KfK 3331

Mai 1982

Thermal and Mechanical Behaviour

of PWR Fuel Rod Simulators
for LOCA-Experiments

V. Casal, S. Malang, K. Rust

Institut für Reaktorbauelemente
Projekt Nukleare Sicherheit

Kernforschungszentrum Karlsruhe
 KERNFORSCHUNGSZENTRUM KARLSRUHE

Institut für Reaktorbauelemente

Projekt Nukleare Sicherheit

KfK 3331

Thermal and Mechanical Behaviour of PWR Fuel Rod Simulators

for LOCA-Experiments

V. Casal, S. Malang, K. Rust

Kernforschungszentrum Karlsruhe GmbH, Karlsruhe

 Als Manuskript vervielfältigt
Für diesen Bericht behalten wir uns alle Rechte vor

Kernforschungszentrum Karlsruhe GmbH

ISSN 0303-4003
Sunrrnary

Performance of the out-of-pile test program REBEKA (reactor typical bundle

~xperiments Karlsruhe) called for prior development of a fuel rod simulator
(FRS) whose thermal and mechanical behaviour corresponds largely to that of a
nuclear fuel rod during the low-pressure phase of a loss-of-coolant accident
(LOCA). To meet this requirement fuel rod simulators with 10.75 mm outer
diameter were developed, fabricated,and used in a variety of single rod and
several bundle tests.
For new experiments scheduled to provide information about the behaviour of fuel
subassemblies having fuel rods with 9.5 mm o.d. quasi-REBEKA FRS's are needed.
The thermal and mechanical behaviour of such simulators and of some variants
was examined by calculation and compared to that 6f a fuel rod. Besides the low-pressure
phase, the thermal behaviour of some rod types was investigated also at nominal
power and in the blowdown phase.
FRS's were designed which simulate almost perfectly fuel rods with respect to
the temperatures and deformation of the claddings during low-pressure phase of
a LOCA, Some of these FRS's are even suitable for blowdown experiments, if the
simulators are operated with a modified decay heat curve,

Zusanrrnenfassung
Thermisches und mechanisches Verhalten von Brennstabsimulatoren für Druck-
wasserreaktoren für Experimente zum Kühlmittelverluststötfall

Voraussetzung für die Durchführung des out-of-pile Versuchsprogramms REBEKA

(reaktortypische Bündelexperimente Karlsruhe) war die Entwicklung eines
B~nnstabsimulators, (FRS), dessen thermisches und mechanisches Verhalten weit-
gehend dem eines nuklearen Brennstabes während der Niederdruckphase eines Kühl-
mittelverluststörfalles entspricht, Für dieses Vorhaben wurden Brennstab-
simulatorenmit einem Außendurchmesser von 10,75 mm entwickelt, gefertigt
sowie für eine Vielzahl von Einzelstab- und mehrere Bündelversuche ver-
wendet.
Für neu geplante Experimente zum Verhalten von Brennelementen bestehend aus
Brennstäben mit 9,5 mm Außendurchmesser werden REBEKA-ähnliche FRS's mit ent-
sprechenden Abmessungen benötigt. Das thermische und mechanische Verhalten
solcher Simulatoren und einiger Varianten wurde rechnerisch überprüft und mit
dem eines entsprechendenBrennstabesverglichen. Zusätzlich zur Niederdruck-
phase wurde für einige Stabtypen das thermische Verhalten auch bei nomineller
Leistung und der Druckentlastungsphase untersucht.
FRS's wurden ausgelegt, welche Brennstäbe hinsichtlich Hüllrohrtemperaturen
und Hüllrohrverformung in der Niederdruckphase eines Kühlmittelverluststär-
falles nahezu vollkommen simulieren. Einige dieser FRS's eignen sich sogar
für Experimente zur Druckentlastungsphase, wenn die FRS's mit einer modifi-
zierten Nachwärmekurve betrieben werden,
Contents page

1. Proble.m definition
2. Assumptions for calculating the different phases of LOCA 2
2.1 Steady state operation before LOCA 2
2.2 B1owdown 2

2.3 Refi11 and ref1ood phases 2

3. Design of the fue1 rod simu1ators 2

4. Results 4

4.1 One-dimensiona1 thermal behaviour during the refill and

re flood phases 4
4.2 Two-dimensional calculation of the thermal behaviour during
the refill and reflood phases 7
4.3 Mechanical behaviour of the Zircaloy cladding during the
refill and reflood phases 8

4.4 Thermal behaviour during nominal operation 8

4.5 Thermal behaviour during blowdown 9

5, Assessment of different fuel rod simulators 11

6. Feasibility of fuel rod simulators discussed 12

7. References 13
 1. Problem definition

At KfK REBEKA fuel rod simulators (FRS) were developed to simulate the
thermal and mechanical behavrourof a KWU-PWR fuel rod during the refill
and reflood phases (RR-phases) of a loss-of-coolant accident (LOCA) /1/.
REBEKA-FRS's consist of the Zircaloy cladding· with KWU dimensions (10,75 mm
o.d.) and specifications, an electrical heater rod with boron nitride (BN)
as insulating material,and annular Al o -pellets in the annular
2 3
gaps between the cladding and the heater rod (Fig. 1). The cosine
shaped power profiitle of the fuel rod is adapted in 7 steps with 4 different;:
power levels by use 'of heater rods with a tubular conductor with:-axially
variable wall thickness.

Adaption of REBEKA FRS's to ~ diameter of 9.5 mm o.d. and evaluation

of the prospect of applying them to simulate the whole LOCA, beginning
wi th nominal l.oad. and' ·proceeding_ wi th 'b 1owdown. and RR-phases are the
subjects of this report. In order to undergo the same clad de~ormation

as a fuel rod, an FRS should meet the following requirements:

identical transient of the average clad temperature,
- identical azimuthal temperature variation in the cladding.

