained data base can be done only after all the files containing data on the uniform elongation are

corrected, otherwise those date are to be excluded from the data base.

6.2.6. Validation of the procedure to measure mechanical properties with simple ring

specimens

It was already noted that the main problem in measuring mechanical properties with the help of ring

specimens are related to the non-uniformity of tensions and displacements along the specimen perimeter, and

the uncertainty in the gauge length value. Moreover, it should be noted that while recording the diagram,

changes in the linear distance between mandrels are measured as the displacement, rather than the elongation

of the specimen working section. In case of ring specimens, when the tension process is accompanied by

specimen shape changes, the difference between these values can be significant.

Despite the fact that the procedure of measuring mechanical properties with the help of simple ring

specimens is generally accepted in Russia, and seems to be well justified in the past, special effort was made

to check the obtained results. During the first stage of this checking we compared the results of

measurements done by the specialists from RIAR (Russia), ANL (USA), and CE-Saclay (France). Section of

the VVER tube was divided into three parts and each part was sent to one of these organizations. Specialists

of each organization used their own original procedures to fabricate ring specimens and to measure

mechanical properties of those specimens. Detailed comparison of the used procedures and obtained results

is still planned for the future. But it is already possible to formulate one conclusion. It was clarified that the

measured values of the uniform elongation for 20°C at the strain rate of 10-3 I/s are in the range of 4 - 15 %,

the corresponding range for the total elongation is equal to 35 - 87 %. These results have initiated the study

targeted at finding the source of the potential methodical error.

The above research work (described in section 6.2.7) started after completion of theoretical analysis of

results obtained in RIAR and ANL. This analysis was based on the assumption that true stress-strain curve

can be described with the help of the power law presented as follows:

o=Kce,

where o = true stress;

= true plastic strain;

K, n = coefficients.

If the measurements were performed correctly, and Zr-lNb alloy follows the power law, then the true

stress-strain curve are to be described by the straight line in the logarithmic coordinates. Fig. 6.15 presents

the data illustrating the attempt to present in such a manner the results obtained in RIAR and ANL [18, 22].

" none of dependencies is a straight line;

* good agreement was observed only in the determination of the ultimate strength;

" difference in the determination of the yield stress between the RIAR and CE-Saclay is quite acceptable;

" ANL yield stress is quite different. from RIAR and CE-Saclay data;

" uniform elongations are quite different between all three institutes.

6.23
500

400 C"W0 US

X~- 1PSN/CEA dnfaconmcted

3 0 0 stm i .......ra ts

200 . . . ..... .. . . ..... . . . ..... . . . ..... . .I .I .... EIJI

0.001 0.01 0.10 1.00 10.00 100.00

True plastic strain (per-unit)

Fig. 6.15. Comparison RIAR, ANL and IPSN data for true stress-strain curve

At least two explanations can be given for the presented results:

" a = K e law is correct for Zr-lNb alloy but not a single procedure allows to get probable results to

characterize it;

" mechanical behavior of Zr-l%Nb cladding does not follow cy = K e" law, and at least one curve presented

in Fig. 6.15 is not correct.

In any case it is evident that the procedure described in section 6.2.5 needs to be additionally analyzed, and

probably improved. A number of sequential upgrades of procedures, that allowed to develop a new modified

procedure, was made on the basis of a detailed analysis of the existing data base, as well as results obtained

within the framework of the present studies, including comparative trilateral experiments. The next Section

covers the procedure description and validation.

6.2.7. Modified procedure to obtain mechanical properties using simple ring specimens

From the point of view of diagram processing procedures, the above physical causes of errors in the

determination of mechanical properties during tests of ring specimens are related to the accuracy of

determining two values:

* specimen absolute elongation;

• specimen gauge length.

6. 2.7.1. Determination of the specimen absolute elongation

A special test was conducted to analyze causes of possible mistakes due to errors in measuring the absolute

elongation that can occur in the determination of the uniform and total elongation.

Simple ring specimen was tested for the load much less than the yield stress, i.e. in correspondence with the

tolerances adapted in the procedure residual strain was to be equal to zero, because the specimen was tested

in the region of elastic strain. Fig. 6.16 presents cross-sections of the standard ring specimen before and after

tests.

6.24
I ý Before test U After test7

Fig. 6.16. Cross-sections of simple ring specimen before and after mechanical test with c << ay

The respective measurements showed that the value of residual hoop strain was equal to 2 %. But in the

framework of the existing procedure this elongation is not considered. Loading of the ring specimen causes

not only its elastic tension, but also its bending and partial plastic deformation. Hence, when processing the

stress-strain curve, in this case it is important to consider that this curve has not the linear, but the pseudolinear section, which includes both elastic and plastic strain components. That is why the main task for the

procedure modification is to determine the tangent of the slope angle of the actual elastic part for the stressstrain curve. Young's modulus characterizes this value according to the Hooke's law.

•s= Es, (1) E.8,

where q,= stress;

E, = Young's modulus for the material of specimen;

8 = specimen relative elongation;

Al, = specimen absolute elongation;

1, = specimen initial length.

Still, it is important to remember that the stretched specimen combines both mandrels of the machine, thus

closing the kinematic circuit. That means that all the parts of the machine are subject to the same load as the

specimen, and thus they are also displaced. Hence, the measured displacement of the machine mandrels

characterizes the set of elastic deformations for the machine and specimen, and can be described by the

following expression:

A/. =Alm +A/,, (2)

where Alr = measured mandrels displacement;

AIM = displacement of machine elements;

Al, = displacement of specimen.

If we express the Hooke's law for the kinematic circuit in the way similar to (1), and to change from the

stresses to the measured load P, then we can have expression ( 2 ) as follows:

6.25
A =Is S,,., I., E., m ) (3)

S, 1.E, =0, t=1 Sin, 1, E.,

where P = measured load;

S,. S,, = cross-section area of the specimen, and of the i machine element;

Im. = the length of the i machine element;

Ein = Young's modulus for the i machine element;

0 = compliance of machine.

0 coefficient, called compliance of machine, characterizes the ratio of the absolute elastic strains of machine

elements to the absolute elastic strain of the specimen and it depends only on ratios between the Young's

modulus, and geometric dimensions of the specimen, and elements of the test machine. By arithmetic

procedures we can transform equation ( 3 ) into the following:

cr = E, (4)

S, 1+0

where or = stress of the specimen (MPa);

= relative elongation of specimen (per-unit);

E, = Young's modulus for the specimen (MPa);

0 = compliance of machine (per-unit).

Hence the theoretical tangent of the slope angle of the stress-strain curve linear part is to be equal to the ratio

of the Young's modulus to the functional 1+0. Machines used to measure mechanical properties are rigid

enough, that is why 0 value for them is equal to 4 - 6 [9]. Really according to ring tensile test results the

tangent of the slope angle of the stress-strain linear part is essentially less than Young's modulus. This is

related to the fact that in case of simple ring specimens, at tensile loads below the yield point, the measured

value of mandrels movement Al. consists not only of the sum of absolute elastic deformations of machines

and the specimen, but of an additional movement of mandrels caused by changes in the specimen shape from

the ring to an elongated loop as a result of the bending and partial plastic deformation.

In such case the follow expression could be written by analogy with expression ( 4):

a-, = E,(s

J, I+O+A'

A = S*E'AIh

P1' ' pg

where A = additional compliance as a result of specimen shape changes;

Alh = additional movement of mandrels as a result of specimen shape changes;

lg = gauge length of specimen.

The additional compliance A characterizes the ratio between the additional movement of mandrels as a result

of specimen shape changes and the absolute elastic deformation of the specimen, and unlike the compliance

0, depends not only on the Young's modulus and geometric dimensions of the specimen, but also on the

load. This is because of this dependence on the load, the starting section of the simple ring specimen stressstrain curve till the yield point is of pseudo-linear, rather than linear nature.

Graphical illustration of this approach is presented in Fig. 6.17. Part of an actual stress-strain curve obtained

for one of the tested specimen was used for this purpose.

6.26
600

400

200 -t2"

- A=25

0 11

0.00 0.04 0.08 0.12 0.16 0.20

Elongation (per-unit)

Fig. 6.17. Comparison of slopes for the linear part of stress-strain curve for ideal and imperfect

specimens

So, the example presented in Fig. 6.17 has demonstrated the following:

use of the pseudo-linear part of the stress-strain curve as the basis in order to determine uniform and total

elongation results in underestimation of these parameters, because the slope angle of the respective

straight lines (see Fig. 6.14) is determines with great error;

* in order to correctly calculate uniform and total elongation, taking into account only elastic deformation,

the slope angle of the linear part of the stress-strain curve is to be calculated by the expression.( 4 ) for the

corresponding temperature of testing and the type of the specimen (unirradiated, irradiated). This is the

angle to draw the straight lines necessary to determine uniform and total elongation.

The example of using this method is presented in Fig. 6.18.

Fig. 6.18. Modified method to determine uniform and total elongation

6.27
Formally, in order to apply this method we need the data base characterizing Young's modulus versus temperature for both unirradiated and irradiated specimens. But the other procedure - more convenient and

accurate can be used in practice in order to define the required slope angle of the straight part of the stressstrain curve for the ring specimen-machine system.

Determination of the real inclination angle of the diagram linear section

The main idea of this procedure is that the process of reduction of load for specimen in the elastic

deformation area is described by the same straight line as the process of the specimen tension under the

influence of the load. That is why the true slope angle of the straight part of the stress-strain curve can be

determined if we reduce the load for the specimen at some point of this curve. Fig. 6.19 presents the example

of realization of this procedure.

400

300 tga- 2691 - N_ ,_

tga, 17331 MtPa

tg-x, = 22429 MIPa

- t, = 23448 MIPa _

200 tgcL, = 23448 MIPa

100

0 Za, : a. a. a _ _ _

0.0 0.1 0.2 0.3 0.4 0.5 0.6

Elongation (per-unit)

Fig. 6.19. Curve of the deformation with a partial relief

True inclination angles of relief lines were determined in experiments during which the test specimen was

subjected to a partial relief at various stages of its deformation in the tensile process. In this case inclination

angles of relief lines a 2-•as correspond to the expression (4), and the inclination angle of the pseudo-linear

section a, corresponds to the expression (5). A significant (several times) difference between inclination

angles of partial relief lines and the pseudo-linear section is caused by an additional compliance A during

specimen shape changes from the original ring to an elongated loop due to a simultaneous bending and

tension. A minor increase in inclination angles of partial relief lines is explained by a reduced compliance 0

due to a certain increase in the specimen length during its shape changes (see expression 3).

