Tests of closed-end, internally pressurized, Zircaloy-4 tubing specimens were utilized to develop low strain creep characteristics as a function of time at temperatures in the range of 1475/sup 0/F to 2000/sup 0/F (802/sup 0/C to 1093/sup 0/C) and hoop stresses in the range of 250 to 2500 psi for use in loss-of-coolant accident (LOCA) analyses. The strain rate above the start of the alpha to beta phase transformation region, approximately 1490/sup 0/F (810/sup 0/C), was found to be sensitive to the test procedure (stress-temperature history). This is believed to result from variations in the metallurgical structure. A prediction model is presented which provides a conservative upper bound to the low strain test data provided in this report and reported in the literature.

None

Stress corrosion cracking (SCC) in unirradiated recrystallized Zircaloy-4 internally pressurized tubing specimens in atmospheres containing iodine vapor, cesium, or combinations of iodine and cesium is evaluated experimentally in terms of the effects of internal surface flaw morphology, iodine and cesium concentrations, tubing hydrogen content, test temperature, and test atmosphere water vapor content on the time to failure. The iodine vapor SCC data are analyzed in the framework of a fracture mechanics model. Expressions are developed which relate the iodine SCC threshold stress and lifetime for stresses above threshold to temperature, iodine concentration, and surface flaw geometry.

Twenty-one LWBR irradiation test rods containing ThO/sub 2/-UO/sub 2/ fuel and Zircaloy cladding with holes or cracks operated successfully. Zircaloy cladding corrosion on the inside and outside diameter surfaces and hydrogen pickup in the cladding were measured. The observed outer surface Zircaloy cladding corrosion oxide thicknesses of the test rods were similar to thicknesses measured for nondefected irradiation test rods. An analysis model, which was developed to calculate outer surface oxide thickness of non-defected rods, gave results which were in reasonable agreement with the outer surface oxide thicknesses of defected rods. When the analysis procedure was modified to account for additional corrosion proportional to fission rate and to time, the calculated values agreed well with measured inner oxide corrosion film values. Hydrogen pickup in the defected rods was not directly proportional to local corrosion oxide weight gain as was the case for non-defected rods. 16 refs., 6 figs., 8 tabs.

This report provides a usable reference of methods and procedures for the construction of both one-sided and two-sided ..gamma../P statistical tolerance limits for design application to both linear and nonlinear models in any number of variables.

The development program to identify the critical parameters for the process of converting thorium nitrate solution into thoria powder is described. Thorium oxalate hexahydrate is precipitated from the reaction of thorium nitrate solution with oxalic acid. The resulting thorium oxalate hexahydrate slurry is filter pressed into a cake which is air calcined to form thoria powder. Changes in the critical processing parameters such as free nitric acid content of the thorium nitrate solution, precipitation temperature, and calcining temperature altered the thoria powder characteristics, and thus its capability for being fabricated into fuel pellets. The objective of the powder preparation effort was to obtain thoria powders which could be formed by conventional ceramic fabrication techniques into thoria and thoria-urania pellets of high density and high integrity having a nearly uniform large grain structure.

Wear of the Zircaloy cladding of LWBR irradiation test fuel rods, resulting from relative motion between rod and rod support contacts, is reported. Measured wear depths were small, 0.0 to 2.7 mils, but are important in fuel element behavior assessment because of the local loss of cladding thickness, as well as the effect on grid spring forces that laterally restrain the rods. An empirical wear analysis model, based on out-of-pile tests, is presented. The model was used to calculate the wear on the irradiation test fuel rods attributed to a combination of up-and-down motions resulting from power and pressure/temperature cycling of the test reactor, flow-induced vibrations, and assembly handling scratches. The calculated depths are generally deeper than the measured depths.

A model has been devised for incorporating into the thermal feedback procedure of the PDQ few-group diffusion theory computer program the explicit calculation of depletion and temperature dependent fuel-rod shrinkage and swelling at each mesh point. The model determines the effect on reactivity of the change in hydrogen concentration caused by the variation in coolant channel area as the rods contract and expand. The calculation of fuel temperature, and hence of Doppler-broadened cross sections, is improved by correcting the heat transfer coefficient of the fuel-clad gap for the effects of clad creep, fuel densification and swelling, and release of fission-product gases into the gap. An approximate calculation of clad stress is also included in the model.

Zircaloy clad oxide fuel rods are subjected to a variety of core power transients. One of these, an up-power transient, can place a severe burden on the fuel rod cladding that would potentially lead to rupture if not properly allowed for during the fuel rod design and plant operation. The cladding stress during such a transient can be increased by the presence of fuel chips between the oxide fuel pellet and the cladding. An analysis procedure based on mechanical tests of fuel and cladding was developed that permits calculation of the stress increase due to chips, so that the stress penalty can be accommodated without unnecessary penalties to fuel rod performance. The method of evaluating the maximum cladding bending tensile stress near the chip is described and test data are presented to support the analysis method.