Both variables are influenced by the thermohydraulics of the steam-water

mixture in the coolant channels and by the non-steady state thermal behaviour
of the FRS. The thermal and mechanical behaviour of a fuel rod and of
different FRS's has been investigated for typical cooling transients.

To calculate the one-dimensional thermal behaviour the HETRAP /2/ computer

code was used, For the two-dimensional calculation of temperatures and
clad deformation the AZI module from SSYST /3/ was applied.
 - 2 -

2. Assumptions for calculating the different phases of LOCA

2. I Steady state operation before LOCA

- rod power 450 W/cm
- cladding temperature 327 °C

2.2 Blowdown
2.2. I Blowdown experiments with the rod power adapted to that of the
fuel rod
- identical to fuel rod power
- heat transfer coefficient (HTC) during nucleate boiling calculated
using Thom's correlation /4/
- transition from nucleate to film boiling with the same delay as in
the fuel rod
- HTC during film boiling calculated using Berenson's correlation /5/.

2.2.2 Blowdown experiment with cladding temperature adapted to that of fuel

rod
- change of rod power to adj ust cladding temperature
- HTC's as in 2.2. I.
transition from nucleate to film boiling as in 2.2. I.

2.3. Refill and reflood phases

0
- during refill phase HTC , coolant temperature I44 C,
system pressure 4. I bar
- HTC versus time during reflood phase from a FEBA-test (Fig. 2)
-rod power during refill phase changed for the FRS's to achieve a ramp
of cladding temperature identical to that of the fuel rod
- rod power of FRS's during reflood phase identical tothat of fuel rod.

3. Design of the fuel ·rod simulators

The dimensions and materials of all FRS 's calculated are listed in Table I.
~11 of them have a Zircaloy with 9,5 mm o.d. The following types of simu-
lators are compared:

FRS REBEKA-type; dimensions modified,

FRS REBEKA-type, dimensions modified,Al o annular pellets replaced by
2 3
uo2-pellets.
FRS REBEKA-type, dimensions modified,without a filler in the conductor
 - 3 -

I Fuel Rod I FRS-No. 11 FRS-No. 21 FRS-No. 31 FRS-No. ~IFRS-No. SI

I I I I I I I
------------------1 ---------1 ---------1 ---------1 ---------1 ---------1 ---------1
c l.add i ng I Zr-1.1. I Zr-1,1 I Zr-1,1, I Zr-LJ. I Zr-IJ. I Zr-1.1. I
outer diemehr rrm I 9.50 I 9.50 I 9.50 I 9.50 I 9.50 I 9.50 I
Inner diemehr rrm I 8.36 I 8.36 I 8.36 I 8.36 I 6.36 I 8.36 I
gop wldth rrm I o.os I 0.05 I o.os I o.os I o.os I o.os I
------------------1 ---------1 ---------1 ---------1 ---------1 ---------1 ---------1
ennulor pellet I -- I Al203 I Al203 I U02 I -- I -- I
out.er diemehr rrm I I 8.26 I 8.26 I 8.26 I I I
Inner diemehr rrm I I 6.02 I 5.02 I 6.02 I I I
gap width rrm I -- I 0.01 I 0.01 I 0.01 I -- I -- I
------------------1 ---------1 ---------1 ---------1 ---------1 ---------1 ---------1
heater rod I I I I I I I
c ladd I ng I I Inconel I Incone l I Incone l I Incone L I Incone L I
outer diemehr rrm I I 6.00 I 5.00 I 6.00 I 8.26 I 8.26 I
Inner diemehr rrm I I 1.&.80 I I.J.OO I ~.80 I 6.61 I 6.61 I
lneulator I I BN I BN I BN I BN I BN I
heat I ng ~>ource I U02 I Incone L I Incone L I Incone L I Incone L I Incone L I
outer diemehr rrm I 8.30 I 3.50 I 2.92 I 3.50 I 1.1.82 I 1!.82 I
Inner dlemelar rrm I I 2.97 I 2.1.18 I 2.97 I ~.09 I IJ:.09 I
f I Ll.er I I HgO I MgO I MgO I HgO I I
-------------------------------------------------------------------------------

I FAS-No. SI FAS-No. 11 FRS-No. 81 FAS-No. 91 FRS-No.lOIFAS-No.lll

I I I I I
------------------1 ---------1 ---------1 ---------1 ---------1 ---------1 ---------1
I
c ladd I ng I Zr-IJ. I Zr-~ I Zr-IJ: I Zr-1.1: I Zr-IJ. I Zr-IJ. I
outer d I emet.er rrm I 9. 50 I 9. 50 I 9. 50 I 9. 50 I 9. so I 9. so I
Inner diemehr rrm I 6.36 I 8.36 I 6.36 I 6.36 I 6.36 I 8.96 I
gap wl dth rrm I o. 05 I o. 01 I o. 01 I 0.10 I o. 20 I 0.10 I
----------------·--1 ---------1 --------1 ---------1 ---------1 ---------1 ---------1
annular pet.lot I Rl203 I RL203 I I I I I
outer diemehr rrm I 8.26 I 6.3\A I I I I I
Inner diemehr rrm I 6.02 I 6.02 I I I I I
gep wldth rrm I 0.01 I 0.01 I I I I i
------------------1 ---------1 ---------1 ---------1 ---------1 ---------1 ---------1
heater rod I I I I I I I
c LaddIng I Incone l I Inconel I Incona L I Incone L I Incone l I Incone L I
outer d I t'lmeter rrm I 6. oo I 6. oo I a. 3LJ. I 6.16 I 7. 96 I 8.16 I
Inner diamehr rrm I I.J.BO I IJ:.BO I 6.61 I 6.61 I 6.61 I 6.61 I
lnsut.ator I BN I 8N I BN I BN I BN I BN I
heat I ng eource I Inconel I Incone L I Incone L I Incone L I Incone L I Incone L I
outer dlemeter rrm I 3.50 I 3.50 I 1.,\.62 I 1,1..62 I 1.1.62 I IJ..62 I
Inner diemehr rrm I 2.97 I 2.97 I 1.,\.09 I IJ:.09 I ~.09 I 1:1:.09 I
fiLLer I I Hgrl I MgCl I HgO I MgCl I I
---------------~---------------------------------------------------------------

