Research Article |
Corresponding author: Alexander K. Podshibyakin ( podshibyakin@grpress.podolsk.ru ) Academic editor: Yury Kazansky
© 2023 Valentin M. Makhin, Alexander K. Podshibyakin.
This is an open access article distributed under the terms of the Creative Commons Attribution License (CC BY 4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.
Citation:
Makhin VM, Podshibyakin AK (2023) ‘Cliff edge effects’ in safety justification and operation of NPP units. Nuclear Energy and Technology 9(1): 33-42. https://doi.org/10.3897/nucet.9.100755
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The authors consider phenomena that have signs of ‘cliff edge effects’ according to the definitions of the IAEA and NP-001-15: (1) degradation of the protective barrier (fuel rod claddings in surface boiling mode with the deposition of impurities and borates on their surface and heating of the claddings) and (2) departure from nucleate boiling (DNB) on the fuel rod claddings. Despite the fact that the first phenomenon was previously unknown, the safety of the power unit is ensured by the decisions adopted in the project.
The DNB was studied and measures were taken in the project to prevent it under normal operating conditions and anticipated operational occurrences. The protection against the DNB is also obviously ensured by reducing the reactor power due to the control systems and reactor scram. These phenomena do not reach the state of ‘cliff edge effects’ (according to the terminology of the IAEA and federal NPs of the Russian Federation) and are prevented at the initial stages. For a small-size reactor using dispersive fuel, it is possible to provide self-protection against the DNB, namely, due to partial washout of the fuel with the insertion of negative reactivity, followed by a decrease in power and termination of the crisis.
Cliff edge effects, safety
The IAEA materials and the Russian Federal Standards and Regulations (FNP RF) introduce the concept of a cliff edge effect (
The paper presents information on the selected and explored phenomena, based on which a situation with the said ‘cliff edge effect’ could take place, and demonstrates technical solutions and measures to make sure that cliff edge effects are avoided.
The set of the incidents exemplified and the data considered in the paper is not exhaustive but allows, as the authors believe, assessing the sufficiency and timeliness of the measures taken in design of plants in the form of design margins, and in implementation of a full-scale defense-in-depth approach (Appendix 2 (
The IAEA materials define a cliff edge effect as follows: “A ‘cliff edge effect’, in a nuclear power plant, is an instance of severely abnormal plant behavior caused by an abrupt transition from one plant status to another following a small deviation in a plant parameter, and thus a sudden large variation in plant conditions in response to a small variation in an input” (
Attention needs to be focused on the quality of design, fabrication and operation expected to provide for such condition that “…a small deviation in a plant parameter does not lead to a cliff edge effect”, that is, there is a functional link between the quality of the power unit design, fabrication and operation and the conditions for a cliff edge effect to occur.
The following is noteworthy: “a small variation in an input” causes “an abrupt transition from one plant status to another following a small deviation in a plant parameter”. According to (
A Russian regulatory document, General Provisions for Ensuring Safety of Nuclear Power Plants (NP-001-15), (
A situation is also considered for the VVER power units of generation I (prior to upgrades), in which no NPP auxiliary power systems suggested full independence of the system channels (including the safety system channels). “A cliff edge effect consisted in this case in that the failure of one component, the plant’s dc board, could lead to cascade deterioration, up to a severe accident, in the nuclear power plant status due to a common-cause failure of systems and components” involved in different defense-in-depth levels (Appendix 2 (
In accordance with NP-001-15, the “NPP safety shall be ensured through the consistent implementation of defense-in-depth based on using a system of physical barriers to the spread of ionizing radiation and radioactive materials into the environment, and a system of engineering and organizational measures to protect the barriers and keep these efficient, as well as to protect personnel, the public and the environment”. The system of engineering and organizational measures shall form five defense-in-depth levels, the first of which (the conditions for the NPP deployment and prevention of operational occurrences) includes the development of the NPP design based on a conservative approach with a well-developed property of the reactor inherent safety and measures aiming to exclude the cliff edge effect as implemented in the considered example for plants of generation I.
Thus, NP-001-15 states that the NPP design shall include measures for avoiding a cliff edge effect. The criterion for such measures to be taken is justification of the required defense-in-depth (DID) efficiency at all levels while implementing the strategy for the preemptive prevention of unfavorable events at the first or second levels.
Par. 1.2.9 of NP-001-15 requires that deterministic and probabilistic safety analyses be provided for all operational states and all locations of nuclear materials, radioactive substances and radioactive waste in which there is a potential for an operational occurrence to take place.
In accordance with the NP-006-16 requirements for providing safety analyses, Chapter 15 reads: “It shall be justified for all operational states that the safety criteria are complied with during operational occurrences” and “The minimum (maximum) values shall be defined for the parameters that characterize the margins to the safety criteria”.