The correspondence between the inclination angle of partial relief lines and the true inclination angle of the

deformation diagram linear section in case of no specimen bending was experimentally verified using a

cylindrical specimen of Zr-lNb alloy with the recording of the elongation to increase the accuracy by a

strain transducer located in the working section of the specimen (see Fig. 6.20). The inclination of the

starting section of the diagram practically coincides with partial relief lines.

6.28
Fig. 6.20. Diagram of the cylindrical specimen deformation

Special experiments were performed to determine the dependence of the inclination angle of partial relief

lines on the temperature; their results are presented in Fig. 6.21.

24000 T

irradiated

unrradiated

120000," ..

*lineare appordmaion

temperature deciec

S16000-

......... "xt-:-..aL -o

12000-

8000

200 400 600 800 1000 1200 1400

Temperature (K)

Fig. 6.21. Dependence of the inclination angle of partial relief fines on the temperature

The solid line represents the linear approximation of experimental data, and the dotted line corresponds to

the Young's modulus dependence on the temperature (see section 5.6) related according to formula (4) to

one of the experimental points. A good agreement between the calculated and experimental lines confirms

the possibility of using partial relief lines for the determination of the elastic component of the ring specimen

deformation in a wide temperature range. Above data are presented for irradiated specimens, however a

weak irradiation influence on the Young's modulus [3] allows to use these data for unirradiated specimens;

this is confirmed also by test results for an unirradiated specimen at the temperature of 293 K.

6.29
Due to a low accuracy of the load determination at high temperatures, experiments to determine the

dependence of the inclination angle of partial relief lines on the temperature were performed only for the

temperature up to 800 K, however the above noted good agreement of data with the calculated dependence

that is of the linear nature allows to use the linear extrapolation in the temperature region of 800 - 1200 K.

The temperature dependence was further used to determine the real inclination angle of the linear section of

the diagram.

Determination of the proportionality limit

It is obvious that the value of the residual elongation determined according to the diagram depends not only

on the adopted inclination angle of the. linear section, but also on the selected origin of the coordinates.

Theoretically, this is the problem of determining the proportionality limit - the load at which a deviation

from the linear law begins. In the standard procedure this problem was solved as shown in Fig. 6.14, by the

continuation of the linear section until it crossed the abscissa axis. After this, the straight line, that was

distant by 0.2 % from the coordinate origin, allowed to determine the yield stress without the determination

of the proportionality limit in an explicit form. In the modified procedure the proportionality limit must be

determined directly, since, to determine the coordinate origin, the point of the diagram corresponding to the

limit must be used to draw the straight line with the real inclination angle that is significantly different from

the inclination angle of the pseudo-linear section.

The analysis of deformation diagrams obtained within the framework of the present work allowed to develop

a formalized approach for the determination of the proportionality limit on the basis of the following

mathematical considerations.

Let us have an ideal diagram (Fig. 6.22 a), that has the linear form yl=kx at section 0<x<xl and the arbitrary

form y2=f(x) at section x1<x, and conditions y1(xj)=y2 (xi) and dy1/dx(x) = dy2/dx (xi) are satisfied in the

point x1. It is obvious that the point x, for first derivative is the inflection point, and for second derivative -

the point of discontinuity and of the maximum negative value (Fig. 6.22 b, Fig. 6.22 c).

Fig. 6.22. Method to determine the proportionality limit using the second derivative

6.30
The real diagram of the ring specimen deformation and the dependence of its second derivative are presented

in Fig. 6.23. As expected, at the pseudo-linear section of the diagram the second derivative is not equal to

zero, but has positive values that reflect the change of the specimen shape, however a sharp reduction of the

second derivative to maximum negative values is rather obvious. It is this approach to determine the

proportionality limit in the point of the maximum negative value of the second derivative that was used for

the processing of diagrams according to the modified procedure.

400

200

0

0.0 0.1 0.2 0.3 0.4 0.5

Elongation (per-unit)

0.6

4000

2000

0

-2000

-4000

-6000

A

0.0 0.1 0.2 0.3

Elongation (per-unit)

0.4 0.5 0.6

Fig. 6.23. Determination of the proportionality limit using the second derivative

6.2.7.2. Determination of the gauge length

As it has already been indicated, the formula to determine the gauge length lg was obtained as a result of

special studies at the end of 1970s, and since then has been used within the framework of the standard

procedure. Nevertheless it was necessary to confirm it during current studies due to the following reasons:

6.31
" it is obvious that many changes and upgrades of both the test equipment, and cladding manufacturing

technology took place since the conduct of the above studies;

" the standard procedure to determine short-term mechanical properties of simple ring specimens was

developed and validated as a single complex that included the formula of I., determination, and it would

be inappropriate to believe that it is possible to adjust certain parts of the procedure while leaving other

parts intact;

" due to significant differences obtained in results of comparative experiments with the participation of

specialists from the USA and France it was necessary to perform a careful analysis of all provisions of the

procedure.

However, since the problem of the validation of the gauge length of the simple ring specimen in a wide

temperature range for various types and dimensions of specimens and mandrels requires a large scope of

experiments, and taking into account a serious degree of studies of the past, in spite of above shortcomings, a

decision was made to perform a selective verification of the applicability of the old formula to our

conditions.

For this purpose, the polished face surface of the original specimen was marked using a micro hardness

indentor. The marking is impressions near the internal and external surfaces at the distance of about 0.1 mm

from the edge. The distance between the impressions is about 0.18 mm. The appearance of the specimens

with marks is shown in Fig. 6.24.

Fig. 6.24. Appearance of the original specimen with marks

The specimen tension was interrupted in several points of the diagram: approximately in the middle of the

pseudo-linear section, in the region of the proportionality limit and ultimate strength limit. Changes in

distances between analogous marks for various points of the diagram were measured for each specified

point. The scheme of the processing of measurements to determine the specimen length, that participated in

the elongation is presented in Fig. 6.25.

6.32
Fig. 6.25. Scheme of the processing of measurement results to determine the gauge length

It is obvious that with the increase in the length of the segment a, that changes symmetrically relative the

specimen center in both directions, the share of the deformation occurring within this segment in comparison

with the deformation of the entire specimen will increase and will reach 100 % when the length of the

segment a becomes equal to the working length of the specimen. In this case, at sections with the uniform

deformation, the dependence of the deformation share on the variable length of the segment must be of the

linear nature. Results of the processing of the specimen elongation measurement according to this scheme

are presented in Fig. 6.26.

Fig. 6.26. Determination of the gauge length

As it can be seen from the above results, the dependence of the deformation share on the segment length is

* well approximated by a straight line, and the segment length that makes practically all the contribution to the

elongation is close to the value of the gauge length of 7.85 mm determined according to the old formula.

Fig. 6.27 shows results of determining the gauge length for various temperatures.

6.33
10

4 1 i i i i 1

200 400 600 800 1000 1200 1400

Temperature (K)

Fig. 6.27. Dependence of the specimen gauge length on the temperature

6.2.7.3. Confirmation of the modified procedure in general

A special test was conducted to confirm the modified procedure, its results are presented in Fig. 6.28. The

unirradiated ring specimen A was tested in accordance with the standard approach. The unirradiated ring

specimen B was pre-loaded to about 90 % of the yield point, i.e. the formation of the loop was practically

completed. After that the specimen B was annealed at the temperature of 580°C during 3 hours, and then was

subjected to another test till rupture. The curve B in Fig. 6.28 corresponds to the specimen loading after the

annealing.

It is obvious that the annealing operation returns initial properties of the non-deformed specimen, and the

comparison of curves A and B allows to detect the influence of specimen shape changes on mechanical

properties.

400

300,

a 200,

, A UE(%) E_(%) YS(MPa) US(MPa)

006.7 33.1 284 328 (A)

B0: 8.6 31.3 267 322 (B) B j.:8.8 31.0 280 329 (AJ)

0

0 10 20 30 40

Elongation (%)

Fig. 6.28. Confirmation of the modified procedure on the test results for the specimen which was

annealed after prestretching

6.34
The processing of curves A and B using the standard procedure revealed the 1.9 % difference in the relative

uniform elongation. This difference corresponds to the partial plastic deformation in the process of specimen

shape changes and is in a good agreement with the result of direct measurements of the residual

circumferential deformation presented in the description of Fig. 6.16. The processing of the curve A using

the modified procedure (dotted lines Amo) results in the value of the uniform elongation, that is only by

0.2 % different from that for the curve B; in combination with a good agreement of the appearance of curves

B .and Amd, this confirms the fact that the modified procedure allows to rather adequately determine

mechanical properties based on tensile test results of simple ring specimens without the conduct of the

intermediate annealing.

This modified procedure was used to obtain the data base with mechanical properties of unirradiated and

irradiated Zr-l%Nb cladding. The last stage of this work was checking the results obtained with help of

modified procedure for conformity to the power law a=Ke. The result of application of the given procedure

to the RIAR and CE-Saclay data (see Fig. 6.15) is presented in Fig. 6.29:

" the RIAR true stress-strain curve becomes quite linear;

" deviations of the CE-Saclay true stress-strain curve from a straight line are reduced;

" difference in the yield stress between the RIAR and CE-Saclay is negligible;

" the RIAR and CE-Saclay uniform elongations are coincided.

500I

Unirradiated samples

t=20'C

400 I/s c=10" 

_ RIAR/RRC data

200 ........ ........ dat.......................... a

200.

0.001 0.01 0.10 1.00 10.00 100.00

True plastic strain (per-unit)

Fig. 6.29. Example of corrected stress-strain curve

6.2.8. Results of the tests to measure mechanical properties of Zr-l%Nb cladding

Data base characterizing results of the tests for unirradiated VVER tubes and irradiated VVER cladding is

presented in Appendix J of Volume 3. This data base consists of the following data:

* parameters to characterize the state of the VVER unirradiated tube and VVER irradiated cladding, which

were used to fabricate ring specimens;

* photographs of ring specimens after the tensile tests;

* data base with mechanical properties of Zr-l%Nb versus temperature and strain rate.

Main provisions of the procedure to measure mechanical properties with the help of simple ring specimens

are presented in the previous section. This section describes data processing procedures, and systematization

of the obtained results.

6.35
Measured types of mechanical properties

According to the final procedure the following properties were to be determined for each of the tested

specimen:

" yield stress;

" ultimate strength;

* uniform elongation;

" total elongation.