essumed contect coefflclents:

Zlrcoloy- U02 • 1 W/lcmMM2NKl
InconeL - BN = 25 W/lanMN2MK)
Inconel - MgO • 3 W/lanMM2MK)

geps hellum fllled (pressure: 60 berl

heat tranamleelon by conducllon end radlatlon

Table 1: Dimensions and MateriaLs of

FueL Rod and FueL Rod SimuLators
 - g -

of the internal heater rod.

FRS without annular pellets and an enlarged diameter of the internal
heater rod,
FRS without annular pellets and an enlarged diameter of the heater rod
but without a filler in the conductor of the heater rod.

4. Results

For the calculations with HETRAP code and AZI module materials properties
were taken from /6/, But deviating from the data recommended,the density
of BN was chosen tobe 2. I g/cm3 and its thermal conductivity 0.2 W/cmK,
All the data of Al 2o heat capacity were multiplied by a factor of 0,9. It was
3
assumed that the gaps in all FRS's in the fuel rod are filled with helium
(60 bar). The pressurewas kept constant for all calculations and did not
vary with temperature and clad deformation. For calculation of heat trans-
mission over the gaps inside the FRS conductivity of the gas and radiation
weretaken into account. Values of emissivity were chosen which arevalid
for Zircaloy and Al o , respectively. For FRS's without annular pellets
2 3
an emissivity of the heater surface equivalent to that of Al o was assumed.
2 3

4. I One-dimensional thermal behaviour during the refill and reflood phases

The range of application of REBEKA-FRS are the RR-phases during a LOCA. There-
fore, at first the thermodynamic behaviour of 6 FRS's is discussed for the
RR-phases.Then four of them, with the best thermal simulation quality are
analysed in addition with respect to clad deformation and to the thermal
behaviour during the phases preceding the RR-phases,The design characteristics of
6 FRS's from Table 2 will be discussed in detail below. The conditions
prevailing during the RR-phases are_ plotted versus time in Fig.-2. Timezero
is the transition from the refill to the reflood phase. This diagram shows
the course of HTC and rod power of the fuel rod and FRS-No. 1. The FRS has
a modified rod power in the refill phase (power factor : 1.19) to adjust
the ramp of cladding temperature to that of the fuel rod. The basis for this
adjustment is the knowledge of HTC during the refill phase. In Table 2
the power factors are listed for FRS's investigated which are necessary to
adapt the ramp of the cladding temperature to that of the nuclear fuel rod
during the refill phase.
 - 5 -

FRS-No. pellet material diameter of heater rod filler material power factor
(mm)

I A1 o
2 3 6 MgO 1. 19
2 A1 o 5 MgO I. 20
2 3
3 uo 2 6 MgO I. 13
4 no pellet 8.26 MgO I. 19
5 no pellet 8.26 no filler 0.99
6 Al o
2 3 6 no filler I. 08

Table 2: Power factor for FRS during refill phase

A comparison of the power factors does not indicate a significant influence of

the annular pellets on the heat capacity. Neither in case of modification of
the geometry (FRS's-Nos. I, 2) nor in case of modification of the material
(FRS 's-Nos, 1 ,, 3), If the annular pellets are replaced by a heater rod with
a greater diameter, the samepower factor is required (FRS's-Nos. I, 4).
But, if the filler material in the tubular conductor of the heater rod, inside
the FRS's, is replaced by a gas, one gets a significant approximation to the
power factor I. In case of FRS-No. 5 (no annular pellets) the power factor
reaches almost unity. In case of FRS-No. 6 (with annular pellets) the power
factor is calculated t0 be 1.08.

Contrary to the refill phase,the rod powers of all FRS 1 s are kept constant
and identical to that of the fuel rod during the reflood phase. The reason
is the rather small change of cladding temperature during the reflood phase.
The ratio of rod power to change in stored heat is much greater than during
the refill phase. Deviations in heat capacities therefore influence the
cladding temperature at a lower degree. Additionally, the HTC's during
reflood phase are varying with time and are dependent from experimental con-
ditions; a change in rod power would be more difficult to realize.

The thermal behaviour of the FRS's discussed is shown in Figs, 3 through 5.

The time dependent values of average cladding temperatures, surface heat fluxes,
and heat contents are plotted until the point where quenching occurs.
The fÜei' rod and ·FRS's~Nos. I through 6 are considered. A comparison of the
different diagrams shows the following trends:
 - 6-

- Surface temperature:
• FRS's-Nos~ I, 2, 3, 4 show for the turnareund time an .almest identical
behaviour, deviations up to 24 K fr.o·m the fuel rod occur •
• FRS-No, 6 deviates only 10 K•
• FRS-No. 5 shows an absolutely identical behaviour.

