PLUS7 Fuel Design for the APR1400 · No foreign material-induced and fretting wear-induced rod...

APR1400-F-C-EC-13008-NP

PLUS7 Fuel Design for the APR1400

1. Improvement of Topical Report

2. Contents of PLUS7 Fuel Design Report

3. Design Features

4. Fuel Assembly Design Evaluation

5. Fuel Rod Design Evaluation

6. Experience and Performance

7. Conclusion

Non-Proprietary

1 APR1400APR1400-F-C-EC-13008-NP

1. Improvement of Topical Report (1/2)

a. Fuel Performance Codes

NRC approved codes and methodologies were used for fuel performance The applicability of the codes and methodologies were described in detail Used codes : FATES3B, CEPANFL, PAD

b. In-reactor Data

Additional Pool Side Examination(PSE) data for the four Lead Test Assemblies(LTAs) were added

PSE data for the four Commercial Surveillance Assemblies(CSAs) were added

Hot cell data for one LTA were added including cladding hydrogen content evaluation

2 APR1400APR1400-F-C-EC-13008-NP

1. Improvement of Topical Report (2/2)

c. Test, Inspection and Surveillance Plan

PLUS7 TR describes that the test, inspection and surveillance plan are described in the DCD Tier 2 section 4.2 in detail

d. Seismic/LOCA Analysis

The separate technical report for the Seismic/LOCA events will be submitted with DCD

3 APR1400APR1400-F-C-EC-13008-NP

2. Contents of PLUS7 Fuel Design Report

1. Introduction

2. Fuel Assembly and Components Design

3. Fuel Rod Design

4. PLUS7 Fuel Experience

5. Conclusion

6. References

Appendix

A. Summary of PLUS7 Fuel Assembly TestsB. Commercial Operating Experiences of KEPCO NF PWR FuelsC. PLUS7 Scram Data VerificationD. PLUS7 Wear Performance Analysis

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A. Overview B. Fuel RodC. Mid GridD. Top NozzleE. Bottom Nozzle

3. Design Features

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3.A Overview (1/4)

PLUS7 Developed for the APR1400 & OPR1000 PWRs

Joint program with Westinghouse Electric Co. (WEC) April 1999 ~ March 2002 Designed/tested at WEC-Columbia, SC

Design Goal

Improvement of fuel performance compared to CE-Guardian Batch average discharge burnup > 55 MWd/kgU Overpower margin > 10% increase Seismic resistance > 0.3g ground acceleration No foreign material-induced and fretting wear-induced rod failure

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3.A Overview (2/4)

More than 2,300 PLUS7 fuel assemblies were loaded as of 2012

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3.A Overview (3/4)

•Guide post, holddownspring, holddown plate and adapter plate remains one piece

•Mixing vanes Enhancing thermal

margin•Straight grid straps Improving Seismic

Resistance•Conformal spring/dimple Reducing GTRF

•Advanced cladding tube ZIRLO tube

•Optimized rod OD STD rod OD

•Axial blanket Improving neutron

economy

• Increasing debris filtering efficiency

•Small hole/slot bottom nozzle

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3.A Overview (4/4)

Item Guardian RFA PLUS7

Cladding Zry-4 ZIRLO ZIRLO

Rod diameter 0.382″ 0.374″ 0.374″

Axial blanket X O O

Mid grid

Spring Cantilever Diagonal Conformal

Dimple Arched Horizontal Conformal

Strap Wavy Straight Straight

Mixing vane X O O

Top nozzle Separated Assembled Assembled

Bottom nozzle Large hole Small hole Small hole & slot

PLUS7 incorporated the proven Guardian structure and the proven Westinghouse type fuel features to improve fuel performance

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3.B Fuel Rod

ZIRLO cladding : advanced material

Variable pitch spring : increase plenum volume

Top & bottom axial blankets : increase neutron economy

Long bottom end plug : protect foreign material induced failure

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3.C Mid Grid (1/2)

ZIRLO : advanced material

Mixing vanes : improve thermal performance

Straight strap : improve strength

Conformal spring & dimple : improve fretting wear resistance

Guide vane & tab : remove hang-up potential

Strap joint : laser welding

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3.C Mid Grid (2/2)

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3.D Top Nozzle

Components : adapter plate instrument housing

holddown springs holddown plate

outer guide posts

Removable top nozzle : possible to reconstruct easily

Top nozzle is jointed to guide thimble by inner extension

TS

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3.E Bottom Nozzle

Small hole bottom nozzle : improve foreign material filtering efficiency

Bottom nozzle is jointed to guide thimble by guide thimble screw

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A. Fuel AssemblyB. Bottom NozzleC. Top NozzleD. Holddown SpringE. Guide ThimbleF. GridG. Joint and Connection

4. Fuel Assembly Design Evaluation

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4.A Fuel Assembly

Item Design CriteriaEvaluation

ResultsRemarks

Rod-to-top nozzle axial clearance

Hydraulic stability

Shipping and handling loads

Mechanical compatibility

TS

The evaluation results for the Seismic/LOCA events are described in a separate technical report.

