EPRI MRP Research on Irradiation Effects on PWR Internals Materials NRC-ANL Meeting
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EPRI MRP Research on Irradiation Effects on PWR Internals Materials NRC-ANL Meeting
EPRI MRP Research on Irradiation Effects on PWR Internals Materials NRC-ANL Meeting September 25-26, 2007 H. T. Tang EPRI MRP Internals Program Development Time Line Summary 1999 - 2000 1999 - 2003 Owners Groups © 2007 Electric Power Research Institute, Inc. All rights reserved. 1999 - 2007 EPRI 2006 - 2008 2005 - 2007 Utility, EPRI, NEI EPRI, Utilities 2 2009 Cracked Baffle/Former Bolts Crack N° 1 © 2007 Electric Power Research Institute, Inc. All rights reserved. 3 MRP PWR Internals Testing Projects – Objectives • Characterize irradiated PWR internals materials properties – Mechanical Property – IASCC Susceptibility – IASCC Initiation/Growth – Fracture Toughness – Microstructure/Void swelling – Thermal Aging/Irradiation Embrittlement Synergism (CASS) – Stress Relaxation/Creep • Develop irradiated materials screening criteria, material constitutive equation and damage threshold – for functionality/safety analysis and I&E Guidelines Development © 2007 Electric Power Research Institute, Inc. All rights reserved. 4 IASCC Initiation – Functional Parameters • Radiation • Stress • Time • Temperature • Environment • Materials © 2007 Electric Power Research Institute, Inc. All rights reserved. 5 Dpa Distribution Example Former Elevation 4 Location A B C D © 2007 Electric Power Research Institute, Inc. All rights reserved. N eutron Fluence (E > 1.0 MeV) [n/cm 2] 1.69e+22 9.37e+22 1.34e+22 6.70e+22 Atom D isplacements [dpa] 24.7 136 19.7 97.3 6 Reactor Spectrum Profiles © 2007 Electric Power Research Institute, Inc. All rights reserved. 7 MRP PWR Internals Testing Projects • • • • • • International IASCC Project GONDOLE Void Swelling Experiment Halden Crack Growth Project BORIS 7 Irradiated Materials Testing – Completed Decommissioned PWR Materials Testing – Completed JOBB Program – Completed © 2007 Electric Power Research Institute, Inc. All rights reserved. 8 Program Materials Program Alloy Component US Baffle-Former bolts CW316 SS Baffleformer bolts Baffleformer bolts 347SA SS CW304 SS International IASCC Adv. Com. Decommissioned 304 SS JOBB/MRP PWR CW316 SS Lock bars & washers BMI thimble PWR CW 316 SS Bar BOR60 304SA SS Baffle PWR 304SA SS Former PWR 304SA SS Barrel PWR 304SA SS Baffleformer bolts PWR bolting PWR Baffleformer bolts Core barrel weld PWR bolting BOR60 CW316 SS-W 304SA SS- FTI 308 SS WeldFTI 347SA SS-W © 2007 Electric Power Research Institute, Inc. All rights reserved. Irradiation Source PWR PWR BOR60 BOR60 BOR60 Irradiation environment Water 8-15 dpa Water 2-21 dpa Water 20 dpa Water 01-65 dpa Sodium 0, 20, 40 dpa Water 0-23 dpa Water 0-18 dpa Water 0-0.07 dpa Water 0-23 dpa Sodium 0, 20 dpa Sodium 0, 20 dpa Sodium 0, 20 dpa Sodium 0, 20 dpa 9 Hot Cell Testing Program Alloy Component Tensile Fracture Toughness SSRT US B-F bolts CW316 SS x x x x x x CW304 SS CW316 SS Baffleformer bolts Baffleformer bolts Lock bars BMI thimble x x x x x x CW 316 SS 304SA SS Bar Baffle x x x x x x 304SA SS 304SA SS 304SA SS Former Barrel Baffleformer bolts Baffleformer bolts Baffleformer bolts Core barrel weld Baffleformer bolts x x x 347SA SS International IASCC Adv. Com. Decommissioned 304 SS