- Surface heat flux:

• No significant deviation from the fuel rod before quenching occurs.
• During quenching FRS's-Noa~ I, 2, 3, 4 have an 20% higher heat flux.
• FRS-No. 6 shows an 8 % too high heat flux during quenching •
• FRS-No. 5 shows a behaviour identical to that of the nuclear fuel rod.

- Stored heat:
• FRS's-Nos I, 2, 4 deviatebyup to 18%,
• FRS-No. 3 (uo 2-pellet) by up to 10 %,
, FRS-No. 6 by up to 6 %
. FRS-No. 5 identical behaviour.

An assessment of the thermal behaviour can be based upon the course of

cladding temperature. Knowledge of the surface heat flux and stored heat
helps only itsunderstanding. The course of cladding temperatures during
the RR-phases is the dominating condition for clad deformation due to in-
ternal overpressure. A deviation by 10 K can result in a significant change
of deformation, The FRS's investigated under the conditions discussed show
a negligible influence of the dimensions of the annular Al o -pellets on the
2 3
thermal behaviour; even if the pellets are replaced by a heater rod with
a larger diameter (FRS's-No. 4 ), the same course of temperature
is observed, Pellets of uo 2 (FRS-No. 3) give a slightly better adaptation
to the fuel rod. But the improvement is small and does not warrant the
necessary implications in case uo 2 would be used in an out-of-pile experiment.
An excellent adaptation of the thermal behaviour of fuel rod is reached with
FRS-No. 5 which consists of the Zircaloy cladding and a heater rod mounted
directly inside the cladding with an empty tubular conductor. Calculations
with different internal gaps inside the FRS's were carried out (FRS's~

Nos. 7 through 11). No significant deviations of the thermal behaviour

were found resulting from the modifications investigated.
 - 7-

4.2 Two-dimensional calculation of the thermal behaviour during the

refill and reflood phases

The one-dimensional calculations already discussed show the course of average

t_emperatures. A good thermal correspondence between a fuel rod and an FRS
of nominal geometry is a basic requirement but notnecessarily a sufficient one.
In reality the width of the gas filled gap underneath the Zircaloy cladding will
not be constant and uniform. At some axial positions the Zircaloy cladding
will be in contact with the annular pellets beneath. At the opposite side
the gap width will reach twice its nominal value. This ec:centricity will
cause local temperature variations of the Zircaloy cladding which will de-
termine essentially the amount of clad strain before rupture. FRS's with
their different internal structures may have different local temperature
Variations, and therefore a different mechanical behaviour in case of an
eccentricity. This could be expecj:ed especially for FRS 1 s-Nos. 4 and 5 since
they have no annular pellets. The Zircaloy claddings of theDe FRS's are in
contact with the metallic sheath of the heater rod. Because of the great
dift;erence in thermal conductivities of steel and ceramies (U0 or Al o ),
2 2 3
~~e.~ou1~-a~~i~i.E?te.in_ ~~~~.of eccentricity a different local temperature

distribution and, consequently, a different amount of deformation.

To begin with, the results of AZI based calculations of the azimuthal variation
of the cladding temperature in the RR-phases· without clad deformation are plotted .
1n Fig, 6 as a function of time for the fuel rod and FRS's~Nos. I, 4, 5;
negative time marks the refill phase, positive time marks the reflood phase.
One realizes that the azimuthal variation of cladding temperature is lowest
for the fuel rod. All FRS's show about 50 % greater variations. All FRS's
considered behave almost identically. The following boundary conditions were
assumed for the calculations discussed:
- rod power, HTC, and coolant pressure, Fig. 2.
- maximum possible eccentricity, i.e, the pellets or the heater touc;;.h the
cladding at one side,
- geometry and materials properties equal to those in the calculation with
HETRAP.
- fill gas helium
 - 8 -

4•3 Mechanical behaviour of the Zi rcaloy cladding du ring the refi 11 and
reflood phases

The results of calculations with AZI, including clad deformation, are shown
in Figs. 7 and 8, again for FRS's-Nos. 1,4,~ and the nuclear fuel rod.
A constant internal gas pressure of 60 bar has been used which causes the same
cladding stress as in the REBEKA-tests with KWU fuel rod diameter.

The following can be stated:

During the refill phase the fuel rod undergoes the lowest temperature variation
in the cladding (~ 5 K).
- During that period all FRS's undergo approximately the same azimuthal tempera-
ture variation (~ 7 K).
- Rupture of the claddings occurs 28 - 36 seconds after beginning of reflood
phase; deviations from the fuel rod are 2.5 sec (FRS-No. 1) and 7.4 sec
(FRS-No. 5).
- During the reflood phase the azimuthal temperature variation is lowest in case
of the fuel rod (10 K after 10 sec); at the same time, all FRS's considered
undergo temperature variations of 12 - 13 K.
- The cladding of the fuel rod fails after an average circumferential
elongations of 37 %. The corresponding elongation for the claddings
of the FRS's are 31 - 32 %.

Cladding strain of fuel rod and FRS's do not deviate to a large extend.
However, converted geometrically to a blockage ratio, in case of coplanar
strain, the blockage are 70% for fuel rod and 58 % for FRS's, respectively.

Scoping calculations have shown, that fill gases with lower thermal conductivities
lead to a reduction in strain. Therefore a fuel rod with a high burnup may
have a even lower cladding strain than a FRS with helium filling. On the other
hand a smaller eccentricity would increase the strain.

4.4 Thermal behaviour during nominal operation

Although REBEKA-type FRS's have been developed only for simulation of the
RR-phases it will be discussed below whether they could be used to simulate
nominal operation of a nuclear fuel rod.
 - 9-

eonditions: - rod power 450 W/cm

.
- c 1a dd Lng t emperatures 327 °e
- internal pressure 60 bar.

