Manufacture of Core Subassemblies & Fertile Fuel Assemblies for Indian Fast Breeder Programme

R.N.Jayaraj Chief Executive,NFC DAE, India

Three Stage Nuclear Power Program

95 90
A v a ila b ility/C a p a c ity F a cto r (% ) ----->

90 79 69 72 75 75 67 60 71 84 84 82 86 85 90

85 80 75 70 65 60 55 50

80

1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03

Stage I PHWRs

16- Operating 2 - Under construction 40 MWth FBTR Several others planned Operating since 1985 Scaling to 700 MWe Technology Objectives Gestation period being realised reduced 500 MWe PFBR POWER POTENTIAL Under Construction 10,000 MWe LWRs 2 BWRs Operating 2 VVERs under construction

Stage - II Fast Breeder Reactors

Stage - III Thorium Based Reactors

30 kWth KAMINI- Operating 300 MWe AHWRUnder Development POWER POTENTIAL VERY LARGE IS

POWER POTENTIAL 350,000 Mwe

Availability of ADS can enable early introduction of Thorium on a large scale

Schematic Diagram of Fast Breeder Test Reactor

Main Characteristics of FBTR

Parameters
Reactor Type Reactor Power Fuel 40MWt/13.2MWe MOX (30% PuO2 + 70% UO2 with 85% enrichment) 65

Initial Design

Present Small Core

15MWt/2MWe Mark I (70% PuC + 30% UC) Mark II (55% PuC + 45% UC) 25 Mark-I + 13 Mark-II 5.1 61

Sodium cooled, loop type

No. of Fuel subassemblies Fuel Pin Diameter (mm) No. of Pins/Subassembly Max. linear Heat rating (W/cm) Max. Burnup (GWd/t) Peak Neutron Flux (n/cm2/s)

400 100 3.5E15

400 100 2.2E15

FBTR Core Configuration

Materials for FBTR Subassemblies

Axial Gripper Fuel Foot Blanket Spring Clad Assembly Clad SS 316M SS 316L Nimonic 80A SS 316L

OHT SS 316L

IHT SS 316L

Handling Head SS 316L

Hard Chrome Plating on OHT Buttons

Test Subassemblies for FBTR

Carrier SAs with Capsules for Irradiation Experiments ISZ-100 IBZ-100 CIPTEX Type of Subassembly 29 Nos. 14 Nos. 2 Nos. 2 Nos. 2 Nos. 1 No. 1 No. 2 Nos. 8 Nos. 2 Nos. 2 Nos. 1 No. Qty.

INZ-100 Source Carrier SA

SA for Sodium Void-Coefficient Measurement SA for Delayed Neutron Detection (DND) Special SAs for Sodium Filter IFZ-100 IF 1300 SAs for Flow Blockage Experiments

Flow Sheet for FBTR Fuel Subassembly

I. AXIAL BLANKET PIN FABRICATION
1ST END PLUG WELDING (GTAW) WITH CLAD TUBE LOAD THE ThO2 PELLET STACK IN THE 1ST END PLUG WELDED CLAD TUBE 2ND END PLUG WELDING IN CLOSED CHAMBER IN He GAS ATMOSPHERE SPACER WIRE WRAPPING & SPOT WELDING (RESISTANCE) AND WIRE END WELDING BY GTAW INSPECTION ACCEPTED AXIAL BLANEKT PINS

II.

LOWER INNER PORTION OF FUEL SA

ASSEMBLE FUEL RAILS AND RIVETS WITH LOWER INNER HEXAGONAL TUBE ASSEMBLE AXIAL BLANKET PINS (7 NOS.), SPACERS, LOWER INNER HEXAGONAL TUBE AND RIVETS, FORM & FLARE THE RIVETS ASSEMBLE LOWER INNER HEXAGONAL TUBE WITH FOOT ASSEMBLY AND WELD BY GTAW

III.

