Abstract: This technical report contains a description of the nuclear analysis performed upon the SM-2 core and vessel for the period September 1, 1958 to December 31, 1959. Calculations are given for core reactivity, power distributions, lifetime, reactor control, kinetics, radiation problems, fuel and poison burn-ups, and the nuclear effects of poisons, temperature, and geometry. Wherever possible, experimental data is included in order to test the validity of the analytical models. The SM-2 nuclear analysis was performed by Alco Products, in. under Tasks 1, 8, and 10 of Contract No. AT(30-2)-326 for the Atomic Energy Commission.

Introduction: In conjunction with the final design and development of a 70 MW sodium intermediate heat exchanger and a sodium steam generator, an analysis is required which can be used as a basis for a determination to scale up or scale down the designs. Included in this analysis are those considerations leading to the recommendation of the best prototype test unit and to some of the limits imposed on scaling up or down when considering future applications of designs other than those actually tested. In addition, these considerations include aspects required to accurately predict the performance, operation, mechanical reliability, and feasibility of fabrication of the 70 MW design.

Abstract: An analysis of SM-1 Core II and SM-1A Core I zero power experiments was made by comparing these cores to each other and to AM-1 Core I on the basis of critical bank positions, bank calibrations and available chemical analyses of the fuel plate compositions. The effects of replacing boron absorbers by europium absorbers upon rod worth and stuck rod conditions were studied. Comparisons of measured and calculated power distributions were made. It was concluded that both SM-1 Core II and SM-1A Core I contain nearly identical B-10 loading of 17.79 grams, compared to the best estimate of 15.75 grams for SM-1 Core I. The available data indicates that all three cores possess similar nuclear characteristics.

This technical report represents the final design for a sodium to sodium intermediate heat exchanger and a sodium to water steam generator. The intermediate heat exchanger is designed for operation in a nuclear power plant using liquid sodium as the primary and secondary coolant. Since the primary fluid coming fro the reactor is radioactive, the purpose of the IHX is to transfer heat to a nonradioactive fluid which then goes to the steam generator. Because of radioactivity the unit will be enclosed in a concrete pit and will not be accessible during periods of operation. Immediately after shutdown it will be necessary to allow time for radioactive decay before the unit will be accessible to personnel. Because of inaccessibility and possible long periods allowed for decay time, it is imperative that the unit give trouble free operation. During periods of shutdown, the internals should have easy access for inspection and repair if necessary so that down time is held to a minimum. The steam generator is designed to generate superheated steam using liquid sodium from the intermediate heat exchanger as the heat source. Its basic design is a shell and tube unit made up of three difference sections: (1) a …

Introduction: This volume deals principally with the chemical analysis and the stress analysis for a sodium to sodium intermediate heat exchanger and a sodium to water steam generator. The work presented is an extension and modification of the analysis presented in the preliminary design report. The chemical analysis covers the sodium cover gas system and the effects of sodium-water reactions in the event of a leak in the steam generator. Considerable design work was done in an effort to maintain the integrity of the steam generator vessel under maximum leak conditions. The method of sizing relief valves for each unit under varying leak rates is presented in this text and operation of the unit for the various leak rates is resented in the Operation and Maintenance volume. The stress analysis section covers those thermal transients which would be physically possible with this intermediate heat exchanger and steam generator design. Attention has been given to methods of operation which would minimize the magnitude and frequency of thermal shocks. Certain areas have been studied in detail where thermal stresses appear high. This report also includes a structural design basis for handling stress analysis of combined mechanical, hydrostatic and thermal stresses and conditions …

Introduction: Sodium Components Material Specifications. Twenty-three material, inspection and welding specification are presented for the various parts of both the intermediate heat exchanger and steam generator. Tables indicate the applicable parts and assemblies to which these specifications shall apply. For other parts, where the material requirements are not severe, the ASTM or other indicated specifications shall apply.

This technical report contains the operation and maintenance specifications for the intermediate heat exchanger and the steam generator. The report contains eight sections: (1) General Information, (2) Shipping and Installation, (3) Operation Procedures, (4) Scram and Casualty Shutdowns, (5) Leaks, (6) Instrumentation and Control, (7) Maintenance, and (8) four Appendixes (a) Boiler Water Chemistry Recommendations, (b) Final Concept Drawings, (c) Industrial Nucleonics Literature on Liquid Level Detector, and (d) Sodium Purity Control Recommendations.

Abstract: This technical report is concerned with the program and results of the SM-1 reactor vessel head removal and core inspection at Fort Belvoir, Virginia from the period March 7, 1969 to May 17, 1959. It covers the operating procedures in detail and records the conditions found and problems encountered in order to make a record for reference in future work of this nature. The major objective of the program, to obtain irradiation data on the SM-1 type core, has been met. The boron control rod elements were found unsatisfactory for full core life, and europium oxide elements were placed in the core for future irradiation stability data. A major problem was experienced with the cracked pressure vessel head studs. The methods developed for the removal of the broken studs are presented. The complete metallurgical study of the stud failure from stress corrosion is included as Appendix B.

Summary: Prototype testing of the safety and control rod drives indicated that both units functioned properly. No major problems were encountered during testing. Seal leakage data collected indicated that the seal units were performing satisfactorily. Scram times during both cold and hot testing were excellent and actually better than expected.

