Patent Application
20090060114
The present invention relates to a nuclear fuel assembly including a fuel bundle and a tie plate for supporting the fuel assembly and, particularly, relates to a debris shield that is releasably attached to or permanently integrated with an Upper Tie Plate (UTP) of the fuel assembly.
In a nuclear fuel assembly, liquid coolant/moderator flows into the assembly thru the bottom and exits as a water and steam mixture from the top. The core of a boiling water nuclear reactor (BWR) includes a plurality of fuel assemblies arranged in vertical side-by-side relation, each containing a bundle of fuel rods. The fuel assemblies include a fuel bundle and a housing formed by a hollow metal channel. The fuel bundle includes an array of parallel fuel rods, water rods and one or more tie plates, spacers, and finger springs, that support the rods in the bundle. Generally, a fuel bundle includes an upper tie plate near the top of the bundle and a lower tie plate at the bottom of the bundle.
Debris may fall through a conventional upper tie-plate and become lodged within the fuel bundle where the debris may cause fuel rod fretting during normal BWR operating conditions. Fretting is potentially damaging to the fuel rods, resulting in what is typically known in the business, as a “leaker”.
Conventional efforts to address debris falling down into a fuel assembly typically focus on the prevention of debris within the coolant itself and coolant flow passages, prior to coolant flow entering into the fuel assemblies within the core. Conventional efforts typically involve administrative controls regarding the treatment of coolant flow passages and handling of fuel assemblies such that debris does not enter the passages of the fuel assemblies. These controls are designed to alleviate the sources of debris such that debris does not fall down into fuel assemblies. Nevertheless, there is a risk that debris will fall into a fuel assembly, especially while the coolant flow stops and the reactor core is open, or when service work is preformed on the core. There is a long felt need for procedures and special devices to ensure that debris does not fall into fuel assemblies from above, especially during refuel operations, fuel inspections and when the coolant is in a reverse coolant flow pattern.
A nuclear reactor fuel assembly comprising: a fuel bundle including an array of fuel rods mounted in an upper tie plate and housed within a channel, and a debris shield in the upper tie plate and above the fuel rods, wherein the debris shield has a surface at least co-extensive with an at least partially open area of the upper tie plate.
A nuclear reactor fuel assembly has been developed including: an upper tie plate having apertures to receive and support fuel rods of a fuel bundle; the fuel bundle including an array of the fuel rods mounted and housed in walls of a channel, and a debris shield which can be either a removable unit, or it can be attached as a permanent integrated structure that is mounted within the upper tie plate, wherein the shield is porous.
A nuclear reactor fuel assembly has been developed comprising: a fuel bundle including an array of fuel rods mounted in an upper tie plate and housed within a channel, and a debris shield which can be either a removable unit, or can be attached as a permanent integrated structure that is mounted within the upper tie plate and above the fuel rods, wherein the debris shield has a surface at least co-extensive with an open area of the fuel bundle inside the channel.
A method has been developed to prevent debris falling into a nuclear reactor fuel assembly including a bundle of fuel rods mounted below an upper tie plate and housed in a channel, the method comprising: inserting a debris shield which can be either a removable unit, or attached as a permanent integrated structure within the upper tie plate; maintaining the shield in the upper tie plate and above the fuel rods, while the fuel assembly is in an operating nuclear reactor core; flowing coolant through the bundle and the debris shield during operation of the nuclear reactor core, and capturing or deflecting debris falling in the fuel assembly with the debris shield.
A nuclear reactor fuel assembly comprising: a fuel bundle including an array of fuel rods housed within a channel; an upper tie plate including a horizontal, rectangular frame having a rib to receive an upper end of a tie rod of the fuel bundle, wherein an outer surface of the frame is adjacent the channel, and a debris shield in the upper tie plate and above the fuel rods, wherein the debris shield has a surface at least co-extensive with an at least partially open area of the upper tie plate.
