Enhanced VVER-1000 Fuel Technology and Performance

H. Shah – G. Raspopin - NAEK

Westinghouse Electric Columbia NAEC “Energoatom”,
5801 Bluff Rd Vetrova 3, Kiev, Ukraine,01032
Columbia SC 29250 g.raspopin@direkcy.atom.gov.ua
shahhh@westinghouse.com Tel: 380 (44) 201 - 0918
(803) 647-3703
J. Sparrow-
R. Latorre – Westinghouse Electric Columbia
Pacific Northwest National Laboratory 5801 Bluff Rd
902 Battelle Boulevard St. Columbia SC 29250
P.O. Box 999, MSIN K6-66 sparr1ja@westinghouse.com
Richland, WA 99352 USA (803) 647-3698
richard.latorre@pnl.gov
Tel. (509) 372-4418

ABSTRACT

Westinghouse introduced six (6) Lead Test Assemblies (LTAs) for the VVER1000 fuel in the South
Ukraine 3 reactor. This design included advanced VVER1000 fuel features, which has performed
satisfactorily through three (3) annual cycles of operation, and has been reinserted for a fourth cycle.
This design is suitable for multi-region application, remedies known problems with fuel in this reactor
type, and addresses competing technical requirements. The design has been further enhanced to include
features that eliminate assembly bow leading to incomplete control rod insertion, reduce the potential for
grid-to-rod fretting, increase fuel economy, all the while being hydraulically & mechanically compatible
with the competitor core and multiple competitor fuel types.

Post Irradiation Examination was performed after completion of each cycle to assess the condition of all
structural components. Zr-1%Nb grids showed excellent weld integrity and absence of any undesirable
oxide levels. ZIRLOTM fuel rods also showed low to average level of oxides and excellent integrity.
Control Rod Assemblies drop times and pull loads were well within values expected for normal
operation.

Completion of 3 cycles of successful operation of LTAs have demonstrated acceptance of Westinghouse

use of Zr-1%Nb as grid material, and ZIRLOTM for fuel cladding and other structural components in
VVER1000 reactor environment. The enhanced design includes 13 of the 16 grids that use Zr-1%Nb
grids to increase fuel economy. The other 3 grids continue to use alloy 718 material to provide structural
stability. Westinghouse has further improved the design’s skeleton stiffness to gain margin to
incomplete rod insertion by strengthening thimble to grid connections. Out of pile mechanical tests on
the enhanced design have been performed which demonstrate skeletal structural stiffness equivalent to
designs that have performed successfully.

The new enhanced design applied fuel operational experience and blends design features from multiple
sources, including both favorable and unfavorable experiences from both Westinghouse and competitor
designs. The operational experience included Temelin fuel, TVEL (competitor) experience with multiple
fuel types, and the generally favorable experience with Westinghouse square-array fuel performance.
The effort enables success for Westinghouse customer and will help achieve their energy independence
objective.

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1.0 Introduction and Background

The United States Department of Energy, through the Pacific Northwest National Laboratory (PNNL),
provides management and technical support for the International Nuclear Safety Program (INSP) to
improve the safety level of VVER-1000 nuclear power plants in Central and Eastern Europe.

INSP is assisting the Ukraine Ministry of Fuel and Energy’s nuclear industry by transferring technology
and qualifying an U.S. supplier to provide fuel to the VVER-1000 reactor at South Ukraine Nuclear
Power Plant (SUNPP) Unit 3. SUNPP is a 950 MWe plant and is located near the city of
Yuzhnoukrainsk approximately 350 kilometers (over 200 miles) south of the capital Kiev. It is at present
the second largest of the five nuclear power stations in the country.

Westinghouse Electric Company was selected as the U.S. fuel developer and supplier to provide
technology transfer, Lead Test Assemblies (LTAs), and one or more reload batches of fuel assemblies to
NNEGC Energoatom’s SUNPP.

Westinghouse introduced six (6) modern LTAs for the SUNPP reactor in 2005. This modern design
(Figure1) included advanced VVER-1000 fuel features. To-date these LTAs have completed three (3)
cycles of operation, and are currently in the fourth operating cycle. This modern design is suitable for
multi-region application, remedies known problems with fuel in this reactor type, and addresses
competing technical requirements. This modern design has now been further enhanced to include
features that reduce even more the potential for assembly bow that can lead to incomplete control rod
insertion, reduce even more the potential for grid-to-rod fretting, increase fuel economy, all the while
being hydraulically & mechanically compatible with the existing reactor internals and multiple
competitor fuel types.