MRP - Bor-60 Irradiation CW316 SS-W 304SA SS- FTI 308 SS WeldFTI 347SA SS-W © 2007 Electric Power Research Institute, Inc. All rights reserved. x x x Crack Crack initiation growth rate x x x x x x x x x x x x x Microstructure /swelling x x x x x x x x x x x x x x x x x 10 PWR Internals Testing Projects • • • • • • International IASCC Project GONDOLE Void Swelling Experiment Halden Crack Growth Project BORIS 7 Irradiated Materials Testing Decommissioned PWR Materials Testing JOBB Program © 2007 Electric Power Research Institute, Inc. All rights reserved. 11 International IASCC Advisory Committee Project – International Cofunding • Goals – To quantify mechanical and corrosion properties of highly PWR spectrum irradiated PWR internals materials • Tensile • Crack initiation (IASCC) • Microstructure – To provide database and crack initiation model for PWR internals long-term operation functionality analysis • Status – Phases 1, 2 and 3 completed; Phase 4 being proposed • Project Materials – Thimble tubes from PWRs – Samples from decommissioned Zorita – Phase 4 Program © 2007 Electric Power Research Institute, Inc. All rights reserved. 12 Thimbles Tested in Phase 3 80 76 Ringhals Beaver Valley Robinson dpa 60 51 40 31 20 0 0 Thimble Tip 25 Top of Active Fuel (5.2") © 2007 Electric Power Research Institute, Inc. All rights reserved. 50 75 100 Distance from Thimble Tip, inches 125 150 Bottom of Active Fuel (149.2") 13 Beaver Valley Thimble Sections BV-1B 1 to 38 dpa BV-2B 51 to 51 dpa BV-3B 1 to 38 dpa © 2007 Electric Power Research Institute, Inc. All rights reserved. 14 dpa Ranges for Individual Thimble Sections Plant Beaver Valley Unit 1 H. B. Robinson Unit 2 Ringhals Unit 2 Section Length Thimble Section ID inches cm BV-1B 17.40 44.2 BV-2B 14.50 BV-3B dpa Change over Section Length dpa Range per inch per cm 1 to 38 2.1 0.8 36.8 51 to 51 0 0 17.00 43.2 1 to 38 2.2 0.9 HBR-9B 5.98 15.2 17 to 22 0.8 0.3 HBR-10A 17.01 43.2 26 to 30 0.2 0.09 RG-1 9.45 24.0 9 to 50 4.3 1.7 RG-2 9.50 24.1 76 to 76 0 0 RG-3 4.25 10.8 52 to 61 2.1 0.8 RG-4 5.65 14.4 29 to 52 4.1 1.6 © 2007 Electric Power Research Institute, Inc. All rights reserved. 15 O-Ring Stress State © 2007 Electric Power Research Institute, Inc. All rights reserved. 16 Crack Initiation Model based on Phases 2 and 3 Results 120% Chooz A Failures Non-Failures Barsback Bugey 2 % of Irradiated Yield Strength 100% 80% Failures stress threshold 60% Non-Failures 40% Functionality Analysis Curve 20% 0% 0 10 20 30 40 50 60 70 80 dpa © 2007 Electric Power Research Institute, Inc. All rights reserved. 17 Phase 4 Proposed Program • Test highly irradiated PWR internals harvested from Zorita, a decommissioned Spanish PWR – Maximum fluence ~ 58 dpa – 304SS, 316SS, 347SS, Inconel-X750, Inconel-600, CF8 Cast Austenitic • Mechanical properties • IASCC Crack Initiation/Growth • Fracture toughness • Void Swelling • Provide needed highly PWR irradiated materials data Program is planned for 2008 to 2010 pending materials samples harvesting, scope definition and international cofunding © 2007 Electric Power Research Institute, Inc. All rights reserved. 18 Zorita Plant • PWR – decommissioned • 160 MWe 1 Loop • Initial criticality: 06·1968 Commercial start: 02·1969 • 38 years of operation (26 EFPY) • Highest fluence regions ~ 58 dpa José Cabrera (Zorita) Nuclear Power Plant Photograph courtesy of Foro Nuclear © 2007 Electric Power Research Institute, Inc. All rights reserved. 