Fabrication and quality control of MOX fuel for prototype fast breeder reactor
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12/18/2009 1
Fabrication and Quality Control Of Fuel For Prototype Fast Breeder
Reactor (PFBR)
Advanced Fuel Fabrication Facility,Bhabha Atomic Research Centre,
Tarapur, INDIA
J.P.Panakkal and H.S.Kamath
Presented By Presented By Dr. JOSE P. PANAKKALDr. JOSE P. PANAKKAL
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OUTLINE OF THE PAPER
� INTRODUCTION � MOX FUELS FOR FAST REACTORS� FABRICATION STEPS FOR PFBR� QUALITY CONTROL� CONCLUSION� ACKNOWLEDGEMENT
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Advanced Fuel Fabrication Facility (AFFF), BARC, Tarapur
Advanced Fuel Fabrication Facility Advanced Fuel Fabrication Facility (AFFF), BARC, Tarapur(AFFF), BARC, Tarapur
PHWR
FBTR
AHWR
Pu Bearing MOX Fuel Fabrication for Thermal & Fast ReactorsScope of work
(U~4%Pu) MOX for BWRs (TAPS)(U~0.4%Pu) MOX for PHWRs (KAPS)First stage
Second stage
Third stage (Th-3%Pu) MOX for AHWR
(U-44%Pu) MOX for FBTR(U-28%Pu) MOX for PFBR
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MOX FUELS FOR FAST EACTORS
MOX FUEL PINS FOR FBTR♣ (0.44 Pu – 0.56 U)O2
MIXED CARBIDE FUEL PINS FOR FBTR♣ (0.7 Pu – 0.3 U)C
MOX FUEL PINS FOR PFBR♣ ( 21% PuO2 & 28% PuO2)
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MOX Fuel for PFBR Technology Developed
a)a)Fabrication of annular pellets Fabrication of annular pellets using rotary pressusing rotary press
b)b)Sinter to sizeSinter to sizec)c)Dry Centreless grinding of Dry Centreless grinding of
oversize pelletsoversize pelletsd)d)Pellet inspection using Pellet inspection using
digital imagingdigital imaginge)e)Welding technology for DWelding technology for D--99
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12/18/2009 6FLOWSHEET OF MOX FUEL FABRICATION
FABRICATION OF PELLETS
ENCAPSULATION AND QUALITY CONTROL OF FUEL PINS
MIXING PRE-COMPACTION GRANULATION
FINAL COMPACTION SINTERING CENTRELESS GRINDING
PHYSICAL CHEMICAL
DEGASSING ENCAPSULATION He
-
LEAK TEST RADIOGRAPHY
WIRE WRAPPING DESPATCH
QUALITY CONTROL OF PELLETS
POWDER PROCESSING
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PuO2 UO2Attritor Milling
Precompaction& Granulation Compaction Sintering
Dry Centreless Grinding Vacuum Degassing
Stack Making Pellet Loading
Fuel Element Welding Decontamination
Packing & Transport
FUEL FABRICATION STEPSFUEL FABRICATION STEPSPu, Am, Isotopes, Impur.U, O/M, S.A, Impurities
NWCC
GranulometryDensity, Inspection
ρ, U/Pu, α- AutoradiographyPellet Inspection
H, O/M, F, Cl, Met. Impur.Stack Inspection, Visual
Metallography
He leak test, X-Radiography, XGAR,γ-scanning, Metrology, Visual
Final Inspection
PROCESS / Q.C. STEPSPROCESS / Q.C. STEPS
Oxidized Scrap
Microwave/Thermal Processing
CRO
DecladdingReject Elements
Rejects
Rejects
SCRAP RECYCLE SCRAP RECYCLE STEPSSTEPS
Wire Wrapping
Contamination check
FLOWSHEET OF PFBR MOX FUEL
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FABRICATION OF MOX FUELFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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COMPACTION PRESS AND COMPACTED PELLETSFR 09 Kyoto, JapanFR 09 Kyoto, Japan
12/18/2009 10AUTOMATION IN PELLET FABRICATION SYSTEM
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12/18/2009 11AUTOMATION IN FABRICATION SYSTEM
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12/18/2009 12PELLET TRANSFER SYSTEM
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PFBR PELLETS
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PFBR FUEL PIN
Spring Top Blanket Fuel Middle plug Bottom End Plug
Bottom BlanketSpring SupportTop End Plug
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Plug 6.6 mm 4.0 mm 5.71 mm
20 mm
5 mm
Clad
0.45 mm
