Darlington NGD Fuel Handling Head Eight Acceptance Program

Abstract

Darlington NGD requires eight fuelling machine heads to fuel the 4*932MW reactors. Six heads are used on the three fuelling machine trolleys for normal fuelling operations. A further two heads are required to allow for maintenance and to provide for such reactor face activities as PIPE and CIGAR. Seven heads were successfully delivered to site - from the head supplier. During acceptance testing, stalls on the charge tube screw assembly of the eighth and final head prevented its delivery to site. Replacement of the charge tube screw with a spare screw did not alleviate the problem. An in depth series of tests were undertaken at site, at the supplier and at the screw sub-supplier to determine the root cause of the problem. These tests included taking torque measurements under different operating conditions and using different components to assess the effects of the changes on torque levels. An assessment of the effects of changing chemical conditions (particularly crud levels) was also made. To ensure that the results of the testing were well understood, additional torque testing was also completed on a head and screw assembly at site that was known to work well. Based on all of the above series of tests, a recommendation was made to re-machine the charge tube screw(s). The original charge tube screw from Head eight was subsequently returned to the sub-supplier for re-work. Follow-up torque measurements and acceptance testing showed that the screw re-work was effective and that Head eight could be successfully delivered to site. This paper focuses on the results of the head/screw test program. Results of the acceptance testing are also discussed.