19 Prospective Phase 4 Cofunding Members • Japan – Kyushu Electric Power Co. – Shikoku Electric Power Co. – Hokkaido Electric Power Co. • Europe – NOK – TRACTEBEL Engineering – VATTENFALL/RINGHALS AB • US – EPRI – NRC (Materials Samples Harvesting and Shipping) © 2007 Electric Power Research Institute, Inc. All rights reserved. 20 MRP PWR Internals Testing Projects • • • • • • International IASCC Project GONDOLE Void Swelling Experiment Halden Crack Growth Project BORIS 7 Irradiated Materials Testing Decommissioned PWR Materials Testing JOBB Program © 2007 Electric Power Research Institute, Inc. All rights reserved. 21 GONDOLE Experiment in Osiris Reactor (CEA Saclay) for Swelling Assessment • Goals – To quantify void swelling of PWR spectrum irradiated PWR internals materials – To provide database and void swelling model for PWR internals long-term operation functionality analysis • Approach – Irradiate PWR internals materials in mixed spectrum Osiris reactor • Project Materials – Virgin PWR internals materials – Pre-irradiated materials • Status – Ongoing (2004-2011) © 2007 Electric Power Research Institute, Inc. All rights reserved. 22 Background SA304SS > SA316SS > CW316SS SA 304SS % Swelling SA 316SS CW 316SS Irradiation Dose, dpa 304SA at 1.4E-8 dpa/s 0.020 300C 0.018 320C 340C 0.016 360C 380C 0.014 Volumetric Swelling • Limited PWR data show very small swelling (low dose CW316, SA304 and SA347) • Fast reactor data, many from nonPWR type of materials, show significant void swelling under high dose and temperature conditions • 304 appears to swell more that 316 • Swelling is coupled with state of creep and stress relaxation • Need PWR spectrum high dose and high temperature swelling data to develop PWR applicable void swelling models Typical Swelling Response for Stainless Steels at Breeder Reactor Temperatures 400C 0.012 0.010 0.008 0.006 0.004 0.002 0.000 0 2 4 6 8 10 Time (years) © 2007 Electric Power Research Institute, Inc. All rights reserved. 23 12 14 16 18 20 GONDOLE Scope • Collect available virgin and irradiated materials • Prepare material samples – TEM – Density – Temperature variation • Irradiate samples in the Osiris test reactor (mixed spectrum) • Evaluate results • Develop void swelling model © 2007 Electric Power Research Institute, Inc. All rights reserved. 24 GONDOLE Experiment Conditions Temperature 360°C - 400°C Damage dose per year 3.5 dpa + measurements 4.5 dpa without unloading max dose: 15 dpa © 2007 Electric Power Research Institute, Inc. All rights reserved. Unirradiated materials SA / CW 304 and 316 Weld Materials, …. Materials already irradiated with mixed spectrum 25 GONDOLE Experiment Swelling Specimens Density Irradiated and unirradiated • Weight ≈ 0.5 g thickness ≈ 1.5 mm or • Swelling measurements Discs φ 3 mm Irradiated and unirradiated • Microstructure • Small Punch Test + Micro-hardness • Swelling Specimens with thermal gradient (flux gradient) Unirradiated 1 or 2 SA 304 or CW 316 Temperature 360°C - 400°C Damage dose per year 3.5 dpa + measurements 4.5 dpa without unloading "Representative" of the baffle plate or bolt max dose: 15 dpa © 2007 Electric Power Research Institute, Inc. All rights reserved. 