This report describes the use of a delayed neutron pellet assay gage to determine nondestructively the fissile content of fuel pellets during the manufacture of the Light Water Breeder Reactor (LWBR) core. The gage characteristics are described including the nature of the calibration curves and the gage sensitivities to pellet parameters. Statistical methods are derived for analyzing the data to obtain the mean weight percent of total uranium in each blend of fuel material as well as the loading precision of each fuel rod. The fissile loading of each fuel rod was determined to better than 0.25% at the 2 sigma level, and the fissile content of eight fuel compositions in the LWBR core was obtained to better than 0.1%. Use of this gage and the data analysis methods described in this report reduced the need for destructive chemical analysis of fuel pellets by a factor of two.

This report surveys reactor core design features of the Light Water Breeder Reactor which make possible improved fuel utilization in light water reactor systems and breeding with the uranium-thorium fuel cycle. The impact of developing the uranium-thorium fuel cycle on utilization of nuclear fuel resources is discussed. The specific core design features related to improved fuel utilization and breeding which have been implemented in the Shippingport LWBR core are presented. These design features include a seed-blanket module with movable fuel for reactivity control, radial and axial reflcetor regions, low hafnium Zircaloy for fuel element cladding and structurals, and a closely spaced fuel rod lattice. Also included is a discussion of several design modifications which could further improve fuel utilization in future light water reactor systems. These include further development of movable fuel control, use of Zircaloy fuel rod support grids, and fuel element design modifications.

Seamless Zircaloy-4 tubing is utilized as fuel rod cladding in light water reactors. Water corrosion tests at 68OF have been performed to determine the corrosion and hydriding characteristics of Zircaloy-4 tubing, fabricated by cold reduction and finished in two metallurgical conditions: a stress-relief anneal (SRA) and a recrystallization anneal (RXA). These corrosion tests revealed differences in the post-transition corrosion product weight gains of the two materials. A computer corrosion model, designated CHORT, was developed from the test data and ascribes the observed difference in material weight gain to an assumed difference in the periodicity of a postulated cyclic buckling of the oxide.

ASBLT is a computer program consisting of DATATRAN MODULES which was used during the manufacturing phase of LWBR to collect and evaluate as-built data. The program was part of the LWBR fuel rod inspection process and produced sections of module assembly certification reports. ASBLT used fuel pellet, fuel rod and module assembly data to compute core inventories and to supply input to nuclear design programs for as-built core calculations.

The AIRWAY computer program was developed to estimate the radiation dose commitments accured by all the people affected by the atmospheric release of radionuclides from a nuclear facility. This computer program provides dose commitment estimates for people on the boundary of the facility, in the immediate vicinity (i.e., within 80 to 100 km) and in the portios of the world beyond the immediate vicinity which are affected by the release. The AIRWAY program considers dose commitments resulting from immersion in the atmosphere containing the released radionuclides, ingestion of contaminated food, inhalation of gaseous and suspended radioactivity, and exposure to ground deposits. The dose commitments for each of these pathways is explicitly calculated for each radionuclide released into the atmosphere and for each daughter of each released radionuclide. This is accomplished by calculating the air and ground concentrations of each daughter in each of the regions of interest using the release rate of the parent radionuclide. The AIRWAY computer program is considered to be a significant improvement over other programs in which the effect of daughter radionuclides must be approximated by separate releases.

Six different fastened joints representing the various combinations of materials in contact with Zircaloy in the Light Water Breeder Reactor (LWBR) were tested in 520/sup 0/F water for 60 days to determine the out-of-pile hydriding tendencies of the Zircaloy components in the joints. No evidence of massive, accelerated hydriding was found in this test although other testing has shown that local hydriding can occur in one of the fasteners. The same six fastener designs were tested in 600/sup 0/F water for 60 days to assess their load retention capability (thermal relaxation). The measured relaxation of these fasteners confirmed the predicted values for the conditions of the test.

This report presents and discusses the results of physics tests performed at beginning of life on the Light Water Breeder Reactor (LWBR). These tests have confirmed that movable seed assembly critical positions and reactivity worths, temperature coefficients, xenon transient characteristics, core symmetry, and core shutdown are within the range of values used in the design of the LWBR and its reactor protection analysis. Measured core physics parameters were found to be in good agreement with the calculated values.

An experiment has been performed to determine the effect of motion of a thermal shield on the neutron signal expected from ex-core detectors. Using a mockup of the LWBR reactor vessel, thermal shield, and core barrel in conjunction with a /sup 252/Cf neutron source, the change in detector signal with displacement of the various components was investigated. It was found that moving the thermal shield would produce a significant change in detector signal, although the effect was smaller than would be produced by moving the source and core barrel together. The results were substantiated by two-dimensional discrete-ordinate calculations.

This report describes the operation of the Shippingport Atomic Power Station during the LWBR (Light Water Breeder Reactor) Core lifetime. It also summarizes the plant-oriented operations during the period preceding LWBR startup, which include the defueling of The Pressurized Water Reactor Core 2 (PWR-2) and the installation of the LWBR Core, and the operations associated with the defueling of LWBR. The intent of this report is to examine LWBR experience in retrospect and present pertinent and significant aspects of LWBR operations that relate primarily to the nuclear portion of the Station. The nonnuclear portion of the Station is discussed only as it relates to overall plant operation or to unusual problems which result from the use of conventional equipment in radioactive environments. 30 refs., 69 figs., 27 tabs.