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Figure 1 – LTA and Enhanced Design Figure 2- Westinghouse LTA locations within core
Cycle 20

Westinghouse LTA locations within the core for cycle 20 are shown in Figure 2. The LTA 4th cycle
started Nov. 26th 2008 and expected to continue until Feb 1, 2010. LTAs are operating leaker free in the
4th cycle.

2.0 POST IRRADIATION EXAMINATION (PIE)

PIE was performed on each LTA after completion of each operating cycle to assess the condition of
structural components. The Zr-1%Nb grids showed excellent weld integrity and absence of any
undesirable oxide levels. ZIRLOTM fuel rods also showed low to average level of oxides and excellent
integrity. The Rod Cluster Control Assemblies (RCCA) drop times and drag loads were well within
values expected for normal operation

This following is a summary of PIE after the third cycle of LTA operation (examined September 2008, at
end of cycle 19) and comparison with the previous cycle. Specific items include visual inspections,
cladding integrity, RCCA drag forces, fuel assembly drag forces, and fuel assembly relative length
measurements.

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2.1 Fuel Assembly Visual Inspections

All six faces of each LTA were examined via remote control video camera. Full-length videos, both
analog and digital, were recorded for all 6 Fuel Assemblies.

The following subsections describe the LTA visual inspections and present a sample of the photographs
taken in the inspection following cycle 18 (2007) in comparison to the outcome from the inspection
following cycle 19.

2.2 Zr-1% Nb Grids

Each of the LTAs contains Zr-1% Nb material grids at grid elevations 9 and 14, counting from the
bottom. Particular focus was on these grids since this was a first time application of Zr-1%Nb material in
a Westinghouse fuel design.

Some Zr-1% Nb outer strap corrosion (in addition to that found on vertical welds) was observed. The
lighter color indicates corrosion on the outer strap. This is normal and consistent with corrosion
indication on the fuel rods. This appearance is typical of all PWR Fuel Assemblies with similar burn up,
see Figure 3.

Figure 3 - AA02-03 face 3 grid 9 (insp. 2008)

A light coloring along the outer strap vertical welds indicates that some corrosion is present but there is
no significant increase compared to last inspection, see Figure 4.

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 Figure 4 - AA02-03 face 3 grid 9 (insp.2007)

It is noted that the "rippling" effect of the laser welder is still visible, see Figure 5, indicating that the
corrosion thickness is minimal.

Figure 5 - AA 05-03 face 1 grid 9

Some grids have burnishing marks associated with vertical fuel assembly movement and sliding contact
with adjacent hardware, while other grids have no visible wear. In general, the amount of burnishing is
consistent along the vertical axis of a fuel assembly face.

2.3 Zr-1%Nb Inner Strap Intersect Welds

All faces on the Zr-1%Nb grids were inspected but on two different grids (in FA AA03-03 face 5 grid 14
and FA AA02-03 face 5 grid 9) extra inspection of the welds at the inner straps was performed by
zooming and changing the viewing angle. Figure 6 and Figure 7 shows the same grid intersection welds
at the two inspection intervals.

Figure 6 - AA02-03 face 5 grid 9 (insp.2008)

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 Figure 7 - AA02-03 face 5 grid 9 (insp.2007)

The video system was maneuvered to look past the grid outer straps and focus on inner strap intersect
welds of grid 14 (Zr-1%Nb material). This was done to investigate potential corrosion present in the
weld area. The inner strap thickness appears to be uniform within the resolution allowed by the
inspection equipment; this indicates that the level of corrosion is very low, as expected. Figure 8 and
Figure 9 show the same intersect welds on LTA AA03-03 face 14 at the two inspection intervals.

Figure 8 - AA03-03 face 1 grid 14 (insp. 2008)

Figure 9 - AA03-03 face 1 grid 14 (insp. 2007)

2.4 A718 Grids

All LTA top and bottom grids, as well as the non-Zr1%Nb mid-grids, are made of A718 material. All
grids were in very good condition and no defects were observed. Only some burnishing on the outer
strap surfaces was observed. In contrast to the Zr1%Nb grids, the outer strap vertical welds have

Page 6 of 14
retained the original color of the A718 grids. Two additional pictures are presented below (Figures 10
and 11) for reference.