26 PWR Internals Testing Projects • • • • • • • Overview International IASCC Project GONDOLE Void Swelling Experiment Halden Crack Growth Project BOR 60 Irradiated Materials Testing Decommissioned PWR Materials Testing JOBB Program © 2007 Electric Power Research Institute, Inc. All rights reserved. 27 Halden Crack Growth Test in PWR Environment • Obtain in-pile, long term, crack growth data under PWR operating conditions (active flux environment) • Test specimens from preirradiated materials harvested from PWR and BWR (LWR irradiated) • Cofunded by BWRVIP and FRP • Year to year commitment pending testing scope and cofunding from BWRVIP and FRP © 2007 Electric Power Research Institute, Inc. All rights reserved. Outlet thermocouples Fe/Fe 3 O4 electrode Test Setup 2 Pt electrodes Displacement Gauge Irradiated insert: 304 SS Fluence: ~9.0 x 10 21 n/cm 2 Booster rod Irradiated insert: 347 SS Fluence: ~1.5 x 10 21 n/cm 2 Irradiated insert: 347 SS Fluence: ~1.5 x 10 21 n/cm 2 GT ND Irradiated insert: 316 NG Fluence: ~0.9 x 10 21 n/cm 2 Pt electrode Inlet thermocouples 28 Materials Samples © 2007 Electric Power Research Institute, Inc. All rights reserved. 29 Crack Growth vs. Yield Strength © 2007 Electric Power Research Institute, Inc. All rights reserved. 30 PWR Internals Testing Projects • • • • • • • Overview International IASCC Project GONDOLE Void Swelling Experiment Halden Crack Growth Project BOR 60 Irradiated Materials Testing Decommissioned PWR Materials Testing JOBB Program © 2007 Electric Power Research Institute, Inc. All rights reserved. 31 BOR-60 Irradiated Materials Testing • Goals – To quantify mechanical and corrosion properties of fast reactor spectrum irradiated PWR internals materials (accelerated irradiation testing) • Tensile • Fracture Toughness • Crack initiation • Microstructure – To provide database and predictive equations for PWR internals longterm operation functionality analysis • Approach – Irradiate representative PWR Internals materials samples in BOR-60 • Project Materials – – – – SA 304L Baffle plates, Formers, Core barrel CW 316, 347 Baffle bolts 308 Welds, 304 HAZ CASS © 2007 Electric Power Research Institute, Inc. All rights reserved. 32 JOBB Materials in BOR 60 - Boris 6 & 7 Materials Specimen type 5 dpa 308 TIG/MIG weld and 304 HAZ (CE) 304 SA and CW (CE) Tensile O-ring CT 3mm disc Tensile O-ring CT 3mm disc Tensile O-ring CT 3mm disc Tensile O-ring CT 3mm disc 12 2 1 16 6 1 0 8 0 0 0 0 19 5 6 24 316 two heats (W, EDF) Cast austenitic – as-received & two levels of thermal aging* (W) 10 dpa 20 dpa 40 dpa 9 2 2 16 12 2 1 16 12 3 0 16 13 3 6 24 15 4 2 16 14 3 2 16 7 3 0 16 0 0 0 0 *400 oC for 100 and 1000 hours © 2007 Electric Power Research Institute, Inc. All rights reserved. 33 4 0 0 16 5 2 2 16 5 1 0 16 0 0 0 0 Fracture Toughness Testing • CT specimens – B: 5mm, W: 20mm – 304 SS & 308 SS – irradiated in BOR-60 fast reactor to 6-48 dpa • 8 specimens precracked at RT – 7 tested @ 320 °C – 1 tested @ RT © 2007 Electric Power Research Institute, Inc. All rights reserved. 34 BOR-60 Fracture Toughness Testing Summary • 8 Specimens Tested – 304 SA: 6, 26, 26 and 48 dpa – 304 CW: 26 and 47 dpa – 308 Weld: 26 and 45 dpa • Results – 304 SA & 304 CW: toughness remaining high at high fluence when tested at 320°C – 304 SA: low toughness at high fluence when tested at RT – 308 Weld: low toughness at high fluence when tested at 320°C – Results are bound by lower bound curve defined for evaluation assessment • Low Temperature Intergranular Fracture – Observed in room temperature toughness test – Observed in all 304 SS precracks © 2007 Electric Power Research Institute, Inc. All rights reserved. 