The whole set of those properties was measured in accordance with initial procedure described in

section 6.2.7. After the results of individual measurements of mechanical properties were generalized,

correlation dependencies of mechanical properties versus temperature and strain rate were to be obtained.

The following statistic procedure was worked out to perform this task.

Statistic procedure to obtain correlations for mechanical properties of Zr-1%Nb cladding

The first stage of this procedure was intended to exclude crude measurement errors from the data base. The

following standard criterion was used for this purpose:

Xmx(min) -- X

S (n-1)/n <-

where x = sample mean;

- such element of the sample that Xmamm) -- max;

S = sample stdndard deviation;

n = number of measurements;

TI-p = distribution quantile;

i-p = confidence level.

Confidence level was selected as 0.99, and crude measurements were removed from the measurement

results. Then the regression analysis was used to obtain correlations for mechanical properties versus

temperature.

It has been already noted in section 6.1 that mechanical properties depend complicatedly versus temperature.

Different physical phenomena are revealed under certain temperature ranges, that is why it was considered

not expedient to look for universal dependencies describing every type of mechanical properties in the whole

range of the tested temperature (293 - 1223 K). Still, the approach based on development of certain

correlations for each temperature subinterval calls for the necessity to determine the boundaries of those

intervals. One formal method applied by the regression analysis for this class of tasks was used during the

first stage of this studies. This method describes the files with the measurement results obtained for some

random (but reasonable from the standpoint of researcher) temperature range with the help of the following

equation:

6 =jIXTXj'XTy,

where E = vector of regression coefficients;

X = action matrix;

7 = response vector;

T = sign of transposition of operation;

-1 = sign of inversion of operation.

6.36
This equation is transformed into the following regression equation:

y =be +b x+b2x 2 +....

The power index for this equation was chosen by minimization of the sample standard deviation in

accordance with the following expression:

Z•(yimyj,) 2 _

where S = sample standard deviation;

y• = measured value of the parameter;

yj, = calculated value of the parameter using regression equation;

i = current measurement;

n = number of measurements.

The procedure was arranged in such a way that the boundary of the chosen temperature range was step by

step shifted towards its broadening. This was done until abrupt increase of the sample standard deviation

occurred. That was the sign that there existed breakpoint of some derivative, that is why the structure of the

regression equation was to be changed [19]. Operations of this type performed for different sets of

temperature sub-ranges, allowed to reveal all the breakpoints and to finally define the boundaries of

temperature sub-ranges, for which the best regression equations for each mechanical property were obtained.

Thus, it was recommended to describe ultimate strength with the help of correlation dependencies

corresponding to four temperature sub-ranges:

1. 293 - 779.55 K

2. 779.55 - 903.55 K

3. 903.55 - 1123.99 K

4. 1123.99 - 1273 K

Those ranges were obtained for unirradiated cladding. Similar ranges were defined for irradiated cladding,

and for other mechanical properties. Statistic processing of results characterizing mechanical properties

versus strain rate was also performed with the help of regression analysis. Still, the volume of sample for

each strain rate was limited in this case. That is why we used the a priory information that the straight line

describes the dependence of strength versus strain rate in logarithm coordinates. Hence the linear regression

analysis of the obtained data base was done, and the coefficients of respective regression equations were

calculated. The result of statistic processing of all the measurement results was that correlation dependencies

for all mechanical properties versus temperature and strain rate were obtained.

Correlations for mechanical properties of Zr-l%Nb cladding versus temperature

The set of correlations obtained by statistic processing of the measurement results is listed in Table 6.8,

Table 6.9.

Fig. 6.30, Fig. 6.31 present the graphical view of correlations for the ultimate strength and yield stress.

6.37
Table 6.8. Correlations for mechanical properties of unirradiated Zr-1%Nb cladding vs. temperature

hngmeermg

ultimate

strength

(N/a)

293 <[ T - 787.61

787.61 < T5 <903.55

903.55< T <1123.99

1123.99< T <1273

Sw = 658.37 - 1.4605 T + 0.00155977 T2 - 6.87908 10-7 T3

S. = 11072.6 exp (-0.00555345 T)

S. = 308.857 - 0.260714 T

=S = 32.6783 - 0.015 T

Engineering 293< T <786.91 Sy= 502.9982 - 0.8738195 T + 6.124696 104 T2 - 1.418248 I0 TT'

yield 786.91< T •892.32 Sy = 10094.5 exp (-0.0055752 T)

stress 892.32< T _1125.38 Sy = 285.624 - 0.241928 T

(MPa) 1125.38< T <1273 Sy = 44.4448 - 0.027619 T

293< T:5797.42 t =-18.9711 + 0.33792 T - 0.000711456 T2 + 4.82512 107 T3

Total 797.42< T •921.36 St = 1.25035 exp (0.00442943 T)

elongation

(%) 921.36< T 51128.97 Bt = -1193.07 + 2.52887 T - 0.00125208 T2

1128.97< T :1223 8, = 2052.89 - 3.3404 T +0.0014 T2

Uniform

elongation 293< T •1223 ,= 3.21877 + 0.0282662 T - 0.460968 10-4 T2 + 0.192154 10-7 T3

(%)/

Table 6.9. Correlations for mechanical properties of irradiated Zr-l%Nb cladding vs. temperature

Engineering

ultimate

strength

(MPa)

293 < T•9 742.27

742.27 < T < 847.04

847.04< T •903.55

903.55< T <1123.99

112.99< T <1273

S, = 608.908 - 0.0281736 T - 0.000640119 T- + 1.65407 10' TSw = 7.63008 105 exp (-0.0105506 T)

S, = 0.110726 105 exp (-0.00555345 T)

Su = 308.857 - 0.260714 T

S~t = 32.6783 - 0.015 T

293< T <739.97 Sy = 690.3984 - 1.015694 T + 0.001310936 T2 - 9.702603 10-7 T 3

Engineering 739.97< T <846.56 Sy = 4.55945 105 exp (-0.0100762 T)

yield stress 846.56< T •892.32 Sy = 10094.5 exp (-0.0055752 T)

(MPa) 892.32< T •1125.38 Sy = 285.624 - 0.241928 T

1125.38< T <1273 Sy = 44.4448 - 0.027619 T

293< T <750.35 t= -42.4625 + 0.392239 T - 0.00083939 T-2 + 5.80895 10-7 T3

Total 750.35< T •860.93 St = 0.289231 T - 192.36

elongation 860.93< T •921.36 St = 1.25035 exp (0.00442943 T)

(%) 921.36<T •1128.97 St = -1193.07 + 2.52887 T - 0.00125208 T2

1128.97< T <1223 8t = 2052.89 - 3.3404 T +0.0014 T2

Uniform 293< T •749.01 , -- 1.66205 + 0.0238493 T - 0.512487 10-4 T2 + 0.326065 10-7 T3

elongation 749.01<T:5870.67 8,f=i-130.96 + 0.418691 T-4.21118 I0-4OV2+ 1.38229 10'T 3

(%) 870.67< T <1223 8S = 3.21877 + 0.0282662 T - 0.460968 10-4 T2 + 0.192154 10-7 T3

6.38
600

400 0 irdao

corrlation

Q 200

200 400 600 800 1000 1200 1400

Temperature (K)

Fig. 6.30. Engineering yield stress vs. temperature for unirradiated and irradiated Zr-l%Nb cladding

Fig. 6.31. Engineering ultimate strength vs. temperature for unirradiated and irradiated Zr-l%Nb

cladding

Analysis of those correlations for unirradiated claddings allows to reveal the following important processes

influencing mechanical properties of this cladding type versus temperature:

" lower temperature sub-range 293 -(780 - 790) K is characterized by monotonic reduction of strength

properties;

" sub range (780 - 790) - (890 - 905) K reflects most probably the region of dynamic strain aging. In this

case the strength of material at the beginning of this range depends slightly on the temperature, then it

reduces greatly and reaches the value which could be obtained by extrapolation of correlations obtained

for the lower temperature sub-range;

" the third temperature sub-range (890 - 905) - 1125 K practically coincides with the region of a - P3 phase

transformation for Zr-l%Nb alloy. Additional analysis has demonstrated that the determined boundaries

6.39
of this range and the linear character of the dependence for strength parameters versus temperature satisfy

the specified task with good accuracy;

* the fourth temperature region 1125 - 1273 K characterizes the strength of Zr-lNb alloy in the 13 phase.

Linear approximation of experimental data was used, but the sample volume is not great, and it is not

possible to insist that the correlations for this temperature sub-range could not be improved in the future.

It is also necessary to stress that the type of equations for original correlations obtained to describe strength

of Zr-lNb cladding versus temperature coincides with the type of equations developed in MATPRO to

characterize Zircaloy: polynomial of the third power, exponential function, linear functions. This fact

objectively reflects the qualitative similarity of the mechanical behavior of these two alloys.

Analysis of the similar correlations for irradiated Zr-lNb cladding demonstrates significant strengthening

of the cladding in the two lower temperature sub-ranges. This strengthening is obviously the effect of

irradiation, because with the increase of temperature annealing of irradiation damages is revealed, and

strength becomes worsened. The effects of annealing and dynamic strain aging are summed up in this

temperature sub-range and their summarized influence determines the profiles of the corresponding curves.

Shift of the point of the abrupt reduction of strength of irradiated claddings to the region of lower

temperatures (in comparison with unirradiated claddings) corresponds well with the earlier obtained data that

the maximum dynamic strain aging of irradiated claddings is shifted to the left because of the influence of

annealing [5]. It is also interesting to note that the strength curves for irradiated claddings have the concave

up shape in the temperature range of up to approximately 750 K, unlike the concave down shape of these

curves for unirradiated claddings. Such change of the sign of the second derivative under the condition of

approximately constant exposure time of the specimens under each of the specified temperatures can be

explained by the increase of the rate of annealing of radiation defects under temperature growth.

Starting with 860 K strength parameters of irradiated and unirradiated Zr-l%Nb claddings practically

coincide. According to the data presented in section 6.1 the total annealing time for the temperature of 860 K

is about 2000 s, which corresponds to the exposure time of specimens in the given tensile tests. Statistic

analysis of the two samples with the measurement results for irradiated and unirradiated specimens was

performed for the temperatures higher than 860 K. The analysis has demonstrated that both samples belong

to one general set, and, hence, can be combined. That is why unified correlation dependencies were

developed for both types of specimens in this temperature sub-range.

Correlations for total elongation of unirradiated and irradiated specimens are graphically presented in Fig.

6.32.