Figure 10 - AA03-03 face 1 grid 12 (inspection 2008)

Figure 11 - AA03-03 face 1 grid 12 (inspection 2007)

2.5 Fuel Rod Growth

During Fuel Assembly fabrication process, the fuel rod bottoms are axially aligned to within a few
millimetres, see Figures 12 and 13.

Rod tops are also well aligned except for a few "short" rods due to normal and allowable welding rework
during manufacture. An adequate clearance remains between the rod tops and the top nozzle adaptor
plate (at least 1.5 rod diameters, or 0.540 in). Figures 14 and 15 show the fuel rod tops and bottoms on
LTA AA02-03 face 4, in comparison to the condition observed in 2007 and confirm that fuel rod growth
was normal with substantial gap remaining after 3 cycles.

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Figure 12 - Inspection 2008

Figure 13 - Inspection 2007

Figure 14 - Inspection 2008

Figure 15 - Inspection 2007

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2.6 Fuel Rod Corrosion

The LTA photographs taken, especially for AA03-03, can be used to examine fuel rod corrosion (by
surface appearance) as a function of elevation (Figures 16 through 27). Photographs were taken at several
elevations for face 1 of AA03-03, and therefore this is used as the example case. The pictures at the
lowest axial elevation, Figure 21 and Figure 27, shows the fuel rod bottoms, in which all of the rods
exhibit a solid, clean appearance. When the span between grids 2 and 3 is reached, the fuel rods take on
a mottled appearance with lightly shaded spots and patches of oxide. The oxide coating is predominant
between grids 6 and 7, although the underlying surface is still visible. The span between grids 9 and 10
is mostly covered by the oxide but still exhibits some marbling, though the different in comparison to
inspection 2007 is a lighter coloring; likewise between grids 13 and 14, the coloring is lighter than
inspection 2007. Finally, the fuel rod tops acquire a solid, light grey coloring. These indications confirm
that the corrosion performance is normal, and well within acceptable limits for the operational times
experienced by these fuel assemblies.

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 Figure 22 - Fuel Rod Tops (insp. 2007)
Figure 16 - Fuel Rod Tops (insp. 2008)

Figure 17 - Between Grids 13 & 14 (insp 2008) Figure 23 - Between Grids 13 & 14 (insp 2007)

Figure 18 - Between Grids 9 & 10 (insp 2008) Figure 24 - Between Grids 9 & 10 (insp 2007)

Figure 19 - Between Grids 6 & 7 (insp 2008)

Figure 25 - Between Grids 6 & 7 (insp 2007)

Fig. 26 Between Grids 2 & 3 (insp 2007)

Figure 20 - Between Grids 2 & 3 (insp 2008)

Fig. 27 Fuel Rod Bottoms (insp 2007)

Figure 21 - Fuel Rod Bottoms (insp 2008)

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2.7 Top and Bottom Nozzles

Each LTA has been operated in an RCCA core location and for a complete inspection the RCCAs were
removed. No abnormal conditions were detected in this part of the fuel assemblies, even though on the
inside of the top nozzle of LTA AA06-03, see Figure 28, a small flake of debris apparently floated unto
the top plate. This debris was subsequently washed away successfully as part of the inspection
procedures.

Figure 28 - AA06-03 Top Nozzle

The entire bottom nozzles were also inspected and while some minor burnishing was evident, no unusual
conditions were found, see Figure 29.

Figure 29 - AA03-03 face 6 Bottom Nozzle

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2.8 Fuel Rod Clad Integrity

Sipping tests have been conducted as required by the SUNPP procedures. After three cycles of operation
there has been no evidence that any of the LTAs have leaked, and they have all been found fit for return
to service.

2.9 RCCA Drag Forces

RCCA drag tests were performed as part of the PIE at the end of Cycle 17 and during core offload after
Cycle 18. These results indicated that the RCCA drag forces were well within the expected values for
this design and comparable to those of the co-resident fuel. For this most recent completed cycle, Cycle
19, all six of the LTAs were in control rod locations. SCRAM tests were performed at the beginning and
end of this cycle. The SCRAM times at the end of Cycle 19 were well below the specified limit and well
within the drop times of the control rods in the assemblies of the co-resident fuel. This indicates that the
drag of the RCCAs in the six LTAs is low.

2.10 Fuel Assembly Core Offload Drag Forces

The Westinghouse LTAs unloaded from the core after their third cycle, Cycle 19, were well within the
allowable drag force limits. This indicates that the six LTAs have not experienced unacceptable
distortion.