Debris shields are disclosed herein that mitigate the entry of foreign material into the top of a fuel assembly. The debris shields deflect, catch or remove foreign particles introduced into the top of the fuel assembly. By preventing the entry of foreign particles into the fuel assembly, the possibility of a fuel rod fretting failure is substantially reduced. The debris shield may be a removable unit from the upper tie plate or a permanently integrated structure in the upper tie plate. Preventing debris falling into the fuel bundle is expected to assure the expected operational life of the fuel assembly by reducing the risk of fuel rod failure and premature discharge from the reactor core.
Fuel rod expansion springs 16 extend from the upper end plug of the full-length fuel rods 11 and tie rods 24 to the under side of the upper tie plate 13. Hex nuts 17 secure to a threaded end of the tie rods 24. The rods extend through the upper tie plate and the opposite end of each rod is secured to the lower tie plate 14 of the fuel assembly 10. The lower tie plate 14 includes finger springs 18 on the outer sidewalls of the lower tie plate 14 that engage a channel 20 that provides a hollow housing for the fuel bundle 10.
The channel 20 is typically an elongated hollow tube, rectangular in cross-section and having a length that covers fuel rods in the fuel assembly 10. Channel posts 25 on opposite corners of the upper tie plate 13 provide guides to align the channel onto the fuel bundle 10. A channel fastener clip secures the channel 20 to the threaded channel posts 26. Generally, a U-shaped lifting handle 22 is attached as part of the upper tie plate 13. The handle 22 may be used to raise and lower the fuel assembly 10 into a reactor core 21 or to otherwise move the assembly from the core.
Debris may enter the top of the fuel bundle 10 especially during non-operating or operating conditions such as, refuel, new fuel receipt, transport to core, when the coolant flow stops flowing upward through the core, and when moderator flow may be stagnate or reversed. Debris falling into the top of the fuel bundle may become lodged in the tie plate, spacer bracket, between the rods or between a channel wall and a rod. The crevices in the fuel bundle can trap the debris in the bundle. The debris may fall through a conventional upper tie plate 13 (
The debris shield 102 fills the area enclosed by the frame 104 of the upper tie plate. The debris shield may or may not be integral with the frame, and may or may not be removable from the frame. The debris shield 102 is porous and filters debris from the fluid flow through the fuel assembly 10. Coolant flow through the debris shield preferably without substantial pressure loss across the debris shield 102.
Flow passages 108 through the debris shield 102 have an axis or axes that are preferably obtuse to a vertical axis of the fuel assembly 10. By way of example, the passages through the debris shield 102 slant in a first direction in the upper half of the shield and slant in a second direction in the lower half of the shield, with a corner 116 formed between the two halves. The slanting passages of the debris shield 102 blocks light passing vertically through the shield. Due to the slanting of the passages 108 in the debris shield 102, it is not possible to look through the shield. The view is blocked because the obtuse passages 108 in the debris shield prevent a top-down line-of-sight view through the upper tie plate assembly 100.
In the example shown in
The debris shield 102 may remain in the fuel assembly 10 during operation of the nuclear reactor core 21. The debris shield 102 preferably has a porosity, open mesh or matrix structure that allows coolant, especially emergency coolant, to flow down through the debris shield without substantial flow resistance. The porous, chevron, mesh or matrix structure of the debris shield 102 blocks the passage of debris. The debris shield serves as a filter that allows passage of fluids, such as coolant, and blocks the passage of particulates. Preferably the debris shield should have a pore size that minimizes the size of the debris without imposing a significant fluid pressure drop across the debris shield 102.
The debris shield 102 filters and captures debris in the coolant flow, especially debris flowing downward from above the fuel assembly 10 and to the upper tie plate assembly 100. The passages 108 of the debris shield 102 are too narrow to allow larger debris particles to enter the passages. Larger debris particles are captured on an upper surface 114 of the debris shield 102. Smaller debris particles may enter the passages of the debris shield and become lodged in the corners and crevices 116 of the debris shield such that they do not flow down below the upper tie plate assembly 100 and into the fuel assembly 10. The frame may be porous, e.g., have small vertical openings 31 to allow fluid to pass through the frame and block passage of debris. The openings in the frame increase the effective flow area of passages through the upper tie plate 100 and thereby compensate or offset any flow restrictions due to the debris shield 102. Datum points 117 attached to the support frame 104 center the channel with the upper tie plate and are used during fabrication to square the upper tie plate 100 to the fuel rods.