150

Strain ratre 0.002 1/s

0 unirradiated

S100 * irrdiated

-correlation

50

50 0

0

200 400 600 800 1000 1200 1400

Temperature (K)

Fig. 6.32. Total elongation vs. temperature of unirradiated and irradiated Zr-l%Nb cladding

Statistic analysis allowed us to reveal three typical temperature sub-ranges for the total elongation of

unirradiated Zr- INb claddings:

6.40
" The first sub-range 293 - 797 K is characterized by the fact that the expected monotonic increase of the

total elongation versus temperature is interrupted because of the influence of the dynamic strain aging

effect. Slow down of the ductility increase, connected with this effect, starts to reveal under the

temperature of 450 - 500 K. The maximum of this effect is observed at the temperature of 600 - 650 K.

Under this temperature total elongation is almost equal to total elongation at 293 K. Comparison of the

temperature, at which the maximum reduction of total elongation is observed, with the temperature, at

which the maximum improvement of strength is noted, indicates that maximum of the plasticity reduction

is displaced relative the maximum of the strength increase in the direction of lower temperatures. This

corresponds with the earlier obtained data characterizing the influence of dynamic strain aging onto

mechanical properties of claddings [7].

" The second temperature sub-range (797 - 1000 K) is the sub-range where we observe the abrupt increase

of the total elongation caused by the superplasticity effect. This effect described in section 6.1 is

connected with phase transformation in Zr-ilNb alloy. Total elongation in the point T = 1073 K makes

W 100%.

" The third temperature sub-range (1000- 1223 K) is characterized by a reduction in the total elongation

and its value stabilization at the level of~-70%.

The specific feature, of irradiated claddings is that total elongation of this type of claddings is practically

twice less than the total elongation of unirradiated claddings for the lower temperature sub-range. The nature

of total elongation curve in the second temperature sub-range - 750 - 860 K is determined by the effects of

annealing of irradiation damages and superplasticity. Total elongation of irradiated and unirradiated

claddings practically coincide at the temperature of about 860 K, thus indicating that annealing of radiation

defects is practically over by this temperature.

As in the case of strength characteristics, at temperatures above 860 K samplings of unirradiated and

irradiated claddings were combined and are described by common correlation dependencies.

It should be specially noted that temperature dependencies of the total elongation in the superplasticity

region, presented in Fig. 6.32, are significantly different from results obtained at the first stage [23] and from

the existing data base on unirradiated claddings, for which the maximum value of the total elongation

reached 200 %.

As it has already been mentioned, since existing data on irradiated claddings and results obtained at the first

stage were characterized by a large spread and different behavior of unirradiated and irradiated claddings in

the superplasticity region, a decision was made to conduct additional experiments in this temperature region.

A joint analysis of methodologies and results of these and previous experiments allowed to reveal the

following:

a. Previous experiments were performed in the temperature region above 800 K using an analogue recording

system;

b. Two maximum values of the total elongation of 134 and 175 % for irradiated specimens were obtained as

a result of an erroneous diagram interpretation when, due to small loads that were close to the sensitivity

limit, the specimen was considered as failed in case of the failure of the second, rather than the first neck.

With a correct processing of diagrams, these values are reduced to 94 and 115 %, respectively;

c. The application of the modified procedure of the diagram processing to all earlier obtained results leads to

a reduction of the total elongation value by 10- 15 relative percents;

d. New experiments were conducted at all temperatures for unirradiated and irradiated specimens using the

same equipment with the digital recording, were processed according to the modified procedure and have

a much smaller spread;

e. In case of possible adjustments of results of previous experiments according to items b and c, the old and

the new data bases become closer, however such adjustments can be conducted only using correction

coefficients for the entire data base since there are no diagram available for each test.

Taking into account above considerations, as well as the fact that the main purpose of developing this data

base is to obtain correlations for the use in computer codes, it was decided to use results of only new

experiments in the data base.

6.41
In the graphical form, correlations for the uniform elongation of unirradiated and irradiated specimens are

presented in Fig. 6.33

12

Strain rate 0.002 1/s

o unirradiated

8 irradiated

0 0

corrclation

4

00

200 400 600 800 1000 1200 1400

Temperature (K)

Fig. 6.33. Uniform elongation depending on temperature of unirradiated and irradiated claddings

As it has already been noted, a large spread of the relative uniform elongation in the existing data base and

significant differences in results of the first stage of current studies and of trilateral comparative experiments

were a reason of studies to improve the procedure and to conduct experiments of the second stage. Results of

these studies allowed to obtain a rather consistent data base on the relative uniform elongation, described

below.

Table files of all measurements, as well as of other mechanical properties are presented in Appendix J of

Volume 3. The statistical analysis of data allowed to reveal three characteristic temperature subintervals for

the relative uniform elongation of unirradiated claddings of Zr-l%Nb alloy:

" In the first subinterval (293 - 890 K), as in the case of the total elongation at temperatures 450 - 500 K, a

slowdown of the plasticity growth is observed. Moreover, with a further temperature increase the uniform

elongation decreases.

" The second subinterval (890- 1073 K) practically coincides with the region of the a-P3 transition and is

characterized by practically linear decrease in the uniform elongation.

" In the third subinterval (1073 - 1223 K) the value of the uniform elongation remains constant at the level

of 4 %.

The temperature dependence of the uniform elongation of the irradiated cladding is similar to the nature of

the unirradiated cladding dependence in the lower temperature subinterval, and as in the case of the total

elongation it is 2 times smaller than for the unirradiated cladding. At temperature above 750 K, the annealing

of radiation defects takes place, the value of the uniform elongation of the irradiated cladding increases, and

at temperature 870 K the uniform elongation of irradiated and unirradiated claddings is the same.

Correlations for mechanical properties of Zr-l%Nb claddings vs. strain rate

Tabular files of all measurements are presented in Appendix J of Volume 3. According to the existing

tradition it is accepted to describe the yield stress versus strain rate for Zr-l%Nb alloy by the equation [6]:

hI ay =mint+A,

where cyy = yield stress;

= strain rate;

m = strain rate sensitivity exponent;

A = constant.

6.42
I.e. yield stress in the double logarithmic coordinates is the straight line with the tangent of slope angle equal

to m. Statistic processing of the measurement results according to this approach allowed to get correlation

dependencies presented in Table 6.10 and in Fig. 6.34, Fig. 6.35. It is important to remember that

comparison of the measurement results versus strain rate is to be performed for the same deformations of

specimens. That is why it is usually yield stress to be used for this purpose, as this parameter always changes

at the elongation equal to 0.2 %. The influence of strain rate onto other parameters is considered with the

help of the law, which allows to consider dependence of these parameters versus strain rate. This approach

will be described in detail in section 6.4.

Table 6.10. Correlations for yield stress vs. strain rate for unirradiated and irradiated Zr-i %Nb

cladding

293 InSy = 0.0205123-In t + 5.94628

623 InSy = 0.0192842.in 9 + 5.20023

873 InSy = 0.104469.in e + 5.01359

923 lnSy = 0.1 1364.in i + 4.80329 unirradiated

1023 InSy = 0.14491.ln 9 + 4.57372

1073 lnSy = 0.172774.1n 9 + 4.53082

1123 InSy = 0.201979.1n e + 4.18842

1223 InSy = 0.162062.in i + 3.02398

293 InSy = 0.0252894.in t + 6.29366

653 InSy = 0.0250984.1n t + 5.90415

753 lnSy = 0.0229939.1n 9 + 5.7549

irradiated 793 InSy = 0.0566845.1nt + 5.26949

923 InSy = 0.13 1023.1n 9 + 5.01256

1023 InSy = 0.19018.int + 4.78353

1123 InSy 0.180971.In 9 + 4.51703

100 0 __

104 0 29

0.001 0.01 0.10 1.00

Strain rate (1/s)

Fig. 634. Yield stress vs. strain rate for unirradiated Zr-l%Nb cladding

6.43
1000

I A• + 293 K

633 K

753 K

100 K

91073 K

101 1

0.001 0.01 0.10 1.00

Strain rate (11s)

Fig. 635. Yield stress vs. strain rate for irradiated Zr-i%Nb cladding

Analysis of correlations presented in Table 6.10 indicated that strain rate sensitivity exponents for

unirradiated and irradiated Zr-lNb claddings does not differ from the studied temperature range.

Qualitative physical assessment of the strain rate influence onto mechanical properties can be done with the

help of analysis of the data presented in Fig. 6.36, Fig. 6.37.

So, the obtained results demonstrate that the cladding strength increases significantly when the strain rate

increases from 10"3 I/s to 0.1 - 0.5 V/s. In the absolute sense the influence of rate is mostly important for the

temperature range of 750- 1273 K.

Fig. 6.36. Data base to characterize yield stress of Zr-l%Nb cladding vs. temperature and strain rate

6.44
150 -

-. 100 - A irrdiated, sInratMC 0.5 1f

A uninzdiatcd, strain rate 0.5 1/s 0

50 A uitdsnue.V

00

200 400 600 800 1000 1200 1400

Temperature (K)

Fig. 637. Data base to characterize total elongation of Zr-l%Nb cladding vs. temperature and strain

rate

Analysis of total elongation of unirradiated claddings is not completed yet. It is interesting, though, that total

elongation of irradiated claddings demonstrates its insensitivity to the strain rate in the lower (up to 770 K)

and upper (above 1100 K) temperature ranges. We still need to understand whether this is a real physical

phenomenon or the deficiency of experimental data. Within a-+P transformation temperature range total

elongation decreases significantly as the strain rate increases. But, it is necessary to perform additional

measurements to reveal the tendency of the change of total elongation of 3--phase of Zr-1%Nb alloy.

6.2.9. Summarizing of the obtained data base with mechanical properties of Zr-1 %Nb

cladding, and its analysis

The cycle of tensile ring tests allowed to obtain correlation dependencies describing mechanical properties of

two types of claddings versus temperature (293 - 1273 K), and strain rate (0.002 - 0.5 l/s). The variation

range of temperature and strain rate is sufficient to develop the MATPRO/VVER version necessary for

computational analysis of IGR tests.

Analysis of the obtained data base has demonstrated the following:

" strength characteristics of Zr-l%Nb claddings versus temperature are original, and can not be described

with the help of the data base for Zircaloy up to T = 860 K;

" under the temperatures higher than 860 K strength characteristics of Zr-lNb claddings do not depend on

burnup and practically coincide with the properties of Zircaloy;

" total elongation of Zr-l%Nb claddings can reach 100 % for the superplasticity region, still additional

measurements are to be done to improve accuracy of correlations for this region;

" total elongation of 1-phase of Zr-l%Nb claddings versus temperature is to be also specified;

" the performed investigations have indicated that on the whole behavior of Zr-lNb specimens as the

function of strain rate correspond to the behavior of Zircaloy specimens.