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4.B Bottom Nozzle


ResultsRemarks

Structural integrity

Prevent rod ejection

Compatibility with the lower support structure

Compatibility with the instrument

TS

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4.C Top Nozzle


ResultsRemarks


Prevent rod ejection

Compatibility with the upper guide structure

Remote reconstitutability

Compatibility with handling equipment

TS

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4.D Holddown Spring


ResultsRemarks

Holddown force in normal operation

maximum deflection

and solid condition

Holddown spring shear stress

TS

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4.E Guide Thimble


ResultsRemarks


CEA drop time

TS

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4.F Grid


ResultsRemarks

Fuel rod support

Shipping and handling

Fuel rod fretting wear

Fuel rod bow

Mid grid buckling strength

Grid width

TS

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4.G Joint and Connection

Item Design Criteria Evaluation Results Remarks

Top nozzle / guide thimble

Bottom nozzle / guide thimble

Grid / guide thimble and instrument tube

TS

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A. Fuel Rod Design Codes and Methodology

B. Applicability of Design Codes and Methodology

C. Fuel Rod Design Criteria and Evaluation

5. Fuel Rod Design Evaluation

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NRC-approved codes are used for fuel rod design criteria evaluation

5.A Fuel Rod Design Codes and Methodology (1/3)

Code Design Criteria

FATES3B

Cladding strain/stress

Cladding fatigue

Rod internal pressure

Fuel temperature

CEPANFL Cladding collapse

PADCladding external

oxidation & hydriding

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Codes and methodology are described in NRC- approved topical reports FATES3B Code CENPD-139-P-A, C-E Fuel Evaluation Model Topical Report, Combustion

Engineering Inc., July 1974

CEN-161(B)-P-A, Improvements to Fuel Evaluation Model, August 1989

CEN-161(B)-P Supplement 1-P-A, Improvements to Fuel Evaluation Model, January 1992

CEPANFL Code CENPD-187-P-A, CEPAN Method of Analyzing Creep Collapse of Oval Cladding,

Combustion Engineering, Inc., April 1976; Supplement 1-P-A, June 1977

PAD Code WCAP-15063-P-A, Rev. 1, with Errata, Westinghouse Improved performance

Analysis and Design Model(PAD4.0), July 2000

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Fuel Rod Burnup of 60 MWD/kgU Application CEN-386-P-A, Verification of the Acceptability of a 1-Pin Burnup Limit of 60

MWD/kgU for Combustion Engineering 16x16 PWR Fuel, August 1992

Rod Internal Pressure Analysis Methodology CEN-372-P-A, Fuel Rod Maximum Allowable Gas Pressure, May 1990

Gadolinia Absorber Application Methodology CENPD-275-P, Revision 1-P-A, C-E Methodology for Core Designs Containing

Gadolinia-Urania Absorbers, May 1998

ZIRLO Cladding Application Methodology CENPD-404-P-A, Rev. 0, Implementation of ZIRLOTM Cladding Material in CE

Nuclear Power Fuel Assembly Designs, November 2001

Collapse Analysis Methodology EPRI NP-3966-CCM, CEPAN Method of Analyzing Creep Collapse of Oval Cladding

Volume 5 : Evaluation of Inter-pellet Gap Formation and Cladding Collapse in Modern PWR Fuel Rods, Combustion Engineering, Inc., April 1985

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5.B Applicability of Design Codes and Methodology (1/12)

NRC SER(Safety Evaluation Report) Compliance

Item Limitations, Restrictions and Conditions(LRC) Compliance

CENPD-275-P Revision 1-P-A “C-E Methodology for Core Designs Containing

Gadolinia-Urania Burnable Absorbers”

1 The gadolinia fuel properties are acceptable for up to 8 weight percent gadolinia concentration

CEN-386-P-A “ Verification of the Acceptability of a 1-Pin Burnup Limit of 60

MWD/kgU for Combustion Engineering 16x16 PWR Fuel”

1 Impacts of cladding changes should be included in these additional evaluations.

2 The stress analyses should include the effects of cladding thinning due to cladding oxidation.

TS

TS

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CEN-161(B)-P Supplement 1-P-A “Improvements to Fuel Evaluation Model”

1

The approval of the fission gas release and fuel thermal expansion model is based on verification of FATES3B predictions against fission gas release data and thermal data that has operated in the ranges of the code’s intended applications andverification that the code inputs are adequatelyconservative for its intended applications

