MATERIAL AND FABRICATION OF THE

HTTR REACTOR PRESSURE VESSEL XA9846689

Y. TACHIBANA, K. KUNITOMI, S. SHIOZAWA

Japan Atomic Energy Research Institute,
Oarai-machi, Ibaraki-ken

T. ASAMI, S. YAMAGUCHI
Babcock-Hitachi K.K.,
Hiroshima

Japan

Abstract

The High Temperature Engineering Test Reactor (HTTR) is under construction at Oarai
Research Establishment, Japan Atomic Energy Research Institute (JAERI) and planned to be
critical in October 1997. Fabrication of the HTTR reactor pressure vessel (RPV) at Kure
Works, Babcock-Hitachi K. K. took about two years, and the RPV was transported to the
Oarai site in August 1994. Pressure test of the primary and secondary cooling system
including the RPV was performed successfully in March 1996 [1].

Because temperature of the HTTR RPV becomes about 400 °C at normal operation, 2 1/4
Cr-1 Mo steel is chosen for it. Fluence of the RPV is calculated to be less than lxlO 17 n/cm2
(E>1 MeV), and so irradiation embrittlement is presumed to be negligible, but temper
embrittlement is not. For the purpose of reducing embrittlement, content of some elements is
limited on 2 1/4 Cr-1 Mo steel for the HTTR RPV using embrittlement parameters: J-factor
and X.

In this paper design and structure of the HTTR RPV is briefly reviewed first. Fabrication
procedure of the RPV and its special feature is shown. Material data on 2 1/4 Cr-1 Mo steel
manufactured for the RPV, especially the embrittlement parameters J-factor and X, and nil-
ductility transition temperatures TNDT by drop weight tests, are shown, and increase in the
transition temperature is estimated based on data available in literature. Technology of the
HTTR RPV is applicable to RPVs of future commercial High Temperature Gas-cooled
Reactors (HTGRs).

1. Design and structure

Table 1 and Fig. 1 show specifications and schematic diagram of the HTTR RPV
respectively. The RPV consists of a RPV top head, which includes thirty-one stand-pipes, a
top head dome, a top head flange, thermal shields, etc., and a RPV body containing a shell
flange, a shell, three stand-pipes, a bottom head petal, a skirt, a bottom head dome, a support
ring, radial keys, etc. The RPV top head is bolted to the RPV body by 72 stud bolts. The
thirty-one stand-pipes, which include sixteen for control rods, five for irradiation test, three
for surveillance test, three for neutron detection, two for in-service inspection of reactor
internals, and two for measurement of temperatures and core differential pressure are welded
to nozzles on the top head dome. Figure 2 shows arrangement of stand-pipes on the top head
dome. The largest seven stand-pipes, Nl to N7, are also used for refueling. Three other
stand-pipes for hot plenum temperature measurement and fuel failure detection are welded to
nozzles on the shell. Figure 1 shows one of the three stand-pipes. The skirt supports weight

305
 Table 1. Major specification of the HTTR reactor pressure vessel
Design pressure 4.7 MPa [gauge]
Design Temperature 440 °C
Normal operating pressure 3.9 MPa [gauge]
Inlet coolant temperature 395 °C
Inside diameter 5.5 m
Height 13.2 m
Thickness of cylindrical shell and bottom head 122 mm [minimum]
dome
Thickness of top head dome 160 mm [minimum]
Number of stand-pipes 34
Material 2 1/4 Cr-1 Mo steel
(Normalized and
tempered)

and seismic load of the reactor. Horizontal seismic load is sustained by six stabilizers and a
stand-pipe support beam as well as the skirt. The support ring support vertical load of the
core, and the radial keys hold horizontal movement of the core through core restraint
mechanism. The thermal shields are made up of layers of metallic plates, which protect the
RPV top head from overheating, especially in loss of forced coolant circulation accidents.

Because temperature of the HTTR RPV becomes about 400 °C at normal operation, 2 1/4
Cr-1 Mo steel, normalized and tempered, which has higher creep rupture strength than Mn-
Mo steel for RPVs of Light Water Reactors, is chosen for it. Three kinds of 2 1/4 Cr-1 Mo
steel: forgings of Japan Industrial Standard (JIS) specification SFVAF22B, equivalent to
ASTM A-336 Gr. F22, Cl. 3, plates of JIS SCMV4-2, equivalent to ASTM A-387 Gr. 22, Cl.
2, and seamless pipes of JIS STPA24, equivalent to ASTM A-335 Gr. P22 are used for
components as shown in Fig. 3, which also shows weld lines.