The upper tie plate assembly 130 includes a upper tie plate handle 22 that is attached or integral with the frame. The frame 132 may include a rectangular outer support wall structure having hollow ribs 138 to receive rod end couplings, e.g., threaded pins of tie rods and provides backing for the expansion springs of fuel rods. The frame may be porous, e.g., have small vertical openings 131 to allow fluid to pass through the frame and block passage of debris. The openings in the frame increase the effective flow area of passages through the upper tie plate 130 and thereby compensate or offset any flow restrictions due to the debris shield 136. Datum points 117 attached to the support frame 132 center the channel with the upper tie plate and are used during fabrication to square the upper tie plate 130 to the fuel rods.
A three-sided frame 160 of the upper tie plate 150 holds together the upper and lower planar sections 156, 158. The frame may be porous, e.g., have small vertical openings 131 to allow fluid to pass through the frame and block passage of debris. The openings in the frame increase the effective flow area of passages through the upper tie plate 150 and thereby compensate or offset any flow restrictions due to the debris shield 152. Datum points 117 attached to the support frame 160 center the channel with the upper tie plate and are used during fabrication to square the upper tie plate 150 to the fuel rods. The frame 160 also supports a lifting handle 22 and the channel posts 25. The frame 160 includes upper and lower planar sections 156, 158 that are load bearing structures of the upper tie plate 150, and provide structural support for the debris shield 152, channel 20, tie rod 24 and other components of the fuel assembly. Optionally, a structurally strong debris shield 152 may serve as a load bearing structure and replace one or more of the upper and lower sections 156, 158 and the frame 160. The debris shield 152 includes apertures 161 (
The debris shield 152 may be generally planar and have edges 162 (
The debris shield 152 may be a honey-combed metallic structure, a wire or fabric mesh, sponge, grid, array of crossing bars or slats, or other matrix that is porous. The material forming the shield should withstand service in a nuclear reactor core. Preferably, the passages through the debris shield are not entirely straight and include at least one bend or curve. Bends and curves in passages of the debris shield tend to trap debris, especially strands of wires and rods. The passages through the debris shield 152 may be numerous to minimize any fluid pressure drop across the debris shield, while maintaining the debris filtering function of the debris shield. Fluid flows through the disjointed passages, but debris is filtered out of the fluid by the debris shield. A characteristic of the debris shield may be that light does not shine through the debris shield because of the bends and curves in passages.
The bends and curves (
The debris shield 102, 136 and 152 may remain in the fuel assembly 10 during operation of the nuclear reactor core. The debris shield preferably has a porosity that allows coolant, especially emergency coolant, to flow downward through the debris shield without substantial flow resistance. The porosity and disjointed fluid passages of the debris shield blocks the passage of debris. The debris shield serves as a filter that allows passage of fluids, such as cooling fluid, and blocks the passage of particulates. Preferably the debris shield should block the passage of particles of debris material having a pore size that minimizes the size of the debris while maintaining the optimal flow of coolant.
The debris shields 102, 136 and 152 shown in
The debris shields 102, 136 and 152 block downwardly flowing debris, have relatively little resistive area to emergency cooling flow and allow recirculation of fluid flowing through and around the shield to the top of the bundle during application of the emergency core cooling system. Debris shields having other shapes, compositions and arrangements in the top of a fuel assembly 10 may be fashioned to serve the function of preventing debris falling into a bundle, in substantially the same way of blocking passage of debris falling downward into the bundle while passing coolant, to achieve the result of substantially no debris being introduced in the bundle due to debris falling down past the upper tie plate.