We shall remind that, in accordance with NP-001-15, safety criteria are the NPP parameters and/or characteristics in accordance with which the NPP safety is justified and which are set by regulatory documents or in the NPP design. At each DID level, the protection of the barriers is defined by the safety criteria set for each DID level not being exceeded (violated), including the safety criteria that limit radiation effects.
NP-001-15 also specifies the safety targets:
Therefore, implementing the targets specified in NP-001-15 makes it possible to assess the potential for the respective cliff edge effects to manifest themselves, which, subject to high quality of design, manifest themselves as a result of the transition from “operational states” to “accident conditions” and in a “major abrupt deterioration in safety” at all defense-in-depth levels. The higher is the quality of design, fabrication and operation, the smaller is the probability for a cliff edge effect to occur. And justifying the quality of design suggests justifying the consideration of all phenomena and processes that affect the state of the physical barriers as recommended in the IAEA document (
To demonstrate the practicability of the said principles and requirements, we shall discuss examples of effects that could be treated, under certain conditions, as cliff edge effects and that have failed, due to the measures taken in the design (“justification and application of design margins, as well as implementation of a full-scale defense-in-depth” and high quality of operating water-cooled power reactors), to evolve (most unlikely to occur!) with a negative radiation effect on the personnel, the plant, the environment and the public.
Since the potential source for radiation effects are primarily fuel rods that contain radioactive fission products, it is obvious that the experience of their service in reactor cores, as well as the results of tests and experiments with fuel rods and their dummies shall be analyzed when simulating ‘accident’ modes.
The fuel matrix and the fuel cladding are parts of the system of physical barriers to the spread of radiations and radioactive materials. Therefore, degradation of the protective properties of these components, implementation of the conditions for the radionuclide and irradiated fuel spreading due to the cladding failure, and the presence of radiation specific to these phenomena will characterize the hazard from the phenomena under consideration. The characteristics of the above barriers are expected to degrade as a result of the fuel cladding and fuel matrix temperature growth. This does not rule out other phenomena and processes, and does not narrow down the domain of ‘cliff edge effects’ in the light of the IAEA definition, but defines more exactly the objective of the study and makes it possible to trace how the quality of design limits or excludes the evolution of the process that can potentially lead to a ‘cliff edge effect’ (
The fuel rod properties are expected to degrade due to the interaction of the cladding material with the coolant and fuel at a high temperature. A temperature growth intensifies the processes of interaction. Oxidation and embrittlement of the cladding material (zirconium alloys) due both to restructuring and formation of hydrides with their undesired radial orientation, that affects the cladding strength, can be determining in terms of fuel failure and, ultimately, the escape of fission products from fuel rods into the coolant (
In operational states and in accident conditions, it is required to ensure not only that uranium fission products are localized and the absorbed dose is not exceeded for the public and personnel, but also that the core can be dismantled after the emergency process is over, excluding the processes taking place during severe beyond-design-basis accidents.
There is an example of the PWR operation when minor variations in one parameter, the fuel rod power density with a particular combination of the WC characteristics and the reactor lifetime, led to an Axial Offset Anomaly (AOA), that is, an anomaly of the axial power density distribution, a phenomenon earlier unknown in PWRs (
Such ‘earlier unknown processes’ manifested themselves when the reactor life was extended and the power of individual FAs was increased. The AOA was caused by the PWR operation cycle, i.e. the reactor life, extended to 16 to 18 months and by fuel with an increased enrichment used to that end, that is, when the earlier adopted design conditions were changed. As a result, such changes in the design conditions led to an increase in the power density in a number of fuel rod in the core and, sequentially, to a greater intensity of the surface boiling in the upper part of the reactor core. At the same time, as found in simulation tests in the Halden research reactor (
Porous deposits of corrosion products form on the fuel rod upper part surface in the mode under consideration, in which boron compounds concentrate and formation of such compounds as lithium metborate is possible (Fig.
Steam channels in deposits in high-energy areas of the PWR FA fuel rod surface a. A photograph with three regions (intermediate, light – ZrO2) (
Abnormal deposits of corrosion products also form in the FA upper part and the maximums of the deposit distribution match the violent coolant boiling areas in respective FAs. More high-energy assemblies have more deposits in the boiling areas. Coolant boiling is the key factor that induces the formation of deposits on the fuel rod surface. The considered process differs from the crud (coolant impurity) deposition in that the crud deposition can take place on the lower grids and lead to a growth in the pressure drop in the reactor core (
The formation of abnormal deposits and the AOA effect were observed not in all PWRs operating in the mode of an increased energy region. It has been found that, apart from surface boiling, the deposit growth rate is greatly influenced by:
For power units with no AOA, the concentration of nickel in the circuit coolant is in a range of 1 to 5 ppb; for comparison: the concentration of nickel for one of the power units with an AOA of 17% is 11 to 53 ppb.