The safety evaluation criteria for temperatures of the HTTR RPV are as follows:
maximum temperature shall not exceed 500 °C in anticipated operational occurrences and
550 °C in accidents. The maximum temperature of the RPV in the depressurization accident
is calculated to be about 530 °C [2].

2. Fabrication

Figure 4 shows fabrication procedure of the HTTR RPV. As shown in Figs. 3 and 4, two
types of stand-pipes exist, designated "Stand-pipe a" and "Stand-pipe b" in Fig. 4: a forging,
and a forging and a pipe welded together respectively. The inner nineteen stand-pipes for
control rods and irradiation tests, which require dimensional accuracy in manufacturing, are
forgings. Heads of the outer twelve stand-pipes on the top head dome and three stand-pipes
on the shell are forgings, which are welded to seamless pipes, making up the "Stand-pipe b."

The top head dome is a very large forging, and nineteen nozzles for the inner nineteen
stand-pipes above are integrated with itself, that is there are no weld lines between the dome
and the nozzles. Since gaps among the nineteen nozzles are so narrow, it is impossible to
perform in-service inspection: ultrasonic testing, of the weld lines when they exist. Ultrasonic
testing of the weld lines between the stand-pipes and the nozzles is possible utilizing special
equipment for it. The other thirteen nozzles including a manhole nozzle, are welded to the
top head dome. Regarding these weld lines, it is possible to conduct ultrasonic testing,
because there is enough distance between the nozzles, and the weld lines are accessible from

306
 Stand-pipe
Stand-pipe support beam

Thermal shields Top head dome

Stud bolt
head flange

Shell flange
Stabilizer Stabilizer bracket

r Shell

, Stand-pipe

Bottom head petal

f- Support ring

Support rib

Bottom head dome

Fig. 1 Schematic diagram of the HTTR RPV

307
o
00

N30, N31 for in-service inspection

N27~N29 for surveillance test
N24, N26 for measurement
N23, N25 for irradiation test
N20~N22 for neutron detection
N17~N19 for irradiation test
N8—N16 for control rods
27 0*-
N1~N7 for control rods and refueling

Manhole

180*

Fig. 2 Arrangement of stand-pipes of the HTTR RPV

 Plate Forging

Stand-pipe 2 ^ ^
Forging

Forging
Top head dome
Top head flange

Shell flange
Shell 1

Platen
•Plate
Seamless pipe
Stand-pipe 3
-f-
Shell 2

Bottom head
Nozzle
Forging
fz Plate

Forging
petal Plate

Forging Plate

Plate : JIS SCMV4-2, Forging : JIS SFVAF22B,

Seamless Pipe : JIS STPA24

Fig. 3 Material and weld lines of the HTTR RPV

309
 ( R P V top head)
Stand-pipe a
D
Stand-pipe b
Welding |
Top head
dome
Top head
flange Welding SR Final Welding SR(local)
machining
Shell flange

(RPV body)

Shell (upper)
Forming Welding
Shell (lower) Shipping^
Welding Welding SR Final Hydrostatic
Bottom head machining test
petal
7
Bottom head V
dome Forming |Welding | | Welding Welding

Skirt
Forming 11 Welding

Fig. 4 Fabrication procedure of the HTTR RPV

outside. After welding the top head dome to the upper flange, a large forging, stress relieving
(SR) and final machining was performed. Then stand-pipes were welded to the top head
dome, followed by local stress relieving as shown in Fig. 4.

Cylindrical shell of the HTTR RPV is made up of four plates formed and welded together
as shown in Figs. 3 and 4. The shell was welded to the shell flange, a large forging. The
bottom head petal, a large forging, was welded to the bottom head dome, which consists of
formed four plates, and the skirt. These were then welded together, building up the RPV
body, and stress relieving and final machining was conducted.

For the welding of the large components, automatic narrow-gap (groove) MIG welding,
developed by Babcock-Hitachi, K. K. and schematically shown in Fig. 5, was mainly
utilized. The narrow-gap MIG welding is superior to ordinary submerged arc welding (SAW)
in the following points:

(i) higher ductility of weld and narrower heat-affected zone is attained because of
smaller heat input,

(ii) smaller number of path reduces probabilistic occurrence of weld defect,

(iii) smaller amount of welding consumables is needed by adopting square groove.