The radial temperature profiles are shown in Figs. 9 and 10, It can be stated:
- FRS-No. 1 will reach a conductor temperature of 1250 °e; in case of an
increase of the inner gap (heater rod - annular pellet) from 10 ~m to
50 ~m, caused by tolerances of the annular pellets, the temp.erature of the
conductor will reach 1430 °e,
- FRS-No, 3 with annular uo 2-pellets would have a conductor temperature of
1720 °e,
- FRS's-Nos. 4 and 5: The temperature of the conductor is 880 °e; even an
increase of the gap to 100 ~m raises the conductor temperature to 1086 °e
only.

FRS's with Nier conductor were operated at KfK with conductor temperatures of
0
1250 e for about 10 hours /7/. If tolerances of pellets could be excluded,
FRS-No, I with an Al o -pellet could meet the requirement of operating with
2 3
nominal load for a limited period of time. But the realistic tolerances of
the annular pellets exclude this FRS for nominal operation. A reliable
Operation of nominal load would be possible with FRS's-Nos, 4 and 5.

4.5 Thermal behaviour du~ing blowdown

At the beginning of a LOeA, caused by a large break, a blowdown will occur,

For this event the course of coolant pressure and saturation temperature as
well as the course of HTe and decay heat of the nuclear fuel rod are plotted
in Fig. 11, The transient HTe, especially the transition from nucleate boiling
to film boiling, depends on the surface heat flux, The course chosen is valid
for nuclear fuel rods. FRS's with a different thermal behaviour will have this
transition at a different time which is not taken into account in this
calculation. This would result in very different cladding temperatures and
heat contents, The starting conditions for the following RR-phases would be
very different,

4. 5. I Behaviour of FRS 's during blowdmvn with the rod power identical to
the decay heat of the riuclear fuel rod

With the assumptions plotted in Fig. 11 calculations were carried out with
 - 10 -

HETRAP to evaluate the thermal behaviour. The results are shown in Figs. 12 and J4.
A comparison of the results of these two figures leads to the following con-
clusion. The heat stored during normal operation is highest for the fuel rod
and lowest for FRS-No. 5. This causes during a blowdown too low temperature
ramp after DNB for all FRS's compared. Even FRS~No. 1 which is closest to the
fuel rod deviates by up to 50 K. None of the FRS's is capable of simulating
blowdown when the FRS's are operated with apower transient identical to
that of the fuel rod.

4.5.2 Behaviour of FRS's during blowdown with changed rod power

One can improve that simulation quality of the FRS's by variation of the
power transient dur~ng blowdown /8/ in order to adjust the course of cladding
temperature to that of the nuclear fuel rod. Because of the very high HTC's
during nucleate boiling and the very low HTC's during film boiling, one gets
the best approximation with an adaptation of heat flux during the first phase
of blowdown, and with an adaptation of cladding temperature for the following
phase. The success of these calculations is shown in Figs. 15 through 20.

The following can be stated:

- Variations of power transients lead to a course of cladding temperatures
and heat fluxes better approximating those of the nuclear fuel rod; but
identical behaviour is not attained.
- The course of the heat flux of the fuel rod during nucleate boiling can be
fitted best for FRS's-Nos. 4 and 5; FRS-No. 1 deviates by up to 10 %.
- The transients of cladding temperatures during nucleate boiling are
simulated well by all FRS's discussed.
- The transients of cladding temperatures during film boiling are simulated
reasonably with some deviation from the fuel rod.

As a result one can state: If the dependency of HTC on time ~s known during
blowdown, it is possible to adapt the time dependent heat flux of FRS's-
Nos. 4 and 5 to that of a nuclear fuel rod. A good simulation of blowdown
is then possible. It can be assumed that a similar adaptation to the nuclear
fuel rod can be attained, if the courses of rod power (Figs. 16, 18, 20) are
smoothed down adequately.
 - 11 ,...

5. Assessment of different fuel rod simulators

FRS's discussed can be adapted in the RR-phase to fuel rods having

9 • 5 mm o. d, This is possible with both a s~mu · h annu 1 ar Al o -
· 1 a t or w~t
2 3
pellets as with one containing only an 8.2 mm heater rod inside the Zircaloy
cladding (FRS's-Nos. 1 and 4). Both simulators show the same thermal and
mechanical behaviour. A replacement of the Al o -pellets by uo 2-pellets
2 3
(FRS-No, 3) shows no significant improvement that would justify the additional
effort in handling uo -pellets. If the MgO inside the conductor of the heater
2
rod is replaced by a gas-filling (FRS-No. 5), one gets an exact simulation of
the thermal behaviour during the RR-phases;only eccentric gaps cause larger
temperature variations in the Zircaloy cladding which result in a smaller
average circumferential elongation.

The heater rods used inside the FRS's usually have 250% thermal expansion
of the Zircaloy cladding. In the RR-phases,the phase of deformation of
Zircaloy, a temperature rise up to 400 °C may occur. This temperature rise
causes an axial relative motion between Zircaloy and the heater rod of up to
4mm per meter of heated length. At least incase ofFRS's-Nos. 4 and 5 with
their high stability against bending additional forces on the Zircaloy
cladding may be imposed during deformation by thermal expansion of the internal
heater rod, This effect should be investigated before such FRS's are used in clad
deformation experiments.

6. Feasibility of fuel rod simulators discussed

For experimental investigations of a LOCA FRS's-Nos. 1, 4,5 show a suitable

behaviour at least for parts of the accident. Important criter.ia for selection
of one FRS are the possibility of its realization, and the amount of ex-
perience already available about them.