Therefore, an increase in the FA energy with coolant boiling can lead to the surface deposits and cause overheating and oxidation of the fuel cladding with degradation of its protective properties. Processes are possible in deposits with concentration of the boron compounds leading to an AOA.
The adopted axial offset monitoring procedure makes it possible to record the AOA phenomenon. A reduction in the local power density after the boiling stops leads to the dissolution of borates. Specifically, the presence of lithium in the coolant confirms the dissolution of lithium metaborate and elimination of the anomaly. Therefore, there are means both for the process diagnostics and control.
Noteworthy is the complexity of the processes taking place in conditions of developed surface coolant boiling (see Fig.
It became possible to study and reproduce the phenomenon under consideration in a research reactor (Halden) (
The phenomenon with formation of abnormal deposits on the fuel cladding surface was not known earlier (at the design development stage). The process was stopped at early stages and explored through the design approaches taken (axial offset measurement and monitoring), as well as through engineering and organizational solutions practically implemented in the course of redesign in connection with a longer reactor life and the reactor power increase, namely, more accurate WC determination, boiling rate reduction, etc. It will be reasonable to note that the initial step was the reduction of power for investigating the phenomena. After the model representations were explored and developed, tests were conducted in the Halden reactor and proposals were prepared for excluding the phenomenon in question. This example demonstrates that it is possible to control the process at initial stages while avoiding the power emergency condition.
Channels with thermally profiled fuel rods were tested in the PV-2 loop facility of an NPP with the AM-1 reactor in Obninsk (
The design (safety) margin is estimated in this case as the difference in the power at the onset of the ‘heat-exchange drop’ and the critical power (~ 10%). One of the key ways to reduce the negative influence of the cliff edge effect on the NPP safety is to justify and use design margins (see Appendix 2 (
Of practical interest is an experiment conducted in the SM-2 reactor involving a process with local cladding and fuel melting. The purpose of the tests was to determine the fuel rod power at which the fuel rod fails in the DNB conditions (
The test fuel rod had the same shape and composition as the upgraded SM fuel rod (the content of 235U in the fuel rod is 6 g). The fuel rod is cross-shaped, and has a thin-wall stainless-steel cladding and UO2 fuel in a matrix of copper-beryllium bronze. There was a thermocouple installed in the fuel rod’s kernel the reliable contact with which is ensured by the fabrication technology (press molding and annealing). The fabrication technology also provides for the reliable thermal contact of the fuel matrix and the cladding. The SM fuel rod constant with water cooling at a rate of ~ 10 m/s is estimated at less than 0.1 s.
The test procedures, the fuel rod design and the test conditions are described in detail in (
An overall view of the irradiation device is presented in Figs
In Fig.
Violent fuel kernel temperature fluctuations were observed in Segment A (Fig.
With τ ≥ 50 s, the test parameters are as follows:
The design (safety) margin is estimated in this case as the difference in the fuel rod power in Segment B and at the beginning of Segment A (fuel rod temperature fluctuation onset, Fig.
The post-test inspection of the fuel element appearance showed a local damage area of about 40 mm long found 50 mm below the central section, and ~ 225 mm from the fuel rod top, at the computationally predicted point (Fig.
The adopted test termination procedure via scram, after the thermocouple reaches the emergency setting of 709 °C, (the scram delay is estimated at 0.14 s) limited the fuel melting and localized the damage with not more than 0.05% of the accumulated radionuclides having entered the coolant. The radioactivity of the nuclides that had left the fuel did not exceed the permissible activity value (the maximum value is not more than 1⋅10-4 Ci/l).
Therefore, the results of two in-pile DNB test types have been discussed. Using the terminology in (
The in-pile test results for thermally profiled dispersion fuel rods indicate to close values of the critical fuel rod power determined immediately in the in-pile tests, Np, and in bench conditions, Nc. The difference in the values Np and Nc is not large and amounts to (Nр – Nc)/Nc ≤ 13%.
Premature burnout occurs in harder conditions (in terms of temperature growth and the maximum temperature of the fuel composition). The pre-irradiation (bench) tests made it possible to calculate fairly correctly the location of the segment with local fuel rod melting and to minimize the radiation effects.