UPPER SA OF FUEL SUBASSEMBLY

ASSEMBLE AXIAL BLANKET PINS (7 NOS.), SPACERS, UPPER INNER HEXAGONAL TUBE AND RIVETS, FORM & FLARE THE RIVETS ASSEMBLE UPPER INNER HEXAGONAL TUBE WITH LIFTING HEAD AND WELD BY GTAW ASSEMBLE UPPER INNER HEXAGONAL TUBE ALONGWITH LIFTING HEAD WITH OUTER HEXAGONAL TUBE AND WELD BY GTAW ASSEMBLE FUEL PINS (6 NOS.) OVER RAILS OF LOWER PART OF FUEL SUBASSEMBLY. ENVELOPING THE FUEL PINS AND LOWER INNER HEXAGONAL TUBE WITH OHT OF UPPER SUBASSEMBLY WELD OHT TO FOOT BY GTAW FINAL INSPECTION OF FINISHED FUEL SUBASSEMBLY ALCOHOL CLEANING OF FUEL SUBASSEMBLY PACKING AND DISPATCH/STORE

Components for FBTR Subassemblies

Components for FBTR Subassemblies

Tubular Components for FBTR Subassemblies

Welding Techniques Used for FBTR Subassembly Fabrication

OHT to Foot & Head Portion Welding (GTAW)

Bottom Plug Welding (GTAW)

Top Plug Welding (GTAW)

Developments in ThO2 pellet production

Production

1. Addition of MgO (0.5 mol%) to get higher sintered densities while sintered at 1600C under hydrogen. 2. Ball milling of long stored powders to increase sinterability. 3. Low temperature sintering at 1150C in air atmosphere, with addition of Nb2O5 (0.25 mol%) as sintering aid.
Saving in energy consumption. Avoiding usage of hydrogen.

Quality Checks: 1. Thermal etching techniques Re-sintering of well polished pellet surface, revealed clear grain boundaries. 2. Faster dissolution of thoria pellet during chemical analysis by modified technique.

Ceramographs of ThO2+0.5 mol% MgO for 3h in Hydrogen. Sintered at 1600C & thermally etched at 1600C

Particle Size Distribution of Thoria Powder

Th

Chemical Characteristics of Thoria Powder

Symbol Name

Al Be Ca C B

Aluminium Boron Beryllium Carbon Calcium Cerium

Impurities max. level in ppm

Symbol

Name

0.3 100 200 0.1 4.0 5.0 0.2 0.2 10 50 1.0

50

Mn Mo Ni Si S P

Mg

Gd

Gadolinium

Impurities max. level in ppm

Magnesium Manganese Nickel Molybdenum Phosphorus Silicon Antimony Sulphur Samarium Uranium

0.2 2.0 20 30 50 2.0 0.4 50 60 50

Not more than 100ppm of any other element except thorium and oxygen. EBC<1.5ppm

Cd Ce Cr

Cadmium Chromium Copper Dysprosium Europium Erbium Iron Fluorine

Dy Eu Er F

Cu

Sb Sm U V

0.08

Vanadium Zirconium

Fe

100

Zr

100 20

5.0

Need for Certified Reference Materials (CRMs)

The qualification of ThO2 needs the validation of analytical procedure, which, in turn, requires CRMs for the purpose. CRMs are used for assessing the performance of an individual laboratory. Also, ThO2 CRMs are very expensive in international market to buy. NFC has made CRMs of Thoria Powder and also ThO2+2.5%UO2 Powder.

Flow Sheet for producing CRMs

Thorium Nitrate Crystals Dissolution in Hot DM Water Addition of 20 impurity elements mixture Solution to Th(NO3)4 solution Oxalic acid solution Precipitation of Thorium oxalate Filtration Drying & calcination Blending & Storage of Final ThO2 Oxide powder Filtrate for storage & Safe disposal

Sample
ThO2 B ThO2 -S ThO2 - D ThO2+ 2.5% UO2 - MOS

Classification for the Analytes in Four Samples

Elements Class
A A A A

Elements

Class
C C C C

Al,Ca,Cr,Cu,Mg,Mn,Mo,Ni, Sm,V Al,Cd,Ce,Cr,Cu,Dy,Er,Eu,Fe, Gd,Mg,Mn,Ni,Sb,Sm,V Al,Ca,Cd,Ce,Cr,Cu,Dy,Er,Eu, Fe,Gd,Mg,Mn,Ni,Sb, Sm,V Al,Ca,Cd,Ce,Cr,Cu,Er,Eu, Mg, Mn, Ni, Sm, Sb, V

B,Be,Cd,Ce,Dy,Er,Eu, Gd,Fe,Sb B,Be,Ca,Mo B,Be,Mo B, Be, Dy, Fe, Gd, Mo

From the table it is clear that out of 20 elements added as impurities, upto 17 elements have got the status of class A which is the testimony to the homogeneity of the powder made at NFC. Further, more number of elements getting Class-C status in case of ThO2-B sample is attributed to variations associated with analytical measurements of low concentrations

