Dr. JOSE P. PANAKKAL

Transcription

1 Fabrication and Quality Control Of Fuel For Prototype Fast Breeder Reactor (PFBR) J.P.Panakkal and H.S.Kamath Advanced Fuel Fabrication Facility, Bhabha Atomic Research Centre, Tarapur, INDIA Presented By Dr. JOSE P. PANAKKAL 12/18/2009 1

2 OUTLINE OF THE PAPER INTRODUCTION MOX FUELS FOR FAST REACTORS FABRICATION STEPS FOR PFBR QUALITY CONTROL CONCLUSION ACKNOWLEDGEMENT 12/18/2009 2

3 Advanced Fuel Fabrication Facility Advanced (AFFF), Fuel BARC, Fabrication Tarapur Facility (AFFF), BARC, Tarapur Pu Bearing MOX Fuel Fabrication for Thermal & Fast Reactors Scope of work PHWR First stage (U~4%Pu) MOX for BWRs (TAPS) (U~0.4%Pu) MOX for PHWRs (KAPS) Second stage (U-44%Pu) MOX for FBTR (U-28%Pu) MOX for PFBR FBTR Third stage (Th-3%Pu) MOX for AHWR 12/18/ AHWR

4 MOX FUELS FOR FAST EACTORS MIXED CARBIDE FUEL PINS FOR FBTR (0.7 Pu 0.3 U)C MOX FUEL PINS FOR FBTR (0.44 Pu 0.56 U)O 2 MOX FUEL PINS FOR PFBR ( 21% PuO 2 & 28% PuO 2 ) 12/18/2009 4

5 MOX Fuel for PFBR Technology Developed a) a)fabrication of annular pellets using rotary press b)sinter to size c)dry Centreless grinding of oversize pellets d)pellet inspection using digital imaging e)welding technology for D-9D 12/18/2009 5

6 POWDER PROCESSING MIXING PRE-COMPACTION GRANULATION FABRICATION OF PELLETS FINAL COMPACTION SINTERING CENTRELESS GRINDING QUALITY CONTROL OF PELLETS PHYSICAL CHEMICAL ENCAPSULATION AND QUALITY CONTROL OF FUEL PINS - DEGASSING ENCAPSULATION He LEAK TEST RADIOGRAPHY WIRE WRAPPING DESPATCH FLOWSHEET OF MOX FUEL FABRICATION 12/18/2009 6

7 SCRAP RECYCLE STEPS Oxidized Scrap Microwave/ Thermal Processing CRO Rejects Rejects Decladding Reject Elements FUEL FABRICATION STEPS PuO 2 UO 2 Attritor Milling Precompaction& Granulation Compaction Sintering Dry Centreless Grinding Vacuum Degassing Stack Making Pellet Loading Fuel Element Welding Decontamination Wire Wrapping Packing & Transport PROCESS / Q.C. STEPS Pu, Am, Isotopes, Impur. U, O/M, S.A, Impurities NWCC Granulometry Density, Inspection ρ, U/Pu, α- Autoradiography Pellet Inspection H, O/M, F, Cl, Met. Impur. Stack Inspection, Visual Metallography Contamination check He leak test, X-Radiography, XGAR, γ-scanning, Metrology, Visual Final Inspection FLOWSHEET OF PFBR MOX FUEL 12/18/2009 7