6.45
6.3. Measurements ofparameters characterizing mechanical behavior of Zr-l %Nb

cladding under ballooning conditions

6.3.1. Program and procedure of the burst tests

It has already been noted in section 6.1 that high temperature rupture of the cladding due to ballooning is the

specific feature of testing VVER fuel rods under IGR conditions. It was important to obtain the data base to

try to describe this process by computer codes. It should be mentioned that of the two considered codes only

FRAP-T6 code allows to predict mechanical behavior of the cladding under ballooning conditions. That is

why the program of special tests has been developed with consideration of FRAP-T6 code requirements to

the respective data base. Still, the motivation targeted at better understanding of the ballooning key

phenomena was also evidently present.

Burst tests of pressurized specimens are the classical type of tests to study ballooning phenomena. The

special setup was developed for this (Fig. 6.38).

Each specimen 150 mm long was fabricated of the VVER tube, or irradiated VVER cladding. A special cap

was placed in the bottom part of the specimen. The top part of the specimen was connected to the source of

helium supply by the set of special technological elements. The whole assembly was located inside the

protective capsule, which in its turn was put into electrical bakeout furnace. The history of temperature (T)

and pressure (P) in the top part of the specimen was registered in the process of testing. Besides, the original

structure of the furnace was designed to ensure video filming of the specimen surface during testing, and

thus to obtain time history of the cladding hoop strain and burst. Fig. 6.39 presents the typical burst test

scenario.

He flow

electric bakeout

furnace u

protective

capsule -

T,P

pressurised specimen

Fig. 6.38. Principle part of experimental setup for the burst tests

6.46
Prelimna,, •Burst

1500- Preim •--,a heatng _.Mainphase 1.5

1000. 1.0

Tmperature (measured)

0 - Pressur0 (measured).5

0 0.0

0 1000 .2000 3000

Time (s)

Fig. 6.39. Time history of the temperature and pressure for one of the burst tests

Preliminary heating stage of the scenario called for the step by step temperature increase of the specimen up

to the specified T. value under slightly excessive helium pressure inside the specimen. Non-uniformity of the

temperature distribution along the specimen height and radius was not more than ±4°C. Then helium

pressure inside the specimen was increased according to the specified value of the pressure increase rate up

to the burst of specimen. After that the cooling phase took place.

The program of testing of unirradiated specimens called for measurement of the following parameters:

" pressure of the burst versus temperature and pressure increase rate;

" axial radius of the curvature of the cladding burst area versus temperature and pressure increase rate;

* circumferential elongation of the cladding burst area versus temperature and pressure increase rate.

The program of testing of irradiated specimens was the same but for the fact that no study of the influence of

the pressure increase rate was planned.

Burst tests were performed for the following range of input parameters:

" temperature 1073 - 1473 K;

" pressure increase rate 0.01 - 1.0 MPa/s.

Two types of specimens were tested:

" specimens fabricated of unirradiated VVER tubes;

" specimens fabricated of the cladding of commercial VVER fuel element # 153 of the fuel assembly

# 4108 irradiated at Unit 5 of NV NPP.

Two VVER tubes were used to fabricate unirradiated specimens for burst tests. Technological parameters of

the tubes, and the methods used to measure their geometric dimensions were similar to the parameters and

methods described in section 6.2.4 for simple ring specimens. The measured range of geometric dimensions

variation was the following:

" specimen length - 150*1 mm;

" outer diameter - 9.136 - 9.149 mm;

" inner diameter- 7.712 - 7.735 mam;

" cladding thickness - 0.696 - 0.699 mm.

6.47
The data base characterizing parameters of unirradiated and irradiated specimens before burst tests is

presented in Appendix K of Volume 3. The respective characteristics for irradiated specimens were obtained

with the help of the following types of pre-test examinations:

" profilometry;

" eddy current examination;

" y-scanning of fuel element.

These measurements showed that the outer diameter of irradiated cladding was equaled to 9.068 - 9.096.

Fuel burnup in the section used for fabrication of the specimens was 47.15 - 48.03 MWd/kg U. The

following parameters were measured with the help of metallographic cross-sections:

" cladding thickness - 0.69 ± 0.015 mm;

" Zr0 2 thickness on the outer surface of the cladding 3 - 5 pin;

" ZrO2 thickness on the inner surface of the cladding < 1 pm;

" hydrogen concentration in the cladding 0.051 - 0.057 % (by weight);

* hydrogen orientation in the cladding - 0.36 - 0.41.

After burst tests all the tested specimens were subjected to post-test examination to define specific

ballooning parameters. The first stage of the work included making photographs of each specimen in

different projections. Metallographic cross-sections were produced and their photographs made over the

second stage of the post-test examinations, so that to get the view of the specimen in the center and at the

boundary of the cladding rupture area. The third stage of examinations called for computer processing of the

whole set of photographs according to the following issues:

" determination of the middle line profile for each cross-section of the cladding;

" measurement of the cladding thickness;

" measurement of the ballooning axial radius;

" measurement of the circumferential radius of the curvature;

" measurement of the peak circumferential elongation.

The necessary procedures, developed to measure every value are described further.

Determination of the middle line profile

Graphical illustration is presented in Fig. 6.40.

Fig. 6.40. Scheme to determine the middle line profile of the cladding cross-section

6.48
Geometric center, marked with point A is determined at the beginning. Then straight lines with the angle step

equal to 0.50 are drawn from the geometric center of the figure. Two of these lines presented in Fig. 6.40

cross the cross-sections in points NI, K1 and N2, K2. Crossing of the two straight lines drawn through the

points N1, K, and N2, K2 determine the coordinates of the point P. Bisectrix of the angle formed by these two

straight lines crosses the straight lines A-NI-K1 and A-N2-K2 in the points M, and M2.The middle part of the

section of the straight line connecting points M, and M2 is defined as point S. This point lies in the middle

line of the cross-section. Set of Si points specifies the middle line profile.

Cladding thickness

Cladding thickness was determined versus azimuth angle by computer processing of the cross-section

photograph. For each azimuth angle thickness measurement was made according to the normals for the

cladding middle line. The example illustrating this procedure is presented in Fig. 6.41.

!A

IB

A B

initial cross-sections

OO

0O.7 . _ - - - 0.7 ------------------ -- ---..... - ....... .......

0.3 . 0 3 ~ - - - - -

.o.

U 01) --- 4• U ..

0 100 200 300 400 0 100 200 300 400

Azimuthal angle Azimuthal angle

Fig. 6.41. Scheme of the procedure to determine cladding thickness vs. azimuth angle

6.49
It is important to note that A-A type of cross-section was fabricated for all specimens so that to characterize

the cladding maximum hoop strain. This cross-section was made for the half of the cladding rupture length

(Fig. 6.42). Cross-section of B-B type was cut so that to characterize the profile of the unfailed cladding for

the part bordering the cladding rupture (Fig. 6.42).

BI AI

B I A I

Fig. 6.42. Method to obtain cross-sections of A-A and B-B types

It will be shown in section 6.4.1 that the data base characterizing cladding thickness versus azimuth angle is

not sufficient to calculate cladding failure. The special parameter called cladding thickness at the moment of

burst (tB) is to be also determined The special procedure was developed and described in MATPRO to

determine this parameter using the results of burst test with Zry claddings. This procedure included

measurement of the cleavage-like line (ten) presented in Fig. 6.43 for one of the cross-sections.

Fig. 6.43. MATPRO procedure to determine cleavage-like line presented for Zr-l%Nb specimen after

the burst test

6.50
This example vividly illustrates that no clearly seen cleavage-like line is present in the tested specimens. The

attempt to define tfl for the part of the specimen presented in Position 1, and to compare this part with the

part of the specimen presented in Position 2, indicates that it is either not possible to identify the cleavagelike line in Position 2, or the line is practically absent and the specimen rupture takes place at the nearly zero

thickness of the cladding. Hence another approach was developed to determine cladding thickness at the

moment of burst (tB). This approach uses the following scenario of the cladding failure due to ballooning.

The first phase of the process is characterized by the uniform reduction of the cladding thickness in all

azimuth directions along with the increase of the pressure and temperature. Then the local necking of the

cladding takes place. This process is schematically presented in Fig. 6.44.

Fig. 6.44. Scheme of the cladding necking

In the part of the cladding with some length, limited by the ca angle, neck is formed, which is characterized

by the situation that neck thickness becomes less than the thickness of the rest cladding parts. The

consequence of this is that circumferential elongation of the cladding in this part of it starts to increase

quickly simultaneously with the continuous reduction of the cladding thickness. Maximum gradient of the

change of both parameters is in the central part of the necking length. Cladding rupture is the final stage of

this scenario. Analysis indicates that if the minimum thickness of the cladding neck is measured at the axial

boundary between the ruptured andl unfailed regions, we can get the criterion value of the cladding burst

thickness (tB). It has already been noted that the special set of B-B type cross-sections was intended for that

purpose. Fig. 6.45 illustrates the procedure to determine tB.

' 0.6

S0.4----- 4

0.2

0 100 200• 300 400

Azimuthal angle (deg)

Fig. 6.45. Procedure to determine cladding burst thickness

6.51
Axial radius of ballooning

The procedure used to develop MATPRO package in order to determine axial radius of ballooning (rz) called

for measuring of this parameter with the help of specimen photographs after burst tests. Fig. 6.46 presents

this processing for Zr-1%Nb specimen.

ballooning ý,A outline of

relgion • ! photograph A

region

Fig. 6.46. Method to determine the axial radius of ballooning using MATPRO procedure

Analysis of this method indicates that it has a systematic error, because the axial radius of ballooning is to be

determined before the edges of the cladding rupture tear are moved for hr value. It is evident that if hr value is

not large in comparison with rz, this error can be neglected. Still the review of the respective data base

indicates that it is not always that this requirement is satisfied. This issue is mostly important for the

claddings tested under the parameters leading to significant strain (Fig. 6.47).

AA

Fig. 6.47. View of Zr-1%Nb cladding burst under the superplasticity conditions

It is evident that the ballooning axial radius measured after the test and the ballooning axial radius just before

the test differ greatly in this specific case. That is why another procedure was developed to determine rz. It

was determined thus that the outlines of ballooning region for the tested specimens are characterized by the

symmetry against the axis drawn along A arrow. That is why if the cross-sections of A-A and B-B types are

fabricated for each specimen according to the procedure described above, rz value can be determined by the

scheme presented in Fig. 6.48.