35 BOR-60 Crack Initiation Tests (O-rings) Specimen Number Material /Code Fluence (dpa) Test Temp. (°C) Targeted Test Stress YS at 330C (MPa) Applied Test Stress (MPa) 45 340 Y.S. 970 976 J5-41 316CW J1-44 308/J1 25.7 340 Y.S. 800 806 J7-44 304SA/J7 48.1 340 Y.S. 800 803 J2-43 HAZ 25 340 Y.S. 800 807 © 2007 Electric Power Research Institute, Inc. All rights reserved. 36 PWR Internals Testing Projects • • • • • International IASCC Project GONDOLE Void Swelling Experiment Halden Crack Growth Project BOR 60 Irradiated Materials Testing Decommissioned PWR Materials Testing – Completed • JOBB Program © 2007 Electric Power Research Institute, Inc. All rights reserved. 37 Baffle/Former Plate Sample Locations – SA304 Top of the upper baffle Upper Baffle 3 2 Lower region of the upper baffle 1 4 Core former location © 2007 Electric Power Research Institute, Inc. All rights reserved. 38 Core Barrel Sample Location 44” 324° © 2007 Electric Power Research Institute, Inc. All rights reserved. 39 Material Sample Dimensions Component Barrel Baffle 1 Baffle 2 Baffle 3 Baffle 4 Former © 2007 Electric Power Research Institute, Inc. All rights reserved. Length in (cm) Thickness in (cm) Width in (cm) 7.4 1.714 6.97 (-18.8) (-4.354) (-17.7) 7.59 (-19.28) 7.71 (-19.58) 7.68 (-19.51) 7.93 (-20.14) 5 (-12.7) 0.499 (-1.276) 0.501 (-1.273) 0.501 (-1.273) 0.502 (-1.275) 1.022 (-2.596) 1.36 (-3.45) 1.39 (-3.53) 1.48 (-3.76) 1.43 (-3.63) 5 (-12.7) 40 Specimen Cutting ½T-CT © 2007 Electric Power Research Institute, Inc. All rights reserved. 41 Radiation Analysis • 3D discrete ordinates transport code (TORT ORNL) • BUGLE-96 cross-section library (47 neutron and 20 gamma ray energy groups) • Three statepoints: BOL, MOL, and EOL. © 2007 Electric Power Research Institute, Inc. All rights reserved. 42 Radiation Analysis Baffle Plate Results - Midplane Macroscopic Sample Data from Decomissioned PWR Core Midplane XYZ TORT Fast (E > 1.0 MeV) Neutron Fluence and Stainless Steel 304 dpa Baffle Plate - Right Core Side Surface Point Phi dpa 1 1.5E+22 21.4 2 8.2E+21 11.9 3 1.5E+22 21.4 4 8.2E+21 11.9 Middle of Plate Point Phi 1 1.3E+22 2 6.9E+21 3 1.3E+22 4 6.9E+21 dpa 19.2 10.1 19.2 10.1 Back Side Surface Point Phi dpa 1 1.2E+22 17.3 2 5.7E+21 8.4 3 1.2E+22 17.3 4 5.7E+21 8.4 Looking at Sample from Core Side of Sample © 2007 Electric Power Research Institute, Inc. All rights reserved. Pnt 3 Pnt 4 Pnt 1 Pnt 2 43 Radiation Analysis Former Plate Results - Midplane Macroscopic Sample Data from Decomissioned PWR Core Midplane XYZ TORT Fast (E > 1.0 MeV) Neutron Fluence and Stainless Steel 304 dpa Former Plate 3 - Inner Corner Sample Bottom Surface Point Phi 1 1.2E+22 2 3.5E+21 3 4.2E+21 4 7.5E+21 dpa 18.1 5.3 6.3 11.1 Middle of Plate Point Phi 1 1.2E+22 2 3.6E+21 3 4.4E+21 4 7.7E+21 dpa 18.4 5.5 6.4 11.4 Top Surface Point Phi 1 1.2E+22 2 3.5E+21 3 4.2E+21 4 7.5E+21 Looking Down at Sample from Above Pnt 3 Pnt 4 Pnt 2 Pnt 1 © 2007 Electric Power Research Institute, Inc. All rights reserved. 44 dpa 18.2 5.3 6.3 11.1 Thermal Analysis Typical Heat Generation Rate © 2007 Electric Power Research Institute, Inc. All rights reserved. 