FRS-No. 1 which is suitable to simulate RR-phases,is the well known REBEKA

FRS. Only the dimensions of the Zircaloy cladding and of the Al 2o -pellets
3
are modified, With step-wise adaptation of axial power profile, a few
hundred FRS's have already been produced and applied in experiments. Because
in FRS-No. 1 a heater rod is used with dimensions identical to REBEKA-FRS's,
applying them would involve no risk at all. When a continuous approximation
of the axial power profile is required, two solutions are available. One set
 - 12 -

of heater rods for one REBEKA-bundle have been produced already with an
continuous variation of the wall thickness of the tubular conductor inside
the heater rod. The second design uses a conductor in the form of a helix
with variable width of the ribbon. This design offers the advantage of
adapting the axial power profile with high accuracy with usual tolerances during
fabrication, Heaters of this type were applied in sodium boiling experiments
in KfK multi-rod bundle tests. This year one 7-rod bundle with these heaters
fabricated by INTERATOM will be installed in the HALDEN-reactor. Until now
more than 900 ribbon-type heater rods have been produced at KfK,including
90 with cosine power ·profiles. Realized heated length go up to 1500 mm,
greater lengths can be produced without needing additional development work.
Fig. 21 shows the power profile of the FRS's required for HALDEN-reactor and
the corresponding width of the ribbon. One notes that large variations of
the width are necessary which are easy to machine. Fig. 22 shows a radiograph
of a heater rod with cosine power profile. Near the cold end the ribbon has
a great width, in the central part the width has its minimum,

FRS-No. 4 (without annular pellets) which is suitable to simulate the whole

LOCA, can be produced both with a tubular and a helical conductor. The
diameter required (8.2 mm) is in the range already fabricated. FRS's-Nos. 5
and 6 with an empty tubular conductor are more difficult to fabricate.
Densification of BN between the heater rod cladding and the conductor is
performed at KfK by strong diameter reduction of the heater rod. This strong
reduction of diameter offers the significant advantage that heater rods with
uniform BN-density are guaranteed. Other production methods cannot avoid the
possible formation of local zones with low BN-density. Variations of the
BN-density cause unacceptable cold spots on the cladding and, correspondingly
inside hat spots on the conductor. The first effect would lead to an un-
predictable thermal behaviour of the FRS, the latter to an overheating of the
conductor. The KfK production method involving strong reduction in diameter
calls for a filled conductor to achieve the forces of reaction during
diameter reduction necessary for BN· densification. At KfK several prototype-
heater rods have been produced with empty tubular conductor using the
proved technique of KfK. During fabrication the electrodes were filled, after-
wards they were emptied out. Fig, 23 shows photographs of a heater rod with
empty electrode and of a normal heater rod whose helical electrode is · filled
with MgO,
 - 13 -

7. References

/1/ F. Erbacher, H. J. Neitzel, M. Reimann, K. Wiehr:

Out-of-pile Experiments on Ballooning in Zircaloy Fuel Rod Claddings
in a Low Pressure Phase of a Loss-of-Coolant Accident.
CSNI-Report No. 13, Part 2; Proceedings of Specialist Meeting on the
Behaviour of Water Reactor Fuel Elements under Accident Conditions.
Spating, Norway (13 - 16 Sept. 76),

/2/ S. Malang: HETRAP: A Heat Transfer Analysis Program,

ORNL-TM-4555 1 (Sept. 74).

/3/ R. Meyder: SSYST - Eingabebeschreibung und Handhabung.

KFK 2966,(Nov. 80).

/4/ J.R. Thom et al.: Booling in Subcooled Water during Flow Up Heated
Tubes or Annuli. Proc. Inst. Mech. Eng., Vol. 180, Part 3c,
PP• 226 - 246 (1966).

/5/ P.J. Berenson: Film Boiling Heat Transfer from a Horizontal Plate
ARS-Journal, Vol. 33, pp. 553 (April 62),

/6/ K. Rust, S. Malang, W. Götzmann:

PEW- Ein Fortran-Rechenprogramm zur Bereitstellung physikalischer
Eigenschaften von Werkstoffen für LWR-Brennstäbe und deren Simulatoren,
KFK-Ext. 7/76-1 1 (Dez, 76).

/7/ V. Casal: Design of High-Performance Fuel Pin Simulators for Thermo-

dynamic Experiments with Nuclear Fuel Elements.
Nuclear Technology, Vol. 47,pp. 153-162 (Jan. 80).

/8/ S. Malang: Simulation of Nuclear Fuel Rods by using Process Computer

Controlled Power for Indirect Electrically Heated Rods,
ORNL-TM-4712,(Nov. 75}.
14 1075mm magnesiu moxid heater heater rod sheath boron nitrid annular pellets (U0 2 or Al2 03)
'

schematic design f-'

. +:"-'

-E
.._
Co~
F --
rs 13po r
--=tr~.-==m;;;;;.:=::..:=v+.::.=.=------ 24,3 wtcm
--v~wtcm
!t
===------- . 3~00 1--soo---L._ J.nn "'9 14,2Wicm
• J!?.6Wtcm
[
~ ~------------------------~------------------------~
heated length [ mm1
axial power profHe

Fig. 1 REBEKA fuel rod simula tor

 25 0. 10 ~Rod Power: FueL Rod
~Rod Power: FRS-No.l
Z Heat Transf. Coeff.