Fit-up Of PFBR Tube With Plug (Before Welding)
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12/18/2009 16WELDING OF FUEL PIN
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WELDING OF FUEL PIN (CLOSEUP)FR 09 Kyoto, JapanFR 09 Kyoto, Japan
12/18/2009 18CLOSE VIEW OF LASER WELDING SETUP
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LASERWELD TIGWELD
Plug 6.6 mm 4.0 mm 5.71 mm
20 mm
5 mm
Clad
0.45 mm
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PFBR END PLUG WELDS
12/18/2009 20SPACER WIRE WRAPPING OF PFBR PINS
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12/18/2009 21PFBR FUEL PINS
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12/18/2009 22FR 09 Kyoto, JapanFR 09 Kyoto, Japan
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INITIAL INCOMING MATERIALS : HARDWARE, FUEL FEED MATERIALS
DURING PRODUCTION1. GREEN PELLETS : VISUAL, DENSITY, DIMENSIONS 2. SINTERED PELLETS : VISUAL, DENSITY AND
OTHER CHARACTERISTICS3. MONITORING VARIOUS PRODUCTION PARAMETERS AND
COMPARE WITH MANUFACTURING ENGINEERING INDEX 4. FUEL RODS5. FUEL BUNDLES6. DOCUMENTATION
QUALITY CONTROL IN A TYPICAL QUALITY CONTROL IN A TYPICAL FUEL FABRICATION PLANTFUEL FABRICATION PLANT
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12/18/2009 24FLOWSHEET OF PFBR MOX FUEL
PuO2 UO2Attritor Milling
Precompaction& Granulation Compaction Sintering
Dry Centreless Grinding Vacuum Degassing
Stack Making Pellet Loading
Fuel Element Welding Decontamination
Packing & Transport
FUEL FABRICATION STEPSFUEL FABRICATION STEPSPu, Am, Isotopes, Impur.U, O/M, S.A, Impurities
NWCC
GranulometryDensity, Inspection
ρ, U/Pu, α- AutoradiographyPellet Inspection
H, O/M, F, Cl, Met. Impur.Stack Inspection, Visual
Metallography
He leak test, X-Radiography, XGAR,γ-scanning, Metrology, Visual
Final Inspection
PROCESS / Q.C. STEPSPROCESS / Q.C. STEPS
Oxidized Scrap
Microwave/Thermal Processing
CRO
DecladdingReject Elements
Rejects
Rejects
SCRAP RECYCLE SCRAP RECYCLE STEPSSTEPS
Wire Wrapping
Contamination check
12/18/2009 25FR 09 Kyoto, JapanFR 09 Kyoto, Japan
Comparison of NWCC and Chemical Analysis Results of MOX Fuel for Fast Reactors
�
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� � � � � � � ��
Sample Number
NWCCNWCC
Chemical Chemical AnalysisAnalysis
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♦ DISTRIBUTION OF Pu♦ PuO2 AGGLOMERATES� ALPHA PARTICLES FALL ON
CELLULOSE NITRATE FILM � PROCESSED FILM REVEALS TRACKS� UNIFORMITY AND SIZE� COLOUR IMAGE
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ALPHA AUTO RADIOGRAPHY ALPHA AUTO RADIOGRAPHY
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ALPHA AUTORADIOGRAPH OF PFBR PELLETTransverse sectionTransverse sectionLongitudinal sectionLongitudinal section
PHOTOMICROGRAPHS OF PFBR PELLETPHOTOMICROGRAPHS OF PFBR PELLET
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Video Microscope For Micro structural Evaluation Of MOX Pellets
CCD Camera
Zoom Lens
Co-axial Light Source
Binocular Eye PieceSample Stage
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12/18/2009 29FR 09 Kyoto, JapanFR 09 Kyoto, Japan
12/18/2009 30VISUAL INSPECTION & PELLET SORTING SYSTEM
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1. 1. PuOPuO22% ENRICHMENT % ENRICHMENT 2. HEAVY METAL CONTENT2. HEAVY METAL CONTENT3. DISSOLUTION TEST 3. DISSOLUTION TEST 4. O/M RATIO4. O/M RATIO5. NON METALLIC IMPURITIES 5. NON METALLIC IMPURITIES 6. TRACE METALLIC IMPURITIES6. TRACE METALLIC IMPURITIES7. COVER GAS ANALYSIS7. COVER GAS ANALYSIS8. TOTAL GAS ANALYSIS8. TOTAL GAS ANALYSIS
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CHEMICAL CHARACTERISATION OF MOX FUELS
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TIG WELD X-RADIOGRAPHYFREEDOM FROM LACK OF PENETRATION