Noteworthy is the low fuel rod inertia and the fast rate of transition to the cladding and fuel matrix melting stage caused, primarily, by the small value of the fuel rod constant (~ 0.1 s) and by the high heat flux surface density value. The SM fuel rod constant is much smaller than the VVER fuel rod constant (by an estimated factor of 30). This example shows that the said conditions with a low-inertia fuel rod allow the process to be controlled without causing major fuel rod damage and a large quantity of radionuclides entering the circuit with the coolant.
Of practical interest is the possibility for the self-regulation of the process. The crisis is experienced by the segment with the maximum power and neutron flux density. A negative reactivity is inserted with the reactor power reduction as the fuel composition melts and is entrained by the coolant, that is, a local crisis with the fuel composition melting is self-regulated which is specific to small cores. The process regulations reflect the need for the shutdown at intermediate power levels with acquisition and analysis of the key sensor data. No reaching the subsequent power level is allowed before data on the radiation situation is available. This excludes the development of the emergency process after a local DNB occurs, the fuel matrix is washed out, and the reactor power is reduced. The presented data characterizes the dynamics of these processes. The peculiarities discussed indicate that it is possible to regulate or control the process.
DNB and post-DNB peculiarities are considered in (
Therefore, this conclusion proves that there is an additional FA critical heat flux margin estimated at ~ 10% and 3% in the considered AM and SM reactor tests. The difference in the design margin in the considered tests (10% and 3%) is defined by the ‘crisis’ types and by the difference in the fuel rod design and test modes.
An example of both the occurrence of the ‘cliff edge effect’ characteristics and the measures taken to avoid it in further operations is the experience of a power increase for phase 1 of the Beloyarsk NPP (
The notion of a ‘cliff edge effect’ is defined both in the IAEA documents and in Russian materials (NP-001-15). This is a “severely abnormal plant behavior caused by an abrupt transition from one plant status to another following a small deviation in a plant parameter”. Indeed, it has been shown by an example of analyzing the characteristics of fuel cladding as a safety barrier that no characteristics reach the limit values during normal operation, and there are design margins treated as defined in Appendix 2 (
Where current regulatory requirements for high quality of the reactor plant design, fabrication and operation are complied with, no ‘cliff edge effect’ is likely to occur. The sufficiency of the design measures taken or the design margins adopted to limit (avoid) this effect and correct the WC modes is shown by an example of an incident in new PWRs when an earlier unknown phenomenon manifested itself during operation with an axial offset anomaly (abnormal axial power density distribution in the core) and degradation of characteristics. Using the practically implemented engineering solutions adopted in the design development process (more accurate WC determination, boiling intensity reduction, etc.), the process was stopped at initial phases and investigated. After exploring the peculiarities of the coolant boiling in the FA upper part, determining more accurately the conditions for the deposition of boron compounds on the fuel rod surfaces in the boiling region, and reproducing these in a simulation experiment in Halden, measures were developed to avoid the above effect (more accurate WC determination, circuit cleaning, introduction of mixing grids in FAs, etc.).
Based on rather an extensive array of the actual AOA events, a conclusion can be made that the engineering solutions and design margins adopted in the design, as well as the requirements for the operation of NPPs with PWR reactors have ensured the safety of the NPP and excluded the negative development of the AOA effect. This effect did not occur in the VVER operation thanks to the design margins adopted in the development.
A DNB incident appears to be more hazardous. The in-pile tests were considered with two well-known DNB types (premature burnout and dryout). The tests have shown that the bench and in-pile test results are comparable (a power difference of up to 13%). The in-pile experiment conditions are predicted in a pre-irradiation computational analysis with an acceptable accuracy. No new phenomena were identified in the in-pile experiment. As compared with in-pile tests, bench test results are normally conservative, and provide, if used in the design, an additional design margin estimated as 3 and 10% for the two in-pile test modes (premature burnout and dryout). One can therefore believe that no fuel rod DNB occurs during normal operation (NO) and during operational occurrences (AOO) in the reactors, for which the tests have been conducted, thanks to the measures adopted in the design. It is required to investigate additionally the influence the transversal currents in the VVER reactor cores, made up of bare fuel assemblies, have on safety margins.
For small cores, e.g., in the SM reactor with a substantial power peaking, the occurrence of a local crisis with the fuel composition interaction with the coolant and the fuel and fission product being ‘washed out’ into (entering) the coolant is expected to lead to insertion of negative reactivity (self-regulation effect) and to a power reduction with limited fuel and fission product ‘washout’ into the coolant.
The phenomena and processes discussed herein may be ‘cliff edge effects’, as defined in (
The situations at the PWR and AMB reactors discussed in the paper occurred as the result of a power increase (AMB) or the reactor life extension (PWR), that is, when new modes were adopted. The design margins adopted in the design for the key parameters, e.g., for power, are ‘selected’. These modes adopted for economic reasons shall be comprehensively analyzed and investigated.