6.52
rI I rL p. A-A B-B

1.1. Restoration of shape of A-A

cross-section at the burst.

1.2. Measurements of rA.A and rB.B.

rA.A r

. ................ ...... :

Second step: 2

2.1. Two segments of the z length

equal to the length between A-A

and B-B cross-sections are r. rAA\

plotted in the horizontal axis. .-.... Z .

2.2. Vertical segments equal to rA.A

and rB-B are plotted as shown in rZ

the graph.

2.3. The circle of r. radius is drawn

through the points 1, 2, 3.

Fig. 6.48. Scheme of geometric procedures to determine axial radius of ballooning (rz)

Circumferential elongation at the moment of burst

Measured length of the middle-line of the cladding cross-section in A-A position after the burst test (LB), and

the gauge length of the middle-line of the cladding cross-section before the burst test (Lo) were used to

calculate circumferential elongation at burst by the following formula:

(*/(%)= L-L0 100%. Lo

Circumferential radius of curvature

According to the tolerances accepted in the MATPRO package circumferential radius of the curvature (re) is

the radius of such a circle for which the condition is correct that all the points of the middle line of the

cladding cross-section, belonging to ballooning region in A-A position, are within this circle. With

consideration of this definition the following expression was used to determine this radius:

where r. = circumferential radius of the curvature at the moment of burst (mm);

r.0 = radius of the •cladding middle line in the cross-section before the burst test (mm);

c. = circumferential elongation at the moment of burst (%).

Fig. 6.49 illustrates the result obtained by this equation for one test of Zr-l%Nb cladding.

6.53
Fig. 6.49. Comparison of the cladding cross-section in A-A position after burst test and the restored

profile of the cladding middle line at the burst moment

6.3.2. Results of burst tests

Data base to characterize burst tests is presented in Appendix K of Volume 3. It includes the following

parameters:

" parameters of unirradiated and irradiated specimens before tests;

" photographs of specimens after-tests;

* photographs of A-A and B-B type cross-sections of the specimens;

" tables with measured results.

Measurement results of burst pressure versus temperature are presented in Fig. 6.50.

Fig. 6.50. Burst pressure vs. temperature for unirradiated and irradiated Zr-l%Nb cladding

6.54
These results confirm that mechanical behavior of unirradiated and irradiated specimens is identical under

high temperatures. Statistic processing of obtained results allowed to get the following correlation for the

burst pressure versus temperature. Analysis of this correlation indicates that in the temperature sub-range of

973 - 1173 K burst pressure decreases practically 6 times. This fact stresses the importance of studying the

superplasticity temperature region for Zr-l%Nb alloy in order to reliably predict cladding failure due to ballooning. Burst pressure dependence versus temperature becomes less strongly expressed as the temperature

continues to grow. Fig. 6.51 presents important results characterizing cladding hoop strain versus

temperature.

120

80 0

-G- soo

400

*rssr inrradi ated 40

800 1000 1200 1400 1600

Temperature (K)

Fig. 6.51. Circumferencial strain at burst vs. temperature for unirradiated and irradiated Zr-l%Nb

cladding

The obtained data indicate that as it has been already revealed with the ring specimens, cladding elongation

decreases abruptly along with the a+p--,3 phase transition. Beside that the tests indicate that beginning with

1273 K elongation of Zr-l%Nb starts to increase along with the increase of the cladding temperature. The

correlations obtained for the burst pressure and cladding hoop strain are presented in Table 6.11.

Table 6.11. Correlations for burst pressure and maximum circumferential elongation vs. temperature

Burst pressure

(Ma)

973<T11 179 PB-9 4 5 5 9 .

2 exp(-0.0092216 T)

1179<P51473 Pi3=19.1746 exp(-0.200261 10-2 T)

Circumferential 973<T15108 6o=-2 5 2 9 4 .1 + 71.7577 T - 0.067244 T2 + 0.0000208674 T3

elongation (%) 1 108<T1473 1e=1 589.11 - 2.43805 T + 0.000942896 T2

Moreover influence of pressurization rate on burst parameters was studied. Obtained results are presented in

Fig. 6.52. As it was demonstrated for the case with ring specimens the results of the tests in logarithmic

coordinates can be approximated by the straight lines. The tangent of the slope angle of these lines has the

physical sense similar to the notion of strain rate sensitivity exponents that was introduced for ring

6.55
specimens. The data presented in Fig. 6.52 indicate that for all the tested temperature levels strengthening of

the cladding, caused by pressurization rate growth, were observed.

This conclusion is in the agreement with the respective results obtained during testing of ring specimens.

Fig. 6.52. Burst pressure vs. pressure increase rate at different temperatures for unirradiated and

irradiated Zr-1%Nb cladding

6.3.3. Analysis of burst test results

It has been described in section 6.3.1 that burst tests with Zr-lNb specimens were performed with the help

of a non-standard procedure. In this case the specimen was heated up to the specified temperature and then

the gas pressure inside the specimen was increased until the cladding burst. The traditional testing procedure

assumes that the cladding is loaded with the initial pressure, and then the specimen temperature, and as the

consequence, pressure inside the specimen is increased until the cladding burst. Non-standard scenario was

chosen to test Zr-l%Nb specimens, because the results of those tests were necessary to analyze the cladding

behavior under RIA conditions. The proposed approach, satisfies the main requirement to this data base, i.e.

to exclude the influence of the cladding creep onto test results. This is the reason why the specimens were

heated up to the specified temperature under the low pressure drop at the cladding. It is important to note that

burst tests of unirradiated Zr-l%Nb specimens were performed earlier at VNIINM in the frames of the

approach based on the controlled heating at the constant rate until the failure occurred [20].

In order to have the basis for formal analysis it is necessary to compare the results of different type of burst

tests presented in Fig. 6.53. It is also important that the MATPRO data [2] are not uniform. Some part of it

was obtained for the process of heating the specimens in inert environment, some specimens were tested in

steam, heating rate was also different. Still, the generalized data base allows to make the following

conclusions:

" abrupt decrease of the burst pressure is observed in the region of a-P phase transformation for both

alloys;

" slight dependence of burst pressure versus temperature is noted for 13-phase of Zr-lNb and Zry alloys.

6.56
15

10 - - Ia a ion (I is)

80unirradiated 0400 [20

*Ziaataloy (MATFRO data base)[2

800 1000 1200 1400 1600

Temperature (K)

Fig. 6.53. Generalized data base to characterize burst pressure vs. temperature for Zr-l%Nb and Zry

claddings

Additional analysis was performed to reveal the trends characterizing circumferential elongation versus

temperature and pressure increase rate (see Fig. 6.54). Reduction of circumferential elongation is observed in

the area of a+p3-+p transition in the whole range of pressurization rates. In this case deformation rate does

not practically depend on the pressurization rate. Along with the temperature growth in the P-phase, the

higher pressurization rate leads to the higher elongation in comparison with the lower rate. Diffusion

mechanisms of deformation (high temperature creep)'at low loading rates can be most probable reason for

this unexpected effect. This leads to the instability of plastic deformation and to the rupture at the

circumferential elongation lower than in case of fast loading. In case of the higher pressurization rate there is

no time for the diffusion creep to reveal, and strengthening caused by sensitivity to the strain rate becomes

the prevailing factor. Hence, plastic instability and rupture take place in case of greater circumferential

elongation of the cladding. Still, final explanation of the nature of this effect, which is most clearly revealed

in 1273 - 1373 K temperature range, is the subject for the future investigation of the high temperature

behavior of the Zr-l%Nb alloy.

120

~80

140

to

0

I________ ________ ____

800

0 

1000 1200

- - -I---

Temperature (K)

1400 1600

Fig. 6.54. Circumferencial elongation vs. temperature and pressure increase rate for unirradiated

Zr-1%Nb cladding

6.57
Analysis of circumferential elongation (hoop strain) at burst, presented in Fig. 6.51 can become more

interesting if we complete the results by the data obtained for ring specimens (Fig. 6.55)

120

80

40

~00

0

1000 1200 1400 1600

Temperature (K)

Fig. 6.55. Comparison of the Zr-l%Nb tensile and burst test results

It is obvious that comparison of these two data bases can be done with great caution, because unaxial and

biaxial tests are compared.

Moreover, it is impossible to control the strain rate in the cause of burst tests with pressurized cladding

specimens. The preliminary assessments indicate that the peaking rate of circumferential elongation in the

burst tests with pressurization rate of 0.01 MPa/s is -0.1 I/s. Circumferential elongation at burst, obtained in

these tests and the total elongation of the tensile ring tests with strain rate of 0.1 1/s is presented in Fig. 6.55.

Still even the qualitative comparison allows to make the conclusion that values of the ductility parameters

obtained in both types of tests are very close, and their temperature dependencies have similar trends in the

high temperature area.

6.4. Development of the data base with mechanical properties of Zr-1%Nb for the

MA TPRO package and SCANAIR code

6.4.1. Data base for MATPRO package

MATPRO package uses the following basic equation to describe the correlation between the stress and strain

depending on the loading conditions and the state of the cladding material:

a. = Ke'

where a-= true effective stress (MPa);

K = strength coefficient (MPa);

e = true effective strain (per-unit);

(6)

6.58
n = strain hardening exponent (per-unit);

= current strain rate (1/s);

o= basic strain rate (l/s);

m = strain rate sensitivity exponent (per-unit).

In their turn loading conditions and the state of the cladding are finally considered as follows:

K = f(KT,AKf ,AKW,•,ox., AKA),

n = f(nT,An , AAn,, oA),

m= f(mr,Amo),

where K ,n I, mT = strength coefficient, strain hardening exponent, strain rate sensitivity exponent vs.

temperature, respectively;

AKf, Anf = corrections to take into account the neutron fluence;

AKý,, An. = corrections to take into account the cold work of cladding;

AK,,, An,,, Am,, = corrections to take into account the oxygen content in the cladding;

AKA, AnA = corrections to take into account the annealing of fluence and the annealing of cold

work.

Analysis of the presented above dependencies for K, n, m indicates that the approach formulated in

section 6.1 allows to transform these correlations as follows:

K=KU K=Kt,

n=hU n=nl ,

m =m mm -. !1,

where U= index for the given Zr-l%Nb unirradiated tube;

I= index for Zr-l%Nb irradiated cladding of the given commercial fuel element.

That means that formally the obtained data base will be correct only for the given tested tubes and claddings.