Hydrostatic test of the RPV at the fabricator was performed before shipping. The RPV
was transported to Oarai Research Establishment, JAERI in August 1994. After the
installation of the RPV body into the containment vessel, reactor internals started to be
installed, which was followed by closing of the RPV top head in October 1995. After that
stand-pipe closures with control rods, surveillance holders, etc. were fixed. Pressure test of
the primary and secondary cooling system including the RPV was performed successfully in
March 1996.

Bending
Roller
Wire feed
Roller
Torch
Groove

Fig. 5 Mechanism of automatic narrow-gap MIG welding

311
3. Material

Because fluence of the RPV is calculated to be less than lxlO 17 n/cm2 (E>1 MeV),
neutron irradiation embrittlement is presumed to be negligible. However, the integrity of the
RPV can be impaired due to temper embrittlement at 400 °C. For the purpose of reducing
embrittlement, content of some elements is limited on 2 1/4 Cr-1 Mo steel for the HTTR
RPV using embrittlement parameters:
J-factor = (Si+Mn)(P+Sn) x 104 < 100 (Si, Mn, P, Sn : wt%) (1)
X = (10P+5Sb+4Sn+As)/100 < 10 (P, Sb, Sn, As : ppm) (2)
which is called HTGR specification and applied to both base metal and weld metal. J-factor
is a commonly used parameter proposed by Watanabe et al. [3]. This factor implies that the
impurities Si (silicon) and Mn (manganese) alone in the absence of P (phosphorus) and Sn
(tin) cannot cause any embrittlement. Similarly in the absence of Si and Mn, P and Sn, do
not cause any embrittlement. It is indicated by Viswanathan and Jaffee [4] that the former
coincide with their study but the latter does not, that is Si and/or Mn do not cause temper
embrittlement in the absence of the impurity elements P and Sn, however, the combination
(P+Sn) is capable of causing significant embrittlement in the absence of Mn and Si contrary
to the predictions of the J-factor. Thus it is necessary to employ the other parameter X .

Base metal

Figure 6 shows J-factor and X of nineteen heats of manufactured 2 1/4 Cr-1 Mo steels for
the HTTR RPV. J-factor and X ranges from 25 to 55 and from 4.1 to 8.3 respectively, which
satisfies the HTGR specification. Regarding the plates and four large forgings, the top head
dome, top head flange, shell flange, and bottom head petal, which consist main part of the
RPV, J-factor and X are less than 38 and 5.1 respectively. For these nineteen heats of 2 1/4
Cr-1 Mo steel, J-factor and X exhibit almost linear relation. Chemical composition and the
embrittlement factors, J-factor and X, of ten components of the RPV are shown in Table 2,
see also Fig. 3 pointing the components with names in boxes.

Figure 7 shows one example of correlation between J-factor and increase in 50 percent
ductile-to-brittle fracture appearance transition temperatures (AFATT) from the paper by
Viswanathan and Jaffee [4]. According to the figure, which arranges long term (20,000 to
60,000 hr) isothermal embrittlement studies in the range 343 °C to 510 °C on numerous
heats of commercial, heavy section 2 1/4 Cr-1 Mo steels in a variety of product forms, the
AFATT becomes less than 10 °C when J-factor is less than 50. Most components of the
HTTR RPV fulfill this condition except some medium and small forgings whose values
exceed it a little.

Figure 8 shows distribution of nil-ductility transition temperature, TNDT, correlated to J-

factor. The figure contains 68 results (some of which overlap each other) of drop weight tests
on the components made from the nineteen heats of steels. It should be noted that for all the
components reference temperatures, RTNDT, became equal to the nil-ductility transition
temperatures, TNDT. The TNDT or RTNDT lies in the range -80 °C to -30 °C, satisfying another
HTGR specification that RTNDT should be less than -20 °C. Because TNDT depends on
manufacturing process, the results scatter for components of the same heat. Although J-factor
is usually related to increase in ductile-to-brittle transition temperatures, it seems to have
weak correlation with TNDT.

