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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.

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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.

The equations developed for use in the LWBR environmental statement to estimate the dose commitment over a given time interval to a given organ of the population in the entire region affected by the atmospheric releases of a radionuclide are presented and may be used for any assessment of dose commitments in these regions. These equations define the dose commitments to the world resulting from a released radionuclide and each of its daughters and the sum of these dose commitments provides the total dose commitment accrued from the release of a given radionuclide. If more than one radionuclide is released from a facility, then the sum of the dose commitments from each released nuclide and from each daughter of each released nuclide is the total dose commitment to the world from that facility. Furthermore, if more than one facility is considered as part of an industry, then the sum of the dose commitments from the individual facilities represents the total world dose commitment associated with that industry. The actual solutions to these equations are carried out by the AIRWAY computer program. The writing of this computer program entailed defining in detail the specific representations of the various parameters such as …

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.

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.

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.

Mechanical joints between Zircaloy and nickel-bearing alloys, mainly the Zircaloy-4/Inconel-600 combination, were exposed to water at 450/sup 0/F and 520/sup 0/F to study hydriding of Zircaloy in contact with a dissimilar metal. Accelerated hydriding of the Zircaloy occurred at both temperatures. At 450/sup 0/F the dissolved hydrogen level of the water was over ten times that at 520/sup 0/F. At 520/sup 0/F the initially high hydrogen ingress rate decreased rapidly as exposure time increased and was effectively shut off in about 25 days. Severely hydrided Zircaloy components successfully withstood thermal cycling and mechanical testing. Chromium plating of the nickel-bearing parts was found to be an effective and practical barrier in preventing nickel-alloy smearing and accelerated hydriding of Zircaloy.

As part of the Light Water Breeder Reactor development program, hydraulic tests of reactor components were performed. This report presents the results of several of those tests performed for components which are somewhat unique in their application to a pressurized water reactor design. The components tested include: triplate orifices used for flow distribution purposes, multiventuri type flowmeters, tight lattice triangular pitch rod support grids, fuel rod end support plates, and the balance piston which is a major component of the movable fuel balancing system. Test results include component pressure loss coefficients, flowmeter coefficients and fuel rod region pressure drop characteristics.

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.

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.

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.

The DECAG (Deformation of Cladding into Axial Gaps) ex-reactor test program evaluated deformation of Zircaloy-4 cladding into axial gaps in tubular fuel elements. These axial gaps are the result of cladding elongation and fuel stack shrinkage. The test program consisted of twelve series and subseries of both fully recrystallized and stress-relieved highly cold worked tubing tested under pressure-temperature combinations in autoclaves. The test program also verified the validity of achieving test acceleration through the use of elevated temperatures by correlating both ovality and diameter change at lower temperatures with the Larson--Miller Parameter.

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.