LACK OF FUSIONPOROSITY – INCLUSION-OTHER
MODIFICATIONS SHAPE CORRECTION BLOCKDEFECT STANDARDMICRODENSITOMETRY
ADVANCED IMAGE PROCESSINGTECHNIQUES REAL TIME MOTION RADIOGRAPHY
LINEAR ARRAY DETECTORSULTRASONICS
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END PLUG WELD
12/18/2009 33Radiography of End Cap Welds
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Shape Correction Block For PFBR End Cap Welds
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Slit
X-Ray Tube
Monitor
Fluoroscopic arrangement
Pin carriage
REAL TIME MOTION RADIOGRAPHYFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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ULTRASONIC END CAP WELD INSPECTION
Probe Water Tank
Clad
Plug
Beam Path
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Detection of a gross lack of penetration
%FSH
Beam Path (mm)
(a):Ultrasonic signal.
(b): Radiograph
(c): Photomicrograph
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GAMMA AUTORADIOGRAPHY (GAR)� PuO2 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 PuO2 ENRICHMENT� DEFECTS :
� PELLETS OF WRONG ENRICHMENT� PuO2 AGGLOMERATES IN THE PERIPHERY� COMPOSITIONAL VARIATION
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GAMMA AUTORADIOGRAPHY (GAR)� ANOTHER CHECK FOR PuO2 ENRICHMENT� ADDITIONAL QUALITY CONTROL STEP
INTRODUCED� MICRODENSITOMETRY� COLOUR GAMMA AUTORADIOGRAPHY� SIMPLE TEST� X-GAR : (X-RADIOGRAPHY+GAMMA AUTORADIOGRAPHY)
RESULTANT IMAGE GIVES ADDITIONAL INFORMATION ABOUT INTERNAL COMPONENTS LIKE SPRING, SPRING SUPPORT etc.
(Cont…)
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slit
TRAYFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slit
X- RAY CASSETTEFUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-RAYS
X-ray source
slit
FUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slitX-RAYS
FUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slitX-RAYS
FUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slit
TRAYFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slit
FUEL ELEMENTTRAYFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slit
X- RAY CASSETTEFUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-RAYS
X-ray source
slit
FUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slitX-RAYS
FUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slitX-RAYS
FUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slitX-RAYS
FUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-RAY GAMMA AUTO-RADIOGRAPHY
X-ray source
slitX-RAYS
FUEL ELEMENTFR 09 Kyoto, JapanFR 09 Kyoto, Japan
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X-GAR OF PFBR FUEL PIN
DDUO2 MOX
DDUO2 Plenum SpaceMiddle Plug
Spring support
Plenum Spring
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12/18/2009 54FR 09 Kyoto, JapanFR 09 Kyoto, JapanGamma Scanning of Fuel Elements
12/18/2009 55
Gamma scan of PFBR MOX fuel pins with varying composition
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� COLOUR, SPARKING, DENTS, � SCRATCHES� PHYSICAL DAMAGE� MANUAL : CCD-TV� METROLOGY : MECHANICAL
LVDTNONCONTACT (LASER)
SURFACE EXAMINATION AND SURFACE EXAMINATION AND METROLOGYMETROLOGY
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�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
TOTAL QUALITY CONTROL
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• PROCESS PARAMETERS FOR FABRICATION OF MOX FUEL FOR PFBR FINALISED.• ADVANCED TECHNIQUES FOR
FABRICATION AND QUALITY CONTROL DEVELOPED.• AUTOMATION TO REDUCE
MANREM
CONCLUSIONCONCLUSION
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� 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.
ACKNOWLEDGEMENT
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12/18/2009 60FR 09 Kyoto, JapanFR 09 Kyoto, Japan
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