FLASH6 computer program calculations are compared with experimental data from two simulated loss-of-coolant accident blowdown tests which are designated as numbers 2 and 3 in the Standard problem Series sponsored by the Nuclear Regulatory Commission for reactor safety assessment. Both tests are isothermal blowdowns smulating a double-ended, cold-leg break and were conducted in the electrically-heated, 1-1/2 Loop Semiscale System at Idaho National Engineering Laboratory. The blowdown tests were initiated at nominal conditions of 575/sup 0/F, 2250 psia and 17.3 lbm/sec loop flow rate.

Measurements of fission product iodine and cesium are reported for thoria and binary (ThO/sub 2/--UO/sub 2/) fuels with various irradiation histories. These volatile fission products were measured on the cladding surface or in the fuel by using specially developed radiochemical techniques. The radiochemical iodine measurements are found to be in general agreement with a theoretical iodine release model for irradiated fuel. Microprobe examinations of irradiated fuel rod cladding sections show fission product cesium to be located preferentially at the pellet to pellet interface region. Fission product iodine was detected in the interface region of one sample but generally remained below the microprobe limit of detection. 18 figures, 7 tables.

Although not a problem in recent commercial power reactors, including the Shippingport Light Water Breeder Reactor, internal hydriding of Zircaloy cladding was a persistent cause of gross cladding failures during the 1960s. It occurred in the fuel rods of water-cooled nuclear power reactors that had a small cladding defect. This report summarizes the experimental findings, causes, mechanisms, and methods of minimizing internal hydriding in defected Zircaloy-clad fuel rods. Irradiation test data on the different types of defected fuel rods, intentionally fabricated defected and in-pile operationally defected rods, are compared. Significant factors affecting internal hydriding in defected Zircaloy-clad fuel rods (defect hole size, internal and external sources of hydrogen, Zircaloy cladding surface properties, nickel alloy contamination of Zircaloy, the effect of heat flux and fluence) are discussed. Pertinent in-pile and out-of-pile test results from Bettis and other laboratories are used as a data base in constructing a qualitative model which explains hydrogen generation and distribution in Zircaloy cladding of defected water-cooled reactor fuel rods. Techniques for minimizing internal hydride failures in Zircaloy-clad fuel rods are evaluated.

This report summarizes the refueling operations performed to install a Light Water Breeder Reactor (LWBR) core into the existing pressurized water reactor vessel at the Shippingport Atomic Power Station. Detailed descriptions of the major installation operations (e.g., primary system preconditioning, fuel installation, pressure boundary seal welding) are included as appendices to this report; these operations are of technical interest to any reactor servicing operation, whether the reactor is a breeder or a conventional light water non-breeder core.

Destructive examination of 12 representative Light Water Breeder Reactor fuel rods was performed following successful operation in the Shippingport Atomic Power Station for 29,047 effective full power hours, about five years. Light Water Breeder Reactor fuel rods were unique in that the thorium oxide and uranium-233 oxide fuel was contained within Zircaloy-4 cladding. Destructive examinations included analysis of released fission gas; chemical analysis of the fuel to determine depletion, iodine, and cesium levels; chemical analysis of the cladding to determine hydrogen, iodine, and cesium levels; metallographic examination of the cladding, fuel, and other rod components to determine microstructural features and cladding corrosion features; and tensile testing of the irradiated cladding to determine mechanical strength. The examinations confirmed that Light Water Breeder Reactor fuel rod performance was excellent. No evidence of fuel rod failure was observed, and the fuel operating temperature was low (below 2580/sup 0/F at which an increased percentage of fission gas is released). 21 refs., 80 figs., 20 tabs.

The PDQ-8 program is designed to solve the neutron diffusion, depletion problem in one, two, or three dimensions on the CDC-6600 and CDC-7600 computers. The three dimensional spatial calculation may be either explicit or discontinuous trial function synthesis. Up to five lethargy groups are permitted. The fast group treatment may be simplified P(3), and the thermal neutrons may be represented by a single group or a pair of overlapping groups. Adjoint, fixed source, one iteration, additive fixed source, eigenvalue, and boundary value calculations may be performed. The HARMONY system is used for cross section variation and generalized depletion chain solutions. The depletion is a combination gross block depletion for all nuclides as well as a fine block depletion for a specified subset of the nuclides. The geometries available include rectangular, cylindrical, spherical, hexagonal, and a very general quadrilateral geometry with diagonal interfaces. All geometries allow variable mesh in all dimensions. Various control searches as well as temperature and xenon feedbacks are provided. The synthesis spatial solution time is dependent on the number of trial functions used and the number of gross blocks. The PDQ-8 program is used at Bettis on a production basis for solving diffusion--depletion problems. The report describes …