CEN-372-P-A “Fuel Rod Maximum Allowable Gas Pressure”

1

Those licensees referencing this high pressure topical report are required to 1) provide plant-specific LOCA analyses to determine the impact of maximum calculated rod pressures on cladding rupture timing and peak cladding temperatures and 2) provide analyses for DNB propagation in postulated accidents

TS

TS

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CENPD-404-P-A “Implementation of ZIRLOTM Cladding Material in CE Nuclear Power Fuel Assembly Designs”

1 The corrosion limit will remain below 100 microns.

2The fuel duty will be limited for each CENP designed plant

3 The burnup limit for this approval is 60 MWD/kgU.

TS

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Applicability of FATES3B to PLUS7 Fuel Rod Design The FATES3B code applicability extends to all ZIRLO clad and UO2 fuel

pellets currently used in PWRs The main changes of PLUS7 fuel rod compared with GUARDIAN fuel rod

are fuel rod diameter and pellet diameter. The verification data base of FATES3B bounds the PLUS7 fuel rod

diameter.

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Parameters FATES3B D.B PLUS7

Clad OD, in

Clad ID, in

Initial pellet-clad gap, mils

Initial grain size, μm

Initial fuel density, %TD

Fill gas pressure at 70 ℉, psia

Enrichment, % U-235

FATES3B code is applicable to fuel rod design of PLUS7


Comparisons of design parameters between the verification data base and PLUS7 design

TS

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Applicability of FATES3B to the APR1400 Comparisons of irradiation parameters between the verification data base

and the APR1400


DataPeak Local

Power(kw/ft)Rod Average

Burnup(MWD/kgU)

Calvert cliffs

Over-ramp

Petten

IFA-418

RISO

Zorita

BR-3

Super-ramp

DOE ramp

APR1400

TS

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Data Coolant Pressure(psia)Coolant Inlet

Temperature(℉)

Calvert cliffs

Over-ramp

Petten

KWU

IFA-418

Zorita

BR-3

Super-ramp

DOE ramp

APR1400

Comparisons of thermal-hydraulic parameters between the verification data base and the APR1400

TS

33 APR1400APR1400-F-C-EC-13008-NP

Applicability of CEPANFL to Collapse Analysis of PLUS7 fuel CEPANFL is a computer program to determine the minimum time to collapse

for fuel cladding under expected operating conditions

The CEPANFL is a program based on analytical shell theory, therefore, CEPANFL is independent on fuel rod dimension and pressure difference between rod internal pressure and external pressure

CEPANFL uses the same cladding creep model as that of FATES3B code

CEPANFL code is applicable to collapse analysis of PLUS7 fuel


34 APR1400APR1400-F-C-EC-13008-NP

Applicability of PAD to Corrosion Analysis of PLUS7 Loaded in the APR1400 Adjustment of PAD corrosion model multiplier (input variable) based on the

measured oxide thickness of ZIRLO cladding at Yonggwang Unit 4 and UlchinUnit 3 (OPR1000)

Verification of PAD code with adjusted corrosion model multiplier using the CSA data of Yonggwang Unit 5 (OPR1000)

Operating conditions of OPR1000 are very similar to those of the APR1400

PAD code is applicable to cladding oxidation evaluation of PLUS7 fuel in the APR1400


35 APR1400APR1400-F-C-EC-13008-NP

Comparisons of Operating Conditions between the OPR1000 and the APR1400


Parameter OPR1000 APR1400

Coolant inlet temperature(℉)

Coolant outlet temperature(℉)

Coolant mass flow rate (lbm/hr-ft2)

System pressure(psia)

TS

36 APR1400APR1400-F-C-EC-13008-NP

TS


37 APR1400APR1400-F-C-EC-13008-NP

TS


Verification of PAD Code with the adjusted corrosion multiplier based on the measured data from Yonggwang unit 5

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5.C Fuel Rod Design Criteria and Evaluation (1/2)


ResultsCodes

Cladding stress

Cladding strain

Cladding fatigue damage

TS

39 APR1400APR1400-F-C-EC-13008-NP

5.C Fuel Rod Design Criteria and Evaluation (2/2)


ResultsCodes

Cladding oxidation and

hydriding

Rod internal pressure

Cladding collapse

Overheating of fuel pellet

(melting)

Pellet-to-cladding

interaction

TS

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A. Experience B. PSE ResultsC. PIE Results

6. Experience and Performance

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6.A Experience

Commercial Loading of PLUS7 as of 2012

Plant CycleNumber of FAs

Number of FRs

Max. Discharged Burnup

(MWD/MTU)

FA FR

TS

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Burnup Data of PLUS7 LTA and CSA

6.B PSE Results (1/10)