20-l 0. 08

~ 15 :;: 0.06
(\J
':::3: )I(
)I(
a:: ::::;:::
w u
~
:::3:
~ 10 ~ o. ol! I
Cl u
I l """"'
V1
ID ...._
a:: :c

5 0.02

0 0.00+------4------~----~------~----~------~
-50 0 50 100 150 200 250 TIME 5

Fig. 2 Rod power and heat transfer coeffident ( HTC )

during refill and reflood phase
 - 16 -

1000

800

u 600
w
a::
::J
I-
a:
~ 400
Q_
::E
w
1-

200
rJ Fue L Rod
(!) FRS-No.1
2
.1:. FRS-No.
+ FRS-No. 3
0+-----~~~~~---.------~----~----~
-50 0 50 100 150 200 250 TIME 5

1000

800

u 600
w
a::
::J
I-
a:
~ 400
Q_
::E
UJ
1-

200
rJ Fue L Rod
X FRS-No .Ii
~ FRS-No. 5
O+-----~+~F_RS~-~Nro~.6~--.-----~----~----~~
-50 0 50 100 150 200 250 TIME S

Fig. 3 Oadding temperature during refill and reflood phase

 - 17 -
50 [!] Fue L Rod
C) FRS-No. 1
.1>. FRS-No. 2
+ FRS-No. 3
40

X
::::>
_j

lL 20
.....
a:
LJ.J
I

10

0+-~---r-----.------~----~----~------~
-50 0. 50 100 150 200 250 TIME 5

50 [!] Fue L Rod

X FRS-No. 4
~ FRS-No. 5
"f' FRS-No. 6
40

X
::::>
_j

lL 20
.....
a:
LJ.J
I

10

0+-~---r~---.-----.------.-----~----~
-50 0 50 100 150 200 250 TIME S

Fig. 4 Surface heat flux during refiH and reflood p~ase

 - 18 -

2500

2000

::E:
u
'~ 1500
I-
a:
UJ
:r:

~ 1000
a:
D
1-
<n

500
[!] Fue L Rod
C) FRS-No. 1
.!!:> FRS-No. 2
+ FRS-No. 3
0+-----~----~~----~----~----~------~
-50 0 50 100 150 200 250 TIME S

2500

2000

::E:
u
' 1500
~
I-
a:
UJ
:r:

~ 1000
a:
D
1-
(F)

500
[!]FueL Rod
X FRS-No. 4
~ FRS-No.5
1' FRS-No. 6
0+------r~~~~----.-----~----~------~
-50 0 50 100 150 200 250 TIME S

Fig. 5 Stored heat during refill and reflood phase

 50-l I [!] Fue l Rod
(!) FRS-No. 1
X FRS-No .4:
~ FRS-No. 5

4:0
:..::::

IJ._
IJ._
~

0
30
Q_
:::tE
w
1-

......
~ 20 \.0
:::tE
.....
N
a:

10

0+-~---+------~----~------~----~------~
-SO 0 SO 100 1SO 200 2SO TIME S

Fig. 6 Azimuthat cladding temperature variation without clad deformation

during refiU and reflood phase
 100-i r::J Fue L Rod
(!) FRS-No. 1
X FRS-No .I.!
~ FRS-No. 5
I
80
::.:::

lL.
lL.
.......
CJ
60
.
CL
::::E:
w
1-
.
::::J
::::E:
1.!01 I I /II N
0
.......
N
a:

20

0~----~------~----~------~----~~----~~----~
-30 -20 -10 0 10 20 30 1.!0 TIME S

fig. 7 Azimutal cladding temperature variation with dad deformation

during refill and reflood phase
 - 21 -

1,1)

w
:E CU
t- V)
."
0 .c:.
::t' 0..
"'C
0
0
cn -0
.......
CU
'-
"'C
c:
m
-
........
.....
CU
0
..--<
'-
cn
......
c:
'-
:::::.
0 "'C

......
c:
."
0 '-
...... +-
V)
I

"0...-<::t'U") cn
c:
->
0
a:ooo
zzz
I I I
0
C'\J
·-
"'C
"'C

-
Q)(f)(f)(f) I
:::lO:O:O:
lJ_LJ_LJ_LJ._
m
El8X~
u
0 CU
0 0 0
cn
01
cn
Lf) ::t'
0
cn
0
C'\J ....... m
% NitH:HS 3Gt:JtJ3At:J '-
CU
>
<(

CO

cn
.
·-
u...
 FuelRod FRS-No.1
2000 2 000

u
0
1500 ;> 1500
~
~ ..._
:::1 :::1
iii 1000 iii
..... 1000
~ Co)
0.
E E
~ 500 1-
Co)
500

0 0

FRS-No.2 FRS-No. 3
2000 Q': 2685 Ws/ern N
2000 N

~ 1500 u 1500
Co) 0
.....
:::1 .._
4:!1
:::1
iii
..._ 1000 ~
4:!1 ..... l 000
0. 4:!1
c 0.
E
~ 500 ~ 500

0 0

Fig. 9 Cross section, radial temperature profile,

and stored heat 0: during nominal operation
 FuelRod FRS-No.4
Q': 1500 Ws/ern
2000 2000

1500 u 1500
u
0
0

~ ~
.....
-
::1
::1
1000 ~ 1000
,b
IG
~
... ~

0.. 0..
E E
~ 500 ~ 500

0 0

FRS-No. 5 FRS-No.6
---!-
2000 .