8 FABRICATION OF MOX FUEL 12/18/2009 8

9 COMPACTION PRESS AND COMPACTED PELLETS 12/18/2009 9

10 AUTOMATION IN PELLET FABRICATION SYSTEM 12/18/

11 AUTOMATION IN FABRICATION SYSTEM 12/18/

12 PELLET TRANSFER SYSTEM 12/18/

13 PFBR PELLETS 12/18/

14 PFBR FUEL PIN Spring Top Blanket Fuel Middle plug Bottom End Plug Top End Plug Spring Support Bottom Blanket 12/18/

15 Fit-up Of PFBR Tube With Plug (Before Welding) 20 mm Clad Plug 6.6 mm 4.0 mm 5.71 mm 5 mm 0.45 mm 12/18/

16 WELDING OF FUEL PIN 12/18/

17 WELDING OF FUEL PIN (CLOSEUP) 12/18/

18 CLOSE VIEW OF LASER WELDING SETUP 12/18/

19 PFBR END PLUG WELDS LASER WELD 20 mm TIG WELD Clad Plug 6.6 mm 4.0 mm 5.71 mm 0.45 mm 5 mm 12/18/

20 SPACER WIRE WRAPPING OF PFBR PINS 12/18/

21 PFBR FUEL PINS 12/18/

22 12/18/

23 INITIAL INCOMING MATERIALS : HARDWARE, FUEL FEED MATERIALS DURING PRODUCTION 1. GREEN PELLETS : VISUAL, DENSITY, DIMENSIONS 2. SINTERED PELLETS : VISUAL, DENSITY AND OTHER CHARACTERISTICS 3. MONITORING VARIOUS PRODUCTION PARAMETERS AND COMPARE WITH MANUFACTURING ENGINEERING INDEX 4. FUEL RODS QUALITY CONTROL IN A TYPICAL 5. FUEL BUNDLES 6. DOCUMENTATION FUEL FABRICATION PLANT 12/18/

24 SCRAP RECYCLE STEPS Oxidized Scrap Microwave/ Thermal Processing CRO Rejects Rejects Decladding Reject Elements FUEL FABRICATION STEPS PuO 2 UO 2 Attritor Milling Precompaction& Granulation Compaction Sintering Dry Centreless Grinding Vacuum Degassing Stack Making Pellet Loading Fuel Element Welding Decontamination Wire Wrapping Packing & Transport PROCESS / Q.C. STEPS Pu, Am, Isotopes, Impur. U, O/M, S.A, Impurities NWCC Granulometry Density, Inspection ρ, U/Pu, α- Autoradiography Pellet Inspection H, O/M, F, Cl, Met. Impur. Stack Inspection, Visual Metallography Contamination check He leak test, X-Radiography, XGAR, γ-scanning, Metrology, Visual Final Inspection FLOWSHEET OF PFBR MOX FUEL 12/18/

25 NWCC Chemical Analysis Sample Number Comparison of NWCC and Chemical Analysis Results of MOX Fuel for Fast Reactors 12/18/

26 ALPHA AUTO RADIOGRAPHY DISTRIBUTION OF Pu PuO2 AGGLOMERATES ALPHA PARTICLES FALL ON CELLULOSE NITRATE FILM PROCESSED FILM REVEALS TRACKS UNIFORMITY AND SIZE COLOUR IMAGE 12/18/

27 PHOTOMICROGRAPHS OF PFBR PELLET Longitudinal section Transverse section ALPHA AUTORADIOGRAPH OF PFBR PELLET 12/18/

28 Binocular Eye Piece Sample Stage Zoom Lens CCD Camera Co-axial Light Source Video Microscope For Micro structural Evaluation Of MOX Pellets 12/18/

29 12/18/

30 VISUAL INSPECTION & PELLET SORTING SYSTEM 12/18/

31 CHEMICAL CHARACTERISATION 1. PuO 2 % ENRICHMENT 1. OF MOX FUELS 2. HEAVY METAL CONTENT 3. DISSOLUTION TEST 4. O/M RATIO 5. NON METALLIC IMPURITIES 6. TRACE METALLIC IMPURITIES 7. COVER GAS ANALYSIS 8. TOTAL GAS ANALYSIS 12/18/

32 END PLUG WELD TIG WELD X-RADIOGRAPHY FREEDOM FROM LACK OF PENETRATION LACK OF FUSION POROSITY INCLUSION-OTHER MODIFICATIONS SHAPE CORRECTION BLOCK DEFECT STANDARD MICRODENSITOMETRY ADVANCED IMAGE PROCESSING TECHNIQUES REAL TIME MOTION RADIOGRAPHY LINEAR ARRAY DETECTORS ULTRASONICS 12/18/

33 Radiography of End Cap Welds 12/18/

34 Shape Correction Block For PFBR End Cap Welds 12/18/

35 X-Ray Tube Monitor Pin carriage Slit Fluoroscopic arrangement REAL TIME MOTION RADIOGRAPHY 12/18/

36 ULTRASONIC END CAP WELD INSPECTION Probe Water Tank Beam Path Clad Plug 12/18/

37 % F S H (a):ultrasonic signal. Beam Path (mm) (b): Radiograph (c): Photomicrograph Detection of a gross lack of penetration 12/18/