Each of the three embodiments of the debris shield 102, 136 and 152 are suitable for blocking and filtering debris from coolant flow passing through the upper tie plate. The debris shield 102 (first embodiment) may be held in place by, for example, one or more of the following methods: (i) threaded upper end plugs of the tie rods, (ii) the water rods 23, 230, (iii) the full length fuel rods 11 within the bundle assembly, and (iv) a binding force exerted between the cavity opening in the upper tie plate for the debris shield and the debris shield itself. Further, the debris shield 102 may be a removable unit or a permanent integrated structure mounted within the upper tie plate. In addition, the debris shield 102 may be a removable unit or a permanent integrated structure in the upper tie plate and above the fuel rods, wherein the debris shield has a surface at least co-extensive with an open area of the fuel bundle inside the channel.
The debris shields 102, 136 and 152 may be used in a method to prevent debris falling into a nuclear reactor fuel assembly including a bundle of fuel rods mounted below an upper tie plate and housed in a channel, the method comprising: inserting a debris shield which can be either a removable unit, or attached as a permanent integrated structure within the upper tie plate. Similarly, a method has been developed of maintaining the debris shield in the upper tie plate and above the fuel rods, while the fuel assembly is in an operating nuclear reactor core; flowing coolant through the bundle and the debris shield during operation of the nuclear reactor core, and capturing or deflecting debris falling in the fuel assembly with the debris shield. The debris shields 102, 136 and 152 deflect, catch and/or remove foreign materials potentially introduced into the top of the fuel assembly.
The debris shields 102, 136 and 152 may themselves provide structural support for the bundle and thereby render unnecessary a separate array of pin supports in the upper tie plate. Accordingly, the upper tie plate may comprise a rigid debris shield to which is attached the fuel rods, water rods and possible tie rods, wherein the upper tie plate does not include a conventional pin support array.
Coolant flow through the debris shield 102, 136 and 152 is preferably without substantial pressure loss across the debris shield. To reduce the flow resistance of the debris shield, the flow passages may be relatively wide but slanted. The slanting of the passages in the debris shield enhances the ability of the shield to filter debris. Due to slanting, small debris particles cannot flow directly through the shield and will tend to become trapped with in the shield. The view through the debris shield is block because the obtuse passages in the debris shield prevent a top-down line-of-sight view through the upper tie plate assembly.
The debris shield 102, 136 and 152 serves as a filter that allows passage of fluids, such as coolant, and blocks the passage of particulates. The debris shield preferably has a porosity that allows coolant, especially emergency coolant, to flow downward through the debris shield without substantial flow resistance Preferably the debris shield should have a pore size that minimizes the size of the debris without imposing a significant fluid pressure drop across the debris shield. The debris shield 102, 136 and 152 may be formed of a porous material, such as a wire or fabric mesh, sponge, grid, array of crossing bars or slats, or other matrix material. The passages of the debris shield are preferably too narrow to allow larger debris particles to enter the passages. Further, the frame of the upper tie plate may be porous, e.g., have small vertical openings to allow fluid to pass through the frame and block passage of debris. The openings in the frame increase the effective flow area of passages through the upper tie plate and thereby compensate or offset any flow restrictions due to the debris shield.
The debris shield 136 may have a wavy cross-sectional shape that results in openings in the shield that slant with respect to the vertical axis of the fuel bundle. The slant in the opening is advantageous in blocking debris. The wavy shape of the debris shield 136 assists in securing the debris shield in the slot by causing the upper ridges and lower grooves of the debris shield to be biased against the upper and lower surfaces of the slot. The upper ridges and lower grooves 133 of the debris shield contain the apertures for receiving the threaded ends of tie rods, fuel rods, water rods and upper end plugs for each type. The debris shield 136 preferably has a porosity in the side sides between the upper and lower most portions of the grooves and ridges that allows coolant, especially emergency coolant, to flow downward through the fuel bundle.
A structurally strong debris shield 152 may serve as a load bearing structure and replace one or more of the upper and lower sections of the frame. The debris shield 152 may be a honey-combed metallic structure, a wire or fabric mesh, sponge, grid, array of crossing bars or slats, or other matrix that is porous. The passages through the debris shield may be numerous to minimize any fluid pressure drop across the debris shield, while maintaining the debris filtering function of the debris shield.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