ThO2 Powder

PFBR Core Cross-Section

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

Main Vessel

Core Support Structure Core Catcher Grid Plate Core

Inner Vessel Roof Slab Large Rotating Plug Small Rotating Plug Control Plug CSRDM / DSRDM Intermediate Heat Exchanger Safety Vessel Transfer Arm

Primary Sodium Pump Reactor Vault

PFBR Core Configuration

Symbol

TYPE OF SUBASSEMBLY FUEL (INNER) FUEL (OUTER) CONTROL & SAFETY ROD DIVERSE SAFETY ROD BLANKET STEEL REFLECTOR B4C SHIELDING (INNER) STORAGE LOCATION STEEL SHIELDING B4C SHIELDING (OUTER) TOTAL SUBASSEMBLIES

Nos. 85 96 9 3 120 138 125 156 609 417 1758

Materials for PFBR Subassemblies

Fuel Clad Tube - D9 Hexcan- D9 Components- SS 316LN Natural B4C Pellets Top Axial Shielding Clad Tube SS 316LN

Tubes for Core Structurals

FUEL CLAD TUBES (6.6 x 0.45 x 2555 mm) BLANKET CLAD TUBES (14.33 x 0.56 x 2350 mm) CSR CLAD TUBES (22.4 x 1 x 1260 mm) DSR CLAD TUBES (21.4 x 0.7 x 1110 mm) REFLECTOR CLAD TUBES (44 x 1 x 3325 mm) IBC CLAD TUBES (44 x 1 x 3325 mm)

26

Material Compositions
D9 for Clad Tubes: Cr: 13.5-14.5, Ni: 14.5-15.5, Mo: 2, Ti: 5C-7.5C, N: 50 ppm, Inclusion Rating: 1

D9 for Hexcan Tubes: Cr: 13.5-14.5, Ni: 14.5-15.5, Mo: 2, Ti: 5C-7.5C, N: 100 ppm, Inclusion Rating: 4 D9 for Spacer Wire: Cr: 13.5-14.5, Ni: 14.5-15.5, Mo: 2, Ti: 5C-7.5C, N: 50 ppm, Inclusion Rating: 1 Spring Wire: ASTM A-286

316LN for Bulk Components: C: 0.02-0.03, N: 0.06-0.08

Flow Sheet for Natural Boron Carbide Pellets

Boric Acid Powder + Graphite
Blending Heating in Crystal Formation Furnace Crushing of B4C Lumps Pulverising Vibro-sieving & Drying Hot Compaction Sand Blasting Centreless Grinding Surface Grinding

B4C Powder

Boron Carbide Pellet

Flow Sheet for Enriched Boron Carbide Pellets

Boric Acid Enriched Boric Acid KBF4 Elemental Boron Boron Carbide Pellet
Distillation Dissolution in HF Precipitation with KOH Filtration & Drying

Electrolysis Crushing of cathode deposit Leaching, filtration & drying Mixing with carbon Green compaction Heating in vacuum induction furnace

PFBR Test Subassemblies

Fuel SA for Hydraulic Testing Fuel SA for FIV Testing Blanket SA for Hydraulic Testing CSR SA for Drive Mechanism Testing CSR SA for Hydraulic Testing DSR SA for Drive Mechanism Testing DSR SA for Hydraulic Testing Reflector SA for Hydraulic Testing Inner Boron Carbide Shielding SA for Hydraulic Testing Handling Experiment Subassemblies 37 Element Fuel SA

Type of Subassembly

1 no. 1 no. 1 no.

Qty.

2 nos. 2 nos. 1 no. 1 no. 1 no. 1 no. 28 nos. 2 nos.

PFBR Subassemblies Fabricated

Fuel Subassembly Blanket Subassembly Reflector Subassembly

CSR Sheath & Rod Subassembly

DSR Sheath & Rod Subassembly

Inner Boron Carbide Subassembly

Manufacture of Hexcans & Square Channels through Pilgering Route

ROLLER MANDREL

Roller Scheme for Hexagonal Tube Pilgering

PILGERED HEXCAN

ROLLER ASSEMBLY

MANDREL
ROLLER SCHEME FOR PILGERING OF SQUARE SECTIONS FINISHED SQUARE CHANNEL

DIFFICULTIES ENCOUNTERED DURING FABRICATION

32

Components for PFBR Subassemblies

Handling Head Piston Foot Upper Part

Dash Pot Cylinder

Bottom Plug

Coolant Entry Tube

Bottom Plug Welding Machine

Top Plug Welding Machine

Wire Wrapping & Spot Welding Machine

Crimping Machine

Special Features of the Equipment

Precision current control to 0.5Amps with feedback system with smooth arc stability in Helium atmosphere. Automatic initial arc gap setting and arc gap control. Automatic data acquisition and feedback control system with recording facilities for critical parameters like current, voltage, (arc (inert gas quality), etc. techniques. distance), weld speed, vacuum level, Helium pressure, oxygen level Precision special purpose fixturing for GTAW, Resistance welding