Abstract: This technical report summarizes the data obtained in a recent literature survey conducted to determine the effects of neutron irradiation on the impact and other mechanical properties of both ferritic steels and austenitic stainless steels. The survey was primarily aimed at obtaining sufficient data on the behavior of pressure vessel steels at high integrated neutron flux levels in order that a reference material of construction could be selected for the SM-2 (APPR-1B) reactor vessel. Materials studied in this literature survey included carbon and low alloy steels such as: ASTM A-212B, ASTM A-201, ASTM A-301B (CR-Mo), ASTM A-106 (coarse and fine grained), ASTM A-285, ASTM A-302B (Mn-Mo), ASTM A-353, ASTM A-203 Grade D, E-7016 carbon steel weld metal, USS Carilloy T-1, HY-65 and HY-80. In addition, Types 304 and 347 stainless steels were also investigated as representative austenitic materials which might be used in pressure vessel construction. A careful evaluation was made of the irradiation induced changes in the mechanical properties of the above materials. The ferritic steels were evaluated primarily on the basis of increases in transition temperature due to irradiation and decreases in the amount of maximum energy absorbed prior to ductile failure. Factors such as industrial experience, …

Introduction: Objectives and Method of Approach. High plant efficiencies can be realized without excessively high core temperatures and high coolant pressures by the use of liquid metal coolant. In an attempt to prove the feasibility of liquid sodium as a reactor coolant ALCO Products, Inc., under sponsorship of the Atomic Energy Commission, is undertaking a design study of three vital system components: the intermediate exchanger, the boiler, and the superheater. Since, in the past programs, the nuclear reactor had been the major focus of attention, the development of the sodium cooled reactor and sodium pumps for this application are thought to need the less development than the heat exchanger equipment. Consequently, parallel design studies of the reactor, pumps, and other system components have not yet been initiated.

Preface. This technical report is an updated and revised version of the original SM-1 (APPR-1) Hazards Summary Report. The original report was issued July 1955, almost two years before construction of the SM-1 plant was completed. During that time interval there were numerous design changes. Consequently, the original report does not accurately describe the plant as built. This revision is written after the SM-1 has been operated 3 years. It describes the as-build plant and includes plant modifications and experience obtained during the first 3 years of SM-1 operation.

Abstract: Development of welding processes for stainless steel fuel elements, previously initiated by Alco Products, was continued in Task 5. Three objectives were accomplished; (1) development of a suitable reference welding process, (2) evaluation by out-of-pile tests of the structural integrity of reference welded fuel elements, and (3) preparation of specifications and fabrication procedures for the reference welding process.

Abstract: The results of activity buildup studies in the SM-1 performed during Core I lifetime (June 3, 1957 to April 28, 1960) are reported. Data are presented on the extent, nature, and mechanism of the buildup of long-lived gamma emitting nuclides in the reactor primary system. Radiation levels after reactor shutdown are presented, as well as mathematical equations used to account for the observed activity levels. The data have shown that Co60 is the major contributor to radiation levels in the SM-1. Co60 activity arises from the cobalt in Haynes 25 alloy flux suppressors, and the cobalt impurity in stainless steel. After 35 months operation at an average power level of 55%, deposited Co60 activity accounted for approximately 83% of the total radiation level (mr/hr) contributed by the long-lived gamma emitting nuclides. The contribution of the primary coolant activity to the total radiation level is insignificant when compared to the contribution of the activity deposited on the walls of the system. The radiation level on the super-heater side of the steam generator was about 1400 mr/hr after 35 months of reactor operation. The percentages of Co60 activity in the coolant and in the deposits were not the same. This indicates …

Abstract: A zero power experiment on the SM-1 Core II included an element by element reactivity check of fuel elements and control rod absorber sections, and an estimate of burnable nuclear poison loading in stationary fuel elements. An approach to criticality was made by the inverse multiplication method, and critical rod bank position obtained as a function fuel loading up to full core loading. Minimum and maximum core reactivity measurements were obtained by selective loading of stationary fuel elements, and total excess K of the core was established. Power distribution measurements were taken in the regions of the core-reflector interface and the fuel-absorber interface in the control rod assemblies. The effectiveness of europium flux suppressors in the top of control rod fuel elements was determined, and power peaking was measured in stationary elements adjacent to control rod assembly water gaps. Survey measurements established the work of spiking clean, cold SM-1 cores with SM-2 elements and the work of water holes in the SM-1 Core. The reduced scope zero power experiment performed on SM-1A core I included an element by element uniformity check of stationary fuel elements, a core assembly test, comparison of Eu2O3 and B4C absorber sections, and development of …

Abstract: An element by element reactivity check for SM-1 Core II fuel elements and control rod absorber sections was performed and the burnable nuclear poison loading in the SM-1 Core II stationary fuel elements was established. An approach to criticality of the SM-1 Core II was performed by the inverse multiplication method and the critical rod bank position obtained as a function of fuel loading up to the full SM-1 Core II loading. Maximum and minimum core reactivity measurements were obtained by selective loading of stationary fuel elements and the total "excess K" for the core established. Power distribution measurements in the region of the core-reflector interface and the fuel-absorber interface in the control rod assemblies were performed. The effectiveness of europium flux suppressors in the top of control rod fuel elements and the power peaking in stationary elements adjacent to water gaps in control rod assemblies were measured. Survey measurements established the worth of spiking cold clean SM-1 cores with SM-2 elements, and of water holes in the SM-1 core which might be utilized as flux traps for materials irradiation.