On the whole this approach calls for the development of correlations describing dependencies K, n, m versus

temperature for both types of claddings. The procedure to describe these correlations starts with mmu and mTj.

Taking into consideration according to the MATPRO approach strength coefficient (K) and strain hardening

exponent (n) do not depend on the strain rate, strain rate sensitivity exponent (in) for the fixed temperature

can be determined by the following expression:

In $y (e)

M = , (7)

In

where SY(9,), SY(9o)= engineering yield stress for 91 and t. strain rate, respectively;

Expression ( 7) is obtained by taking the logarithm of the expression ( 6). In this case the condition of

equality of true effective strains (c) for two strain rates (9,, t.) is to be satisfied. That is why for this

purpose it is convenient to use the data file characterizing engineering yield stress versus strain rate. Input

data for this procedure are presented in Appendix J of Volume 3. Fig. 6.56 presents graphical illustration of

the procedure for T = 1123 K.

6.59
50 I III

40 3 Mcasured

2 30

........ .......... ..... .. ..... •.~•',•• 

10

0.00 0.01 .10 .00

Strain rate (11s)

Fig. 6.56. Processing of the measured data to obtain strain rate sensitivity exponent of the irradiated

Zr-l%Nb cladding for T = 1123 K

All the measured data were processed according with this procedure, and the values of mTu and mn were obtained for different temperatures. Still, the analysis of the data base indicated that it was not sufficient. That

is why we agreed that it were expedient to try to combine the obtained data base for Zr-lNb alloy with the

data base used in the MATPRO package for Zircaloy. This combined data base is presented in Fig. 6.57.

It is seen that the MATPRO curve describes test results for Zr-l%Nb alloy well enough. That is why it was

proposed not to develop the original curve for the VVER cladding, but to use the standard MATPRO

approach to calculate strain rate sensitivity exponents.

The next stage was directed to defining strength coefficients (Kru and KTI) and strain hardening exponents

(nTm and nn) for the VVER cladding. The strict procedure of calculating these parameters requires that the

data file characterizing uniform elongation was known. Unfortunately, the research work to study this issue

has not been competed yet (sections 6.2, 6.3). That is why the indirect procedure has been developed to get

the preliminary data characterizing strength coefficients and strain hardening exponents.

0.3

Strain rate (1/0)

0. 2A uilradiated Zr-I%Nb .0.50

uAimudiatedZr-tNbAPO >40.3

0 uniun~iated OA0. 0

* im, diated . 0.10

0.1 N

O0.

200 400 600 800 1000 1200 1400

Temperature (K)

Fig. 6.57. Comparison of the strain rate sensitivity exponents for Zr-l%Nb alloy and Zircaloy

6.60
So, it is known that the following expression is correct for the point of the maximum load located in any of

the measured stress-strain curves:

dS --=0,() (8)

wei

where dS = differential of engineering stress;

d8 = differential of engineering strain.

If we put the engineering stress in the form of the power law according to equation ( 6 into equation ( 8),

we can get the following equation:

=0.

This equation was solved according to the MATPRO procedure and expression for true strain at maximum

load was derived:

e, =ln( + .)= n•(9)

1+M

From the power law at the basic strain rate (t = 9) true ultimate strength can be presented as:

,K n (10)

It is evident that after that it is necessary to transfer from the true stress to the engineering stress by the

following transformations:

Cr.t = S(I + ) = Sutexp(e.t) = SutexP(-• n . 1

l+m

It is evident that equations (10 ) and ( 11 ) allow to transfer to the following equation:

St exp(- ) = K(n -). (12)

Equations ( 9 ) and ( 12 ) were solved with respect to K and n for every temperature with the help of:

" measured Sut and Sy presented in Appendix J;

* m defined according to the MATPRO correlation.

All of these calculations were performed for the basic strain rate (t = 10-3 l/s). The obtained data files for

Ku, Kr and n•, nn were statistically processed in accordance with the procedure described in section 6.2.2,

and the correlation dependencies were calculated for each parameter. Results of these calculations are

presented in Fig. 6.58, Fig. 6.59, and in Table 6.12.

The focus of the next stage of research was to develop the data base necessary to calculate specific

ballooning parameters. Formulation of the problem for this task required to determine the parameters

necessary to be provided for the MATPRO package for BALON2 subcode installed into FRAP-T6 code

[23].

6.61
800

600 - P iradie

-correlation

• 400

S200

200 400 600 800 1000 1200 1400

Temperature (K)

Fig. 6.58. Strength coefficient vs. temperature for unirradiated and irradiated Zr-l%Nb cladding

This subcode along with the traditional set of mechanical properties (K, n, m) uses such parameter as local

burst stress. This is the parameter used as the cladding failure criterion. Equilibrium equation for a

membrane element at failure lies in the foundation of the MATPRO approach to calculate local burst stress.

This equation is used as follows:

C'ZB , C'OB = PB,

rZ r. tB

where a., a0 8 = axial and tangential stress at the cladding burst, respectively;

rz, re = axial and circumferential radius of curvature at burst, respectively;

PB = pressure drop at burst;

tB = cladding thickness at burst.

Fig. 6.59. Strain hardening exponent vs. temperature for unirradiated and irradiated Zr-l%Nb

cladding

6.62
To solve this equation MATPRO approach calls for two assumptions:

" cladding shape in the cross-section is circular until the burst occurs;

" axial and tangential stresses are approximately equal at the moment of burst.

The respective procedures are presented in the MATPRO package to justify acceptability of these

assumptions for each case. With consideration of the accepted assumptions equilibrium equation is

transformed as follows:

PB 6 1

tB k/Z +l r)i

where aB = local burst stress.

Table 6.12. Correlations to calculate strength coefficient and strain hardening exponent vs.

temperature for Zr-l%Nb cladding

Type of cladding Parameter

unirradiated irradiated

293<T1!•795.18 K 293<1!•749.45 K

K=863.33 - 1.90882 T+0.00209374 12 - K=738.221+0.0395682 T-0.00100875 T12_

9.91178 10-7 T3 0.370178 10-TY

749.45 <P5•846.44 K

Strength K=8.34707 i05 exp(-0.01035 T)

coefficient

(M[Pa) 1795.18 <17•-926.62 K 846.44 <17•926.62 K

K 1.08414 104exp(-0.00521825 T)

926.62 <T:5,1I23.54 K

K 396.363 - 0.334806 T

T>1 123.54 K

K -56.6424 - 0.0324407 T

293 <r17,752.37 K

n = 0.0054616 + 3.12237 104 T -

0.668358 10-6 T2 + 0.430236 10-9 Ti3

Strain 752.37 <17•5854.12K

hardening n1 -1.58974 + 0.005005941T7- 4.99134 10-6

exponent T2 + 1.62978 10- 14

(per-unit) • i293 1223 iK K _ _.72<.=•

n =0.0462842 + 0.000197952 T - 0.331487 106 T2 +1.39133 10-10 T3

~T>1223 K

n = 0.047

It is evident that all the parameters presented in this equation depend on temperature and state of the

cladding. The data base characterizing PB, tB, rz, r0 values under different temperatures for unirradiated and

irradiated claddings is to be obtained in order to determine local burst stress versus temperature (aB(T )). The

6.63
measured values of PB, tB, rz, ro for different temperatures, described in section 6.3, were used to calculate

the set of crB(T,) = f[P8(Ti), tB(T,),rz(T1 ), ro(T )]. The respective input data and obtained values of cB(Ti)

are presented in Table 6.13.

Table 6.13. Measured data base for local burst stress in Zr-l%Nb cladding

Parameter

Types of Temperature

cladding (K) PB tB r. r0 o

T

B

_(MPa) (mm) (mm) (mm) (MPa)

973 11.27 0.38 49.6 7.77 199.1

1023 8.49 0.36 59.3 8.12 166.6

1073 5.75 0.27 149 6.30 128.8

1126 3.13 0.18 141 6.30 104.9

Unirradiated

1173 1.6 0.23 70 5.77 37.1

1273 1.42 0.26 62 4.55 23.1

1373 1.19 0.30 10.6 4.77 13.1

1473 0.84 0.25 51 7.11 21.0

1073 5.34 0.21 5.9 5.72 73.9

1073 5.43 0.21 150 6.66 164.9

1173 1.95 0.27 10.4 5.43 25.8

1173 1.76 0.28 7.3 5.50 19.7

Irradiated

1273 1.93 0.20 21.8 4.60 36.7

1273 1.46 0.25 45 4.57 24.3

1373 1.11 0.27 272 5.41 21.8

1473 1.24 0.25 28.4 5.09 21.3

The standard statistic processing of the local burst stress files was used to get correlation dependencies

describing aB(T) for unirradiated and irradiated claddings. The correlations obtained this way are presented

in Table 6.14 and Fig. 6.60.

Table 6.14. Correlations for local burst stress of Zr-l%Nb cladding

Range of temperature (K) Local burst stress (MPa) vs. temperature

973<T<1176.44 aB= 2.99522 106 exp(-0.00952232 T)

1176.44<T91473 aB= 1.41537 103 exp(-0.00301426 T)

6.64
300

200

100

0

800 1000 1200 1400 1600

Temperature (K)

Fig. 6.60. Measured local burst stresses and new MATPRO correlation for Zr-l%Nb cladding

6.4.2. Data base for the SCANAIR code

It has been noted in section 5.6 that the current version of the SCANAIR code operates with three

mechanical properties: Young's modulus, Poisson's ratio, yield stress. No-original measurements of Young's

modulus and Poisson's ratio were performed in the frames of this work. That is why the recommended

correlations to calculate these properties for Zr-1%Nb alloy are presented in section 5.6. So of the whole

measured set of mechanical properties only the correlations describing engineering yield stress versus

temperature for unirradiated and irradiated Zr-1%Nb cladding are necessary for the SCANAIR code. The

respective correlations obtained in section 6.2 for the basic strain rate (t = 10 3 l/s) are presented in

Table 6.15.

Table 6.15. Correlations to calculate engineering yield stress vs. temperature for Zr-l%Nb cladding

Unirradiated

293< T <786.91

786.91< T <892.32

892.32< T <1125.38

1125.38< T:51273

Sy 502.9982 - 0.8738195 T + 6.124696 10"- T' - 1.418248 10" T.