45 Hot Cell Testing Program Alloy Component Tensile Fracture Toughness SSRT US B-F bolts CW316 SS x x x x x x CW304 SS CW316 SS Baffleformer bolts Baffleformer bolts Lock bars BMI thimble x x x x x x CW 316 SS 304SA SS Bar Baffle x x x x x x 304SA SS 304SA SS 304SA SS Former Barrel Baffleformer bolts Baffleformer bolts Baffleformer bolts Core barrel weld Baffleformer bolts x x x 347SA SS International IASCC Adv. Com. Decommissioned 304 SS MRP - Bor-60 Irradiation CW316 SS-W 304SA SS- FTI 308 SS WeldFTI 347SA SS-W © 2007 Electric Power Research Institute, Inc. All rights reserved. x x x Crack Crack initiation growth rate x x x x x x x x x x x x x Microstructure /swelling x x x x x x x x x x x x x x x x x 46 PWR Internals Testing Projects • • • • • International IASCC Project GONDOLE Void Swelling Experiment Halden Crack Growth Project BOR 60 Irradiated Materials Testing Decommissioned PWR Materials Testing – Completed • JOBB Program - Completed © 2007 Electric Power Research Institute, Inc. All rights reserved. 47 JOBB Tensile Tests Results (up to 125 dpa) at 330°C 1200 1200 1000 UTS (MPa) YS (MPa) 1000 800 600 800 600 400 CW 316 (300-330°C) 400 CW 316 (300-330°C) 200 SA 304 (300-330°C) 200 SA 304 (300-330°C) 0 0 20 40 60 80 100 120 140 0 20 40 60 dose (dpa) 80 100 120 140 dose (dpa) • Saturation of the hardening between 5 and 10 dpa; earlier for SA304 than for CW316 • Saturation hardening higher for 316CW (1000 MPa) than for 304SA (800 MPa) • No significant change between 10 and 125 dpa (at 330°C) © 2007 Electric Power Research Institute, Inc. All rights reserved. 48 JOBB Tensile Tests Results (up to 125 dpa) at 330°C 40 Total Elongation (%) Uniform Elongation (%) 2,5 2 CW 316 (300-330°C) 1,5 SA 304 (300-330°C) 1 0,5 30 CW 316 (300-330°C) SA 304 (300-330°C) 20 10 0 0 0 20 40 60 80 100 120 140 0 20 40 60 80 100 dose (dpa) dose (dpa) • UE saturation level higher for CW316 than for SA304, TE similar (8-10%) • No significant change between 10 and 125 dpa (at 330°C) © 2007 Electric Power Research Institute, Inc. All rights reserved. 49 120 140 JOBB Tensile Property Summary • Saturation of the tensile characteristics between 5 and 10 dpa; higher for 316CW than for 304SA • No significant change noticed between 10 and 125 dpa (at 330°C) • Residual ductility at saturation is significant at ~10% total elongation while uniform elongation is often <1% • No heat to heat variations of tensile properties after irradiation for CW 316 nor for SA 304 • 308 welds and CASS have roughly the same behaviour as SA 304 1 dpa ~ 7 x 1020 n/cm2 (E > 1.0 MeV) © 2007 Electric Power Research Institute, Inc. All rights reserved. 50 JOBB Creep-Irradiation Results (up to 120 dpa) Argon Diameter 5,65 mm 55 mm Diameter mm 70 dpa 52 dpa 41 dpa 28 dpa Unirradiated 6.5 Length mm Tube Length 6.0 0 © 2007 Electric Power Research Institute, Inc. All rights reserved. 10 20 30 40 50 51 Summary PWR internals material degradation mechanisms have been extensively studied Data obtained and to be obtained will support the development of degradation models The degradation models are technical bases for component screening functionality evaluation inspection findings evaluation and disposition flaw tolerance analysis inspection and aging management guidelines development © 2007 Electric Power Research Institute, Inc. All rights reserved. 52