38 GAMMA AUTORADIOGRAPHY (GAR) PuO 2 AGGLOMERATE AND COMPOSITION BY NDE X RAY FILMS IN PVC CASSETTES KEPT IN CONTACT WITH WELDED RODS DARKENING OF THE PROCESSED FILM IS PROPORTIONAL TO PuO 2 ENRICHMENT DEFECTS : PELLETS OF WRONG ENRICHMENT PuO2 AGGLOMERATES IN THE PERIPHERY COMPOSITIONAL VARIATION 12/18/

39 GAMMA AUTORADIOGRAPHY (GAR) ANOTHER CHECK FOR PuO 2 ENRICHMENT ADDITIONAL QUALITY CONTROL STEP INTRODUCED MICRODENSITOMETRY COLOUR GAMMA AUTORADIOGRAPHY SIMPLE TEST (Cont ) X-GAR : (X-RADIOGRAPHY+GAMMA AUTORADIOGRAPHY) RESULTANT IMAGE GIVES ADDITIONAL INFORMATION ABOUT INTERNAL COMPONENTS LIKE SPRING, SPRING SUPPORT etc. 12/18/

40 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit TRAY 12/18/

41 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit FUEL ELEMENT X- RAY CASSETTE 12/18/

42 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit X-RAYS FUEL ELEMENT 12/18/

43 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit X-RAYS FUEL ELEMENT 12/18/

44 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit X-RAYS FUEL ELEMENT 12/18/

45 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit TRAY 12/18/

46 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit TRAY FUEL ELEMENT 12/18/

47 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit FUEL ELEMENT X- RAY CASSETTE 12/18/

48 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit X-RAYS FUEL ELEMENT 12/18/

49 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit X-RAYS FUEL ELEMENT 12/18/

50 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit X-RAYS FUEL ELEMENT 12/18/

51 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit X-RAYS FUEL ELEMENT 12/18/

52 X-RAY GAMMA AUTO-RADIOGRAPHY X-ray source slit X-RAYS FUEL ELEMENT 12/18/

53 X-GAR OF PFBR FUEL PIN Plenum Spring Spring support DDUO 2 MOX DDUO 2 Plenum Space Middle Plug 12/18/

54 Gamma Scanning of Fuel Elements 12/18/

55 Gamma scan of PFBR MOX fuel pins with varying composition 12/18/

56 SURFACE EXAMINATION AND METROLOGY COLOUR, SPARKING, DENTS, SCRATCHES PHYSICAL DAMAGE MANUAL : CCD-TV METROLOGY : MECHANICAL LVDT NONCONTACT (LASER) 12/18/

57 TOTAL QUALITY CONTROL MORE NDE AND PROCESS CONTROL CHECKS INCREASE RELIABILITY AND CONFIDENCE AND HENCE REDUCE DESTRUCTIVE TESTS e.g. PuO2 ENRICHMENT MONITORED AT DIFFERENT STAGES BY NWCC, PGS, GAR. REDUCTION OF DESTRUCTIVE CHEMICAL ANALYSIS CHEMICAL ANALYSIS NEEDED FOR SAMPLES NEAR THE LIMITS COMBINATION OF PROCESS AND QUALITY CONTROL CHECKS IMPROVE THE QUALITY OF THE FUEL INTELLIGENT PROCESSING TECHNIQUES-FOR TQM 12/18/

58 CONCLUSION CONCLUSION PROCESS PARAMETERS FOR FABRICATION OF MOX FUEL FOR PFBR FINALISED. ADVANCED TECHNIQUES FOR FABRICATION AND QUALITY CONTROL DEVELOPED. AUTOMATION TO REDUCE MANREM 12/18/

59 ACKNOWLEDGEMENT THE AUTHORS WISH TO THANK OUR COLLEAGUES OF ADVANCED FUEL FABRICATION FACILITY, BARC FOR THEIR CO-OPERATION AND HELP. THE FINANCIAL SUPPORT RECEIVED FROM INTERNATIONAL ATOMIC ENERGY AGENCY IS GRATEFULLY ACKNOWLEDGED. 12/18/

60 12/18/