Sy = 10094.5 exp (-0.0055752 T)

Sy = 285.624 - 0.241928 T

Sy = 44.4448 - 0.027619 T

293< T •739.97 Sy - 690.3984 - 1.015694 T + 0.001310936 T2 - 9.702603 10-7 T3

739.97< T :846.56 Sy = 4.55945 105 exp (-0.0100762 T)

Irradiated 846.56< T <892.32 Sy = 10094.5 exp (-0.0055752 1)

892.32< T <1125.38 Sy = 285.624 - 0.241928 T

1125.38<T •1273 Sy = 44.4448 - 0.027619 T

Altogether, the analysis demonstrates that the current version of the code allows to introduce the additional

correction to consider the dependence of yield stress versus strain rate with the help of the following

expression:

6.65
S, = S('J

where S,., = engineering yield stress vs. strain rate;

Sw0 = engineering yield stress at basic strain rate ( = 10o 0- I/s);

9 = current strain rate;

t, = basic strain rate;

m = strain rate sensitivity exponent.

The following equation was used to practically determine strain rate sensitivity exponent:

where Sy(t 1), Sy(to) = engineering yield stress for t, and 9, strain rate, respectively;

tI, to = current and basic strain rate, respectively.

Thus, the obtained expression for the strain rate sensitivity exponent corresponds to the approach to

determine this parameter, presented in section 6.4.1 for the MATPRO package. The respective analytical

correlations to calculate Sý, of unirradiated and irradiated Zr-l%Nb claddings were obtained and put into

ZYS module of the SCANAIR FORTRAN source.

6.66
6.5. References

[1] A.S.Zaimovskyi, A.V.Nikulina, N.G.Reshetnikov, "Zirconium Alloys in the Nuclear Industry". Moscow,

Energoizdat, 1981 (rus).

[2] D.L.Hagrman, G.A.Reyman and R.E.Mason, "MATPRO-V.11 Revision 1: A Hand Book of Materials

Properties for Use in the Analysis of Light Water Reactor Fuel Rod Behavior". NUREG/CR-0497 TREE1280, Rev2, 1981.

[3] G.P.Kobyliansky, A.Ye.Novoselov, "Radiation Tolerance of Zirconium and Zirconium-Based Alloys".

Edited by V.A.Tsycanov. GNC RF NHAR, Dimitrovgrad, 1996 (rus).

[4] L.F.Van Swam, A.A. Strasser, J.D.Cook, J.M.Burger, "Behavior of Zircaloy-4 and Zirconium Liner

Zircaloy-4 Cladding at High Burnup". Proc. of Int. Topical Meeting on Light Water Reactor Fuel

Performance, Portland, 1997, p.421-431.

[5] I.I.Korobkov, "Investigations of Dynamic Strain Aging of Zirconium Alloys". In: "Zirconium and Its

Alloys".Edited by V.S. Emelyanov and A.I. Efstiukhin. Moscow, Energoizdat, 1982 (rus).

[6] L.P.Loshmanov, V.D.Rudnev and O.A.Nechaeva, "Influence of Temperature and Strain Rate on

Mechanical Properties of Zr-1%Nb Alloy". Atomnaya energia 2 (81) 1996 (rus).

[7] Sun Ig Hong, Woo Seog Pyn and Chang Saeng Kim, "Thermally Activated Deformation of Zircaloy-4".

Journal of Nuclear Materials, 120 (1984) 1-5.

[8] D. Douglas, "Metallurgy of Zirconium". Moscow, Atomizdat, 1975 (rus).

[9] M.L. Bernshtein and V.A. Zaimovskyi, "Mechanical Properties of Metals". Moscow, Metallurgia, 1979

(rus).

[10] K.P. Dubrovin, A.V. Sukhikh and V.I. Kusmin, "First Qualitative Analysis of Fuel Irradiation Results

Carried out in the MR Reactor on VVER-1000 Fuel". Proc. Of Int. Seminar on VVER Reactors: Fuel

Performance, Modeling and Experimental Support. Varna, Bulgaria, 1994.

[11] Yu. Bibilashvily, K. Dubrovin and I. Vasilchenko, "Main Examination Results of VVER-1000 Fuel

After Its Irradiation in Power Reactors". Proc. Of Int. Seminar on VVER Reactors: Fuel Performance,

Modeling and Experimental Support. Varna, Bulgaria, 1994.

[12] C.E.L. Hunt and E.M. Schulson, "Recrystallization of Zircaloy-4 During Transient Heating". Journal of

Nuclear Materials 92 (1980) 184-190.

[13] V. Tonkov, A. Kapteltsev, I. Golikov, Yu. Dolgov and A.B. Perepelkin, "Influence of Oxidation in

Water Steam on Mechanical Properties of Zr-l%Nb Alloy at 20 -1000 C". Voprosy atomnoy nauki i

tekhniki. Ser: Materialovedenie i novye materialy. 4 (38) 1990 (rus).

[14] T. Fuketa, K. Ishijima, Yu. Mori, H. Sasajima and T. Fujishiro, "New Results from the NSRR

Experiments with High Burnup Fuel". Proc. Of Twenty Third Water Reactor Safety Meeting, 1995.

NUREG/CP-0149 Vol.1.

[15] F. Schmitz, J. Papin, M. Haessler and N. Waeckel, "New Results from Pulse Tests in the CABRI

Reactor". Proc. Of Twenty Third Water Reactor Safety Meeting, 1995. NUREG/CP-0149 Vol.1.

[16] A. Smimov, K. Dubrovin, V.I. Kusmin, "VVER-1000 and VVER-440 Fuel Operation Experience".

Proc. Of Int. Topical Meeting on Light Water Reactor Fuel Performance. FloridaUSA 1994.

[17] V. Prokhorov, A. Finko and R. Mineev, "Evaluation of Gauge Length of the Ring Specimens from Fuel

Claddings for Tensile Tests in Transverse Direction". Report NIIAR P-23317. Dimitrovgrad, 1977 (rus).

[18] A. B. Cohen, S. Majumdar, W.E. Ruther, M.C. Billone, H.M. Chung, and L.A. Neimark "Modified

Ring Stretch Tensile Testing of Zr-1%Nb Cladding" Proceeding of the Twenty - Fifth Water Reactor

Safety Information Meeting, Bethesda, Maryland, October 20-22 1997. NUREG/CP-0162

[19] N.R. Draper and H. Smith, "Applied Regression Analysis". John Wiley and Sons. New York,1981.

6.67
[20] V.Solyany, Yu. Bibilashvily, V. Tonkov, "High temperature oxidation and deformation of Zr-l%Nb

alloy claddings of WER fuels", IWGFRT-16 L4EA Specialist Meeting on Water Reactor Fuel Safety and

Fission Product Release in off-Normal and Accident Conditions, Denmark,1983.

[21] D.L. Hagrman, "Zircaloy Cladding Shape at Failure (BALON2)". EGG-CDAP-5379, 1981.

[22] V.David CEA/DRN/DMT-Saclay "Hoop Tensile Tests on Unirradiated WER Cladding (Zr-1%Nb)".

Work performed under IPSN contract.

[23] V.Asmolov, L.Yegorova, E.Kaplar, K.Lioutov (NSC RRC KI), V.Smirnov, V.Prokhorov, A.Goryachev

(RIAR) "Development of Data Base with Mechanical Properties of Un- and Preirradiated VVER

Cladding", Proceedings of the Twenty - Fifth Water Reactor Safety Information Meeting, Bethesda,

Maryland, October 20-22, 1997. NUREG/CP-01 62

6.68
NRC FORM 335 U.S. NUCLEAR REGULATORY COMMISSION 1. REPORT NUMBER

(2-89) (Assigned by NRC, Add Vol., Supp., Rev., NRCM 1102, and Addendum Numbers, if any.) 3201, 3202 BIBLIOGRAPHIC DATA SHEET

(See instructions on the revere) NUREGIA-56

2. TITLE AND SUBTITLE Volume 2

Data Base on the Behavior of High Bumup Fuel Rods with Zr-I%Nb Cladding and

U02 Fuel (VVER Type) under Reactivity Accident Conditions 3. DATE REPORT PUBLISHED

Volume 2 Description of Test Procedures and Analytical Methods MONTH YEAR

July 1999

4. FIN OR GRANT NUMBER

W6500

5. AUTHOR(S) 6. TYPE OF REPORT

L. Yegorova, V. Asmolov, G. Abyshov, et. al.

A. Bortash, L. Maiorov, et. al. IPSN 99/08-2 NSI RRC KI-2179

V. Smirnov, A. Goryachev, V. Prokhorov 7. PERIOD COVERED (Inclusive Dates)

V. Pakhnitz, A. Vunrm

manuscript completed Dec 1998

8. PERFORMING ORGANIZATION - NAME AND ADDRESS (If NRC, provide Division, Office or Region, U.S. Nuclear Regulatory Commission, and mailing address; if contractor,

provide name and mailing address.)

Russian Research Center "Kurchatov Institute" Moscow 123182 Russia

State Research Centre "Research Institute of Atomic Reactors" Dimitrovgrad Russia

Institute of Atomic Energy of NNC Semipalatinsk Kazakhstan

9. SPONSORING ORGANIZATION - NAME AND ADDRESS (If NRC, type *Same as above'; if contractor, provide NRC Division, Office or Region, U.S. Nuclear Regulatory Commission,

andmailing address.)

Division of Systems Analysis and Regulatory Effectiveness

Office of Nuclear Regulatory Research

U.S. Nuclear Regulatory Commission

Washington, DC 20555-0001 4

IV Q, o r'IL.QW1I1IRI f~,nI INlU IQO.

11. ABSTRACT (200 words or less)

This volume of the report contains the following information on test conditions and basic procedures used to develop the data

base: objects and conditions of the IGR reactor tests;

test parameters of fuel rods before, during and after the RIA tests; parameters of fuel rods during RIA tests calculated by FRAP-T6 and SCANAIR computer codes;

measured mechanical properties of Zr-I %Nb cladding obtained due to special tests;

parameters of Zr-1 %Nb cladding failure of the ballooning type measured under the burst test conditions;

-input data with original material properties of Zr-I %Nb cadding for the MATPRO package and SCANAIR code.

I

12. KEY WORDSIDESCRIPTORS (Ust words or phrases that will assist researchers in locating the report.)

reactivity initiated accident

impulse graphite reactor (Kazakhstan Atomic Energy Agency) Zirconium-I% Niobium alloy

FRAP-T6 & SCANAIR computer codes

material properties

cladding strain and ballooning

energy deposition

post-test examinations

13. AVAILABILITY STATEMENT

unlimited 14. SECURITY CLASSIFICATION

(This Page)

unclassified

(This Report)

unclassified

15. NUMBER OF PAGES

16. PRICE

&_________________________________________________________________ I I _____

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