312
 Table 2. Chemical composition and reference temperature (RT N D T) on some components of HTTR reactor pressure vessel

(wt%)
Forging C Si Mn P S Cr Mo Cu Ni V Co Al Sn As Sb X J RTNDT
(ladle analysis) (ppm) (wt%) (°C)
JIS spec. £0.15 £0.50 0.30- £0.030 £0.030 2.00- 0.90-
(SFVAF 22B) 0.60 2.50 1.10
HTGR spec. £10 £100 £-20
Top head dome 0.14 0.07 0.55 0.003 0.001 2.29 .06 0.04 0.08 0.005 0.008 <0.005 0.003 0.003 0.0009 5.0 37.2 -50
Top head flange 0.14 0.04 0.54 0.003 0.001 2.29 .05 0.04 0.09 0.005 0.009 <0.005 <0.003 0.004 0.0010 5.1 34.8 -65
Shell flange 0.14 0.03 0.54 0.003 0.003 2.29 1.00 0.03 0.10 0.005 0.008 <0.005 O.003 <0.003 0.0010 5.0 34.2 -55
Bottom head petal 0.15 0.05 0.55 0.003 0.001 2.30 .05 0.03 0.04 0.005 0.007 <0.005 <0.003 0.003 0.0011 5.0 36.0 -35
Nozzle 1 0.13 0.07 0.46 0.006 0.002 2.44 .05 0.02 0.04 0.006 0.007 0.003 0.003 0.002 0.0006 7.7 47.7 -40
Stand-pipe 1 0.12 0.10 0.45 0.005 0.003 2.32 1.03 0.03 0.04 0.006 0.006 0.003 0.003 0.002 0.0007 6.8 44.0 -60
Stand-pipe 2 0.14 0.10 0.46 0.006 0.004 2.37 1.05 0.03 0.06 0.007 0.007 0.003 0.003 0.003 0.0008 7.9 50.4 -65
Plate Si Mn Cr Mo Cu Ni Co Al Sn As Sb X J RTNDT
(ladle analysis) (ppin) (wt%)
JIS spec. £0.17 £0.50 0.30- £0.030 £0.030 2.00- 0.90-
(SCMV4-2) 0.60 2.50 1.10
HTGR spec. £10 £100 £-20
Shell 1 0.15 0.10 0.55 0.003 0.001 2.45 1.06 0.01 0.15 0.010 0.006 0.019 0.001 0.002 <0.001 4.1 26.0 -55
Shell 2 0.14 0.10 0.57 0.004 0.001 2.43 1.05 0.01 0.17 0.010 0.006 0.011 0.001 0.002 <0.001 5.1 33.5 -55
Seamless pipe C Si Mn P S Cr Mo Cu Ni V Co Al Sn As Sb X J RTNDT
(ladle analysis) (ppm) (wt%)
JIS spec. £0.15 £0.50 0.30- £0.030 £0.030 1.92- 0.87-
(STPA24) 0.60 2.60 1.13
HTGR spec. £10 £100 £-20
Stand-pipe 3 0.11 0.02 0.48 0.005 0.002 2.35 0.99 0.02 0.05 0.010 0.004 0.002 0.002 0.002 0.001 6.5 35.0 -30
Note: RT NDT (reference temperature) was equal to TNDT (nil-ductility transition temperature) regarding all the components above.

Weld C Si Mn P S Cr Mo Cu Ni V Co Al Sn As Sb X J RTNDT
(ppm) (wt%)
JIS spec, of wire £0.15 0.20- 0.40- £0.025 £0.025 2.10- 0.90- £0.40
(YG2CM-A) 0.90 1.40 2.70 1.20
HTGR spec. £10 £100 £-20
Wire 0.12 0.38 0.86 0.007 0.007 2.33 1.12 0.01 0.002
u> Weld metal 0.12 0.22 0.63 0.005 0.006 2.25 1.05 0.03 0.02 0.003 0.003 0.004 0.002 0.002 0.001 6.0 60.0 -35
 10

8 . AA
C
A :^ A

A
o
X 6
c§to
rnrn
• Plate
O Lame forging
A Medium and sm all forging
O Seamless pipe

20 30 40 50 60
J-factor

Fig. 6 Distribution of X and J-factor on 2 1/4 Cr -1 Mo steel

for the HTTR RPV

314
 600

Fig. 7 Correlation between J-factor and AFATT by Viswanathan and Jaffee [3]

Weld metal

The embrittlement parameters, J-factor and X, derived by check analysis of weld metal of
the HTTR RPV ranged from 60 to 84 and 6.0 to 9.0 respectively, which satisfies the HTGR
specification. The values of J-factor of weld metal are larger than those of base metal,
because content of silicon (Si) and manganese (Mn) of the weld metal is higher than that of
the base metal, as shown in Table 2. Applying the J-factor to Fig. 7, maximum embrittlement
potential (AFATT) of the weld metal is estimated to be roughly 30 °C. The AFATT at 400
°C, which is temperature of the HTTR RPV at normal operation, is predicted to be lower
than the estimated value, because Fig. 7 includes data at as high as 510 °C.