2.11 Fuel Assembly Relative Length Measurements

The length differences across the 6 LTAs were measured to be less than 2 mm also meeting the plant
criterion.

4.0 SUMMARY OF 3rd CYCLE PIE

The LTA inspection program for the SUNPP Unit 3 2008 refueling outage (end of Cycle 19) was
completed satisfactorily and in full scope. A commission composed of SUNPP, the Center for reactor
Core Design of Ukraine, Westinghouse, and PNNL concluded that the 6 Westinghouse LTAs may be
used in the SUNPP Unit 3 cycle 20 operation. Specific conclusions of the inspection were:

1. All LTAs were found to be hermetically sealed based on leak test.

2. Mechanical integrity of fuel rods and other components was maintained and all fuel rods were
straight.

3. None of the LTAs had indications of damage or improper positioning of the fuel assembly
components that can result in mechanical interaction (engagement) with the adjacent core
components and fuel handling equipment.

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4. The LTAs and RCCAs were removed from the core within the design force limits in each of the 6 W-
LTAs in accordance with the working SUNPP, Unit 3 core reload schedule.

5. The difference in the 6 W-LTA lengths after three years of operation did not exceed 2 mm.

6. The maximum control rod drop time in the W-LTAs at end of cycle in hot reactor state with four
loops in operation was well within design specification.

7. No fretting or any other type of wear scars were present.

8. Corrosion on the fuel rods was well within expected levels.

9. The grids were all intact.

10. No excessive corrosion on the Zr-1%Nb grids.

11. No excessive corrosion on the welds of the Zr-1%Nb grids (inner and outer straps).

12. Inside of top nozzle after a few SCRAMs had no indications of scratching, wear or damage of any
kind.

5.0 FURTHER DESIGN ENHANCEMENTS

Westinghouse has further improved the design’s skeleton stiffness to gain margin on potential
incomplete rod insertion by strengthening thimble to grid connections. One of the design enhancements
introduced is a double bulge at each grid location vs. a single bulge at each grid location. This is shown
schematically in Figures 30 for the LTA design and in Figure 31 for the new enhanced design.

Figure 30 - LTA Design Figure 31 - Enhanced Design

Effect of design enhancement is shown in Figure 32 in terms of lateral stiffness improvements that have
been made on the SUNPP Unit 3 VVER1000 fuel design and shows a relative comparison to the lateral
stiffness of the VVANTAGE 6 fuel design which recently eliminated the incomplete rod insertion in the

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Temelin core. Out of pile mechanical tests on the enhanced design have been performed which
demonstrate skeletal structural stiffness equivalent to designs that have performed successfully.

Skeleton Stiffness

3.5
3

Relative Stiffness
2.5
2
1.5
1
0.5
0
VVER1000 Enhanced VV6 Enhanced
LTA VVER1000 VV6
Design

VVER1000 VV6

Figure 32 - Relative Lateral Stiffness Comparisons

Use of additional Zr-1%Nb grids will further improve Fuel Cycle Cost (Approximately 1%).
Westinghouse has verified that even with the above design change, otherwise well proven design
characteristics still remain well within design criteria

6.0 OVERALL SUMMARY

Completion of 3 cycles of successful operation of LTAs have demonstrated acceptance of Westinghouse

use of Zr-1%Nb as grid material, and ZIRLOTM for fuel cladding and other structural components in
VVER1000 reactor environment. The enhanced design includes 13 of the 16 grids that use Zr-1%Nb
grids to increase fuel economy, while improving lateral stiffness and improving resistance to incomplete
rod insertion. The other 3 grids continue to use alloy 718 material.

The Westinghouse LTAs were designed to operate in the VVER-1000 type reactor. The design is
compatible with other SUNPP Unit 3 fuel designs during transition and meets all design acceptance
criteria for the reactor. Superseding previous design fuel with stainless steel thimbles and grids, non-
removable nozzles, and low burnup capability, the Westinghouse VVER-1000 fuel assembly is designed
for improved fuel economics, performance margins, and reliability.

The new enhanced design applies fuel operational experience and blends design features from multiple
sources, including both favorable and unfavorable experiences from both Westinghouse and competitor
designs. The successful demonstration of this project enables application of fuel in region quantities and
will help achieve Ukraine’s energy independence objective.

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