Preface: 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 from the reactor is radioactive, the purpose of the IHX is to transfer heat to a nonradioactive fluid which then goes to a steam generator. Because of this activity the until will be enclosed in a concrete pit and will not be accessible during periods of operation. Immediately after shut down 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 shut down, the internals should have easy access for inspection and repair if necessary so that down time is held to a minimum. The general arrangement of the heat exchanger described in this report presents a conventional design utilizing known materials and existing methods of fabrication. In further consideration of all concepts, designs and analyses developed during this period of the program, it is felt that this preliminary design will provide an intermediate sodium heat exchanger of lower cost …

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.

Introduction: This is a final report on the evaluation of Kanigen electroless nickel plating for surfaces in contact with water and steam i a sodium heated AISI Type 316 stainless steel steam generator. The purpose of the coasting was to afford protection from stress corrosion cracking originating on the water-steam side of the unit. It has been concluded that the kanigen coating does not afford adequate protection for the services condition intended. This work was performed as part of the research and development program for the United States Atomic Energy Commission sodium Components Design Project.

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.

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.

The designer's concept of a test program for the 30-Mw prototype intermediate heat exchanger and steam generator designed and fabricated as part of the Sodium Components Development Program is presented. The performance data will serve to verify the thermal design, or allow application of improved techniques to future designs, give an improved basis for stress analysis in design of future units, and demonstrate the capability and limitations of the units in relation to the performance specifications for which they were designed. Welding techniques for type 316 stainless steel are described. The specifications and operating conditions of the units are given along with instrumentation drawings showing test equipment design and arrangement.

Special welding techniques for joining Inconel weld overlays on type 316 stainless steel tubesheets and channels are described. The program for the development of the required welding procedures are divided into three specific programs: overlaying Inconel filler Metal 82 on type 316 stainless steel, welding type 316 stainless steel tubes to a type 316 stainless steel tubesheet, and welding Inconel-type 316 stainless steel composite tubes to Inconel weld overlaid type 316 tubesheets. Shock tests are described which attempt to assimilate the most drastic thermal transient that could occur in both units and to evaluate the effect of the resulting stresses on the Inconel overlay and the tube-to-tubesheet welds. (N.W.R.)

The investigation in this report were conducted to determine the required shielding to reduce radiation to a workable level, to determine the heeating in the various core components so coolant flow rates could be determined, and to determine the thermal stress and temperature distribution in the structural and load bearing members.

The primary purpose of this manual is to adopt a radiological safety program to provide all personnel with a safe place in which to work, visit or live.

In the fabrication of the steam generator on APPR-1A it was considered necessary to roll the Type 430M tubes into carbon steel tube-sheets. The rolled joint was a necessary precaution to prevent secondary water from contacting the stainless steel weld.

This program using the IBM 650 electronic data processing machine is used primarily as a tool in order to prepare input data for the IBM 704 code, entitle ATBAC. The code calculates steady state thermal characteristics of a plate type fuel element for both a nominal and adverse channel

A method has been developed for using the IBM 650 Electronic Data Processing Machine to obtain detailed information concerning thermal and hydraulic conditions within a plate type reactor channel when the coolant in the channel is present in both vapor and liquid phases

This report covers fuel element corrosion studies conducted from April,1959 through July,1960, designed to aid in selecting and evaluating SM-2 fuel element welding techniques

The study was conducted to determine the adequacy of the fuel element structural design of APPR-1. The results obtained lead to the conclusion that the element design is structurally sound for all normal operating conditions from the standpoint of thermal stress.

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: 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.

Abstract; SM-1 Reactor Core I Rearranged and Spiked, and Core II with Special Components were analyzed under various off-design conditions to induce nucleate boiling. The steady state code, STDY-3, written for the thermal analysis of pressurized water cores, was employed for the analysis. The code performs a complete steady state parallel channel thermal analysis for both nominal and hot channels. Thermal characteristics of individual elements were investigated while changing the parameters of primary pressure or inlet temperature to introduce the phenomenon of nucleate boiling in the the core. Reduction of system pressures to 1000, 800, and 600 psia and increasing core inlet temperatures to 465 and 500 degree F were studied as the means to induce boiling in the core. This analysis indicates that SM-1 Core I Rearranged and Spiked can be safely operated at the reduced pressure of 910 psia without introducing extensive boiling in the core. SM-1 Core II with Special Components can be operated at 800 psia or at an inlet temperature of 500 degree F at 1200 psia.

Abstract: Test procedures for special tests involving in-core SM-1 temperature and flow instrumentation are described (Task XIV Package Tests). These tests involve in-core steady state flow and temperature measurements, loss of flow transients, load transients, reduced primary system pressure operations and reduced element flow. The thermal and hydraulic conditions prevailing in these tests, including steady state and transient burnout rations, are developed. The effects of reduced system pressure and flow on the burnout ratios are determined as are the expected stuck rod conditions when Task XIV test elements are installed. The effect on the maximum credible accident is included and a recommendation to conduct these Task XIV package tests is made.

On the basis of recent experiment with APPR-1 fuel elements manufactured by ORNL,hot channel factors have been derived from the observed dimensional deviations

A basic kinetic model of the primary system coolant loop is developed for the Army Package Power Reactor-1

A detailed analysis of hydraulic and mechanical forces affecting control rod drop time has been made to determine a mathematical expression for rod position in terms of elapsed time after initiation of a scram.