Thus it is concluded that increase in reference temperatures RTNDT on the HTTR RPV due
to irradiation and temper embrittlement is presumed to be small for both the base and weld
metal.

Fracture toughness requirements

For the purpose of preventing brittle fracture, Japanese regulation on fracture toughness
requirements on RPVs for Light Water Reactors, which is based on ASME Code Section III
and Nuclear Regulation Commission 10CFR Ch. 1 Part 50 Appendix G, is applied to the
HTTR RPV. For example, the temperature of the closure flange regions that are highly
stressed by the bolt preload must exceed the reference temperature of the material in those
regions by at least 67 °C (120 °F) for normal operation, when pressure exceeds 20 percent of
the preservice system hydrostatic test pressure. Because reference temperature of the weld

315
 -20
O
O A
-40 ZA

A A
• KD O A AA
9 -60 n
i i n
i i
A A AA

• O
A
• O
^ ^
-80
. --~~ifFp ate
OL arge forging
AN edium and snail forging
OS eamless pipe
-100
20 30 40 50 60
J-factor

Fig. 8 Relation between TmT and J-factor on 2 l/4Cr-lMo steel

for the HTTR RPV

316
metal is -35 °C as shown in Table. 2, temperatures of the top head and shell flange of the
HTTR RPV must exceed 52 °C:
-35 + 67 + 20 (predicted increase in reference temperature) =52 (°C)
at normal operation including start-up of the reactor.

Though primary coolant of the HTTR can be preheated by three primary gas circulators
before start-up of the reactor, temperature of the primary helium coolant with small heat
capacity decreases rapidly when secondary (water) cooling system start operating. Thus
special start-up procedure has to be taken for the HTTR, which is still being considered.

Surveillance test

Surveillance tests on materials of the HTTR RPV will be performed in order to examine
transition of mechanical properties of the materials due to irradiation and temper
embrittlement. In addition to the mandatory tensile test and Charpy impact test, fracture
toughness test for determination of JIC, and test based on Magnetic Interrogation Method [5] for
assessment of material deterioration and remaining life of the RPV. Surveillance test items
are shown in Table. 2.

Surveillance test specimens are stored in 12 holders, which are installed close to inner
surface of cylindrical shell of the RPV. During the operation of the HTTR for 20 years, the
specimen holders are taken out four times: three holders at a time. The post-irradiation tests
are planned to be performed at JMTR hot laboratory, JAERI. Temperature and dose of the
specimens are measured by temperature monitors and dosimeters stored in the holder
respectively.

4. Conclusion
Fabrication, examination and testing of the HTTR RPV completed successfully in March
1996. By limiting content of elements on 2 1/4 Cr-1 Mo steel, especially impurities of Si, P,
Sb, and Sn, temper embrittlement as well as irradiation embrittlement of the RPV is
presumed to be small.

Table 3. Surveillance test items of the HTTR reactor pressure vessel

Plate Forging
(base metal, H. A. Z., weld metal) (base metal)
Tensile test 0 0 0 0
Charpy impact test 0 0 0 O
Fracture toughness 0 0 0 0
test
Magnetic 0 0 0 -
Interrogation
Method [5]

317
 References

[1] S. Terado, Y. Tachibana, K. Kunitomi, and Y. Fukaya, "Design and Fabrication of HTTR
Reactor Pressure Vessel," Report of the Japan Atomic Energy Research Institute, JAERI-
Tech 96-034,1996. (in Japanese)
[2] S. Saito, et al., "Design of High Temperature Engineering Test Reactor (HTTR)," Report
of the Japan Atomic Energy Research Institute, JAERI1332, 1994.
[3] J. Watanabe, et al., "Temper Embrittlement of 2 1/4 Cr-1 Mo Pressure Vessel Steel,"
Presented at ASME 29th Petroleum Mech. Eng. Conf, Dallas, Sept. 15-18, 1974.
[4] R. Viswanathan and R. I. Jaffee, "2 1/4 Cr-1 Mo Steels for Coal Conversion Pressure
Vessels," Journal of Engineering Materials and Technology, Vol. 104, pp. 220-226, 1982.
[5] K. Ara, N. Nakajima, N. Ebine, K. Sakasai, "Magnetic Interrogation Method for
Nondestructive Measurement of Radiation Hardening of Nuclear Reactor Pressure
Vessels," Proc. of 8th Int. Conference on Pressure Vessel Technology, Canada, pp. 183-
189, 1996.

318