The Post-Irradiation Examination of Fuel in Support of Bruce A Nuclear Division Fueling With Flow Program

Abstract

Bruce A Nuclear Division (BAND) units are operating at - 75% of full power, because of the potential of a power pulse in the event of an inlet header break. As a result, BAND is converting to fueling with flow, to eliminate the potential of a power pulse and to allow for full-power operation. Concerns regarding the integrity of the end-of-life (EOL) bundles interacting with the latch at the downstream end of the fuel channel were raised. BAND carried out a test program in which EOL bundles in the upstream position 13 of Unit 2 were cascaded into the downstream latch position 1 of another channel. Six of twelve cascaded bundles and two typical EOL position 13 (benchmark) bundles were selected for post-irradiation examination (PIE). Incipient cracks were found in the assembly welds (endplate- to-endcap welds) of all six cascaded bundles. No incipient cracks were found in the benchmark bundles. Metallographic and fractographic examination, along with crack dating, and hydrogen and deuterium analyses, indicated that the incipient cracks were the result of delayed-hydride assisted cracking at the EOL. Consequently, Ontario Hydro changed the design of the outlet shield plug to support all three rings of the fuel bundle, to minimize stress and prevent endplate cracking. Also, an ultrasonic endplate inspection tool (UT) was developed and located in the fuel bay, to inspect fuel- bundle endplates for cracks. A second test was done involving a series of four bundle cascades in BAND Unit 4 channels that had new outlet shield plugs. The latch bundles were discharged after a hot shutdown. The cascaded Unit 2 and Unit 4 latch bundles were checked for cracks using the UT. The PIE found incipient cracks or less-than-ideal welds in the assembly welds of fael elements from Unit 2 (latch-supported fuel bundles) that had been identified by the UT as having incipient cracks. No incipient cracks were found in the assembly welds of fuel elements from Unit 4 (new outlet shield-supported fuel bundles) confirming the UT results.