Button Forming Machine

Automatic Hexcan Welding Machine

Both conventional and orbital techniques with GTAW cum Plasma were applied successfully for hexcan peripheral welding with filler addition. Automatic torch inclination with Torch oscillation axis provided for keeping it perpendicular to welding face in synchronization with tube rotation. Software based automatic control with feedback system for all critical parameters with recording facilities.

Arc Distance Control

Automatic Pin Assembling Machine

1. 2. 3. 4. 5. 6. Pin Magazine (127 Pins) Foot Assembly Hexcan assembled with Top Assembly Shielding Input Trolley Material Transfer Robot 1

4 6 9

5 8

2 13 3

7 4 11 12

10

7. 8. 9. 10. 11. 12. 13.

Pin Assembling Robot Pin Pushers Special Grippers for Pin Assembly Stn./Fixture Lower Part Holding Stn. Welding/Bead Grinding Robot Finished Subasembly

Inspection Techniques Involved

Fluorescent Die Penetrant Test Metallography X-Radiography

Ultrasonic Testing (Pulsed Echo & Surface Wave Technique) Helium Leak Testing

Visual & Dimensional

Surface wave based methodology for NDE of Hexcan weld of PFBR subassembly
Edge reflection 2.2 mm (W) 2.7 mm (W)

2.2 mm (HAZ)

1 MHz surface wave transducer

Oxide Dispersion Strengthened (ODS) Steels

1000 Preheated ODS steel Billets Undergoing lubrication
High Temperature Strength

ODS ODS

Upsetted ODS Steel Billets

Maximum Temperature (K)

950

900

Austenitic Austenitic
Radiation Resistance
100 150

PH PHFerritic/ Ferritic/ Martensitic Martensitic

850

200

250 630 T Extrusion Press Billet inserted into the container

Neutron Dose (dpa)

Precipitation hardening effect will be lost in ferritic steels above 923 K. Oxide dispersion strengthening will be effective even above 973 K.

17.75 mm X 1.75 mm WT machined & polished ODS Tube

24 mm rod in red hot condition

Finished ODS Steel Clad tube 6.6mm OD X 0.45mm WT

41

Double clad tubes for Fast Breeder Reactors

Schematic of Double Clad Tube Fabricated at NFC

Tube Section showing Outer & Inner Walls of T91 & Zr Alloy

Enlarged View showing no gap at T91-Zr Interface along with wall thickness measurement

Desired dimensions as per specification

Tube-in-Tube design for metallic fuels

42

Conclusions
1. Indigenous development of technology for core sub-assembly fabrication for FBTR. 2. Development of process equipment and QA procedures for the above. 3. Currently, manufacture of core subassemblies for PFBR underway. 4. Actions on hand to establish facilities for sub- assembly manufacture for future FBRs, as part of Fuel Cycle Complex.

Thank You

Major Components of the Equipment

Rail mounted predefined position mobile trolley with shielding for input components upper & lower parts, pins (217) in pin magazines (2).

Specialized track mounted robots for components handling (R1), pins picking, orientation identifying and placing (inserting) over rails (R2) and hexcan to lower part welding(R3). Lower parts, pins & upper parts assembly fixture (customized lathe with specialized supports and shielding). Upper parts (hexcan & handling head) pin magazine support system with automatic hexcan inserting. Robotics & process controls with feedback system.

Special end of the arm facility effectors for handling, pick and place, welding torch, excess bead grinding and inspection gadgets, tooling, if required. CCTV cameras (3nos.) for vision system.

Special Features of the Equipment

Remotisation of radioactive pins assembling and fabrication processes (weld bead finishing and testing) with robotics.

Specialized robots for heavy duty machine handling, precision pick and place and advanced GTAW welding functions with complete integration for their coordinated activities. Complete operation with remote controlled with CCTV camera and vision system. Localized (source) shielding provided for neutron and Gamma radiation.