Items 1st Cycle 2nd Cycle 3rd Cycle

TS

LTA: Lead Test AssemblyCSA: Commercial Surveillance Assembly

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Configuration of Fuel Rods in PLUS7 LTAs and CSAs


TS

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Core Loading Pattern with PLUS7 LTAs

1st Cycle 2nd Cycle 3rd Cycle


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Core Loading Pattern with PLUS7 CSAs

1st Cycle 2nd Cycle 3rd Cycle


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Fuel Assembly Growth

FA growth has enough margin up to criteria of mm

Measured FA No. 1st Cycle 2nd Cycle 3rd Cycle

LTA 2 2 2

CSA 4 2 2TS


TS

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Grid Width Growth

Upper 2 mid grid widths are shown in the graph Grid width growth has enough margin up to criteria of mm


LTA 1 1 2

CSA 0 2 2TS


TS

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Shoulder Gap

Every fuel rods on the 4 faces were measured Shoulder gap has enough margin up to criteria of zero gap


LTA 2 2 2

CSA 4 2 2TS


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Fuel Rod Channel Closure

Outer fuel rod to rod gaps were measured for every span Fuel rod channel closure has enough margin up to criteria of %


LTA 2 2 2

CSA 0 2 2TS


TS

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Cladding Oxide Thickness

Maximum ZIRLO oxide thickness is Cladding oxide thicknesses are within the limit of 100 μm

Measured FR No. 1st Cycle 2nd Cycle 3rd Cycle

LTA 36 36 36

CSA 0 0 72

TS


TS

51 APR1400APR1400-F-C-EC-13008-NP

Fuel Rod Diameter

Diameters range from Diameter increases are within the strain limit of

Measured FR No. 1st Cycle 2nd Cycle 3rd Cycle

LTA 0 0 8

CSA 0 0 8

TS


TS

TS

52 APR1400APR1400-F-C-EC-13008-NP

Hot cell examinations on selected 6 fuel rods were performed after completing the 3rd cycle operation of PLUS7 LTA, HA03

Ass’y ID Rod IDRod Average

Burnup(MWD/MTU)

Cell Position

HA03

B14 Interior

D15 Interior

D16 Peripheral

A14 Peripheral

K07 Adjacent to IT

C03 Adjacent to GT

6.C PIE Results - Hot Cell Examination (1/9)

TS

53 APR1400APR1400-F-C-EC-13008-NP

LTA HA03 PositionHot Cell Testing Fuel Rods Position

A B C D E F G H J K L M N P R

1

2

3

4

5

6

7

6 7 5 8

9

10

11

12

13

14

15

A B C D E F G H J K L M N P R

1

2

3

4

5

6

7

2 3 1 8

9

10

11

12

13

14

15


54 APR1400APR1400-F-C-EC-13008-NP

Fuel Rod Fretting Wear

B14 rod (inner cell rod) shows darker color at contact area than others (A14, C03)

Slice section of dark color area was examinedTS


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Fuel Rod Fretting Wear (continued)

There is no measureable wear on the spring contact area

TS


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Cladding Oxide Thickness

6 fuel rods were measured using Eddy Current Test Maximum circumferential average oxide thickness is around

TS

TS


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Fuel Rod Diameter

6 fuel rods were measured using Linear Variable Differential Transformer Fuel rod diameters range from Very similar to the results of poolside examination

TS

TS


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Cladding Hydrogen Content

Hydrogen contents of 3 samples were measured Hydrogen contents of PLUS7 LTA fuel rods are bounded by the overall ZIRLO

cladding database

TS


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Cladding Hydrogen Content (continued)

Hydrogen contents averaged over the entire wall thickness were calculated based on the measured oxide thicknesses of PLUS7 LTA/CSA using the correlation of oxide thickness and hydrogen content

Calculated best estimated hydrogen concentrations are less than at discharge burnup of

TS


TS

TS

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Fission Gas Release

2 fuel rods were measured Gas release fractions are Internal pressures are Gas release fractions and internal pressures are well within PWR database

TS

TS

TS


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7. Conclusion

PLUS7 topical report was improved to reflect NRC comments Applicability of the fuel performance codes and methodologies are described in

detail Additional PSE and PIE data for LTAs and CSAs are provided Test, inspection and surveillance plan are described in DCD Tier 2 Section 4.2 The technical report of Seismic/LOCA analysis will be submitted with DCD

PLUS7 fuel assembly meet all of the design criteria up to the maximum fuel rod average burnup of 60,000 MWD/MTU

In-reactor performance of PLUS7 was verified through PSE and PIE

PLUS7 has a lot of in-reactor experience with satisfactory fuel performance

PLUS7 TR will be submitted by the end of September 2013

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PLUS7 Fuel Design for the APR1400 · No foreign material-induced and fretting wear-induced rod...

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