I
Q'= 1104 Ws/ern
----·~:::·_·!~-:::~'
2000
+ Q'= 1683 Ws/ern
---~,=~
N
w

I
u
1500
l u
1500
0

...~
0
~ l
- ::1
IG
.....
~
0...
1000 I
I
.2IG
.....
<»
0..
1000
'

l
~
E 500 1-
~ 500 l
I
I
0
+---- 0 -r--

Fig. 10 Cross section, radial temperature profile,

and stored heat Q· during nominal operation
 125-l 500-l 10 2 -j 500-J Z CooLant Pressure
XCooLant Temperature
ZHeat Transf. Coeff.
[1] Rod Power: FueL Rod

~
1001 L!ool 10' 1 L!OO
0::
CI:
ID

LU
0::
:::::J 75 u 300 ~ 10° Ci 3oo
r.n )I( -......
r.n Q__ ru 3:
LU ::::E )I(
a:: LU )I( 1-
CL 1- ::::E CI:
u
1-
z
1-
z
-
-......
LU
:::r::
CI:
_j
D
50 5
D
200 3:
u
10- 1
~ 2001
u I \ ~ ~
N
.f>
D 0 1- LU
u u :::r:: 0

25 100 10-2 100

0 0 10-3 0+--------.--------~--------.-------~
0 5 10 15 20 TIME 5

Fig. 11 Boundary conditions for a fuel rod during blowdown phase

 - 25 -

1250 ~ CLadTemperature: Fuel Rod

~Clad Temperature: FRS-No.1
*max. Temperature: FRS-No.1

1000

u
w
0:::
::::J 750
f-
a:
0:::
w
Q_
::E
w
f-
500

250+-------~-------.-------,,--------.
0 5 10 15 20 TIME 5

200 2500 [!]Heat Flux: Fuel Rod

~ Heat Flux: FRS-No. 1
I Stored Heat: FueL Rod
* Stored Heat: FRS-No. 1

150 2000
0.1 ::E
»: u
)j(
::E
u
'
Ui
3:

'
3: f-

>< 100 ~ 1500

::::J :c
_J
LL D
w
f- 0:::
a: D
w f-
:c Ui
50 1000

0 soo+-------~-------.--------.-------.-
0 5 10 15 20 TIME S

Fig. 12 Thermal behavior of rods under identical

boundary conditions during blowdown phase
 - 26 -

1250 ~ Clad Temperature: Fuel Rod

X CLad Temperature: Frs-No.~
~max. Temperature: FRS-No.~

1000

u
w
0:::
::::> 750
1-
a:
0:::
w
Q_
::E
w
1-
500

250+-------~-------,--------,--------,
0 5 10 15 20 TI ME 5

200 2500 ~ Heat FLux: Fuel Rod

X Heat Flux: FRS-No.~
I Stored Heat: Fuel Rod
~ Stored Heat: FRS-No.~

150 2000
(\J ::E
::1( u
::1(
::E
u
'
(f)
3:

'
3: 1-

X 100 ~ 1500
::::> :c
_..J
LL 0
w
1- 0:::
a: 0
w 1-
:r:: (f)

50 1000

0 500+--------.-------.--------,--------.
0 5 10 15 · 20 TI ME 5

Fig. 13 Thermal behavior of rods under identical

boundary conditions during blowdown phase
 - 27 -

1250 ~Clad Temperalure: Fuel Rod

~ CladTemperalure: FRS-No.S
Ymax. Temperalure: FRS-No.S

1000

u
w
a::.
:::::> 750
I-
a:.
a::.
w
CL
:X:
w
I-
500

250+-------~------~--------~------.-
0 5 10 15 20 TIME 5

200 2500 ~ Heat Flux: FueL Rod

X Heat Flux: FRS-No.5
~ Stored Heat: FueL Rod
Y Stored Heal: FRS-No.S

150 2000
(""\] ::E
:+: u
)I(
::E
u
'
(f)
3:

'
3: I-

X 100 ~ 1500
::::> I
__j
LL 0
w
I- a::.
a: 0
w I-
I (f)

50 1000

0 500+---~--~------~--------,-------,-
0 5 10 15 20 TI ME S

Fig. 14 Thermal behavior of rods under identical

boundary conditions during blowdown phase
 - 28 -

1250 ~ Clad Temperature: Fuel Rod

~ Clad Temperature: FRS-No. 1
*max. Temperature: FRS-No. 1

1000

u
w
er:
::::l 750
I-
<I
er:
w
a....
:I:
w
I-
500

250+--------.--------,-------~--------.
0 5 10 15 20 TI ME 5

200 2500 ~ Heat Flux: Fue l Rod

~Heat FLux: FRS-No.l
I Stored Heat: Fuel Rod
* Stored Heat: FRS-No. 1

150 2000
('\.] ::E
:I( u
"
:I(
::E (f)
u 3:

"
3: I-

>< 100 ~ 1500

::::l I
_j
lL D
w
I- er:
0:: D
w I-
;;c (f)

50 1000

0 500+-------~--------.-------~--------r
0 5 10 15 20 TI ME 5

Fig. 15 Thermal behavior of rods achieved by

modifying heater rod power
 - 29 -

500

LIOO ~Rod Power: FueL Rod

0Rod Power: FRS-No. 1

:I!: 300
u
'
3:
a:
w
3:
0
Q._ 200
Cl
0
a:

100

0+-~~--~-----.,------,-------.
0 5 10 15 20 TIME S

Fig. 16 Fuel rod power and modified heater rod power

 - 30 -

1250 ~ Clad Temperature: FueL Rod

X CLad Temperature: FRS-No.4
~max. Temperature: FRS-No.4

1000

u
w
a:
:::) 750
I-
a:
a:
w
[L
:E
w
f,,_

500

250+--------.--------.-------~-------.-
0 5 10 15 20 TI ME S

2tJO 2500 CJ Heat FLux: FueL Rod

C)Heat FLux: FRS-No.4
X Stored Heat: FueL Rod
~ Stored Heat: FRS-No.4

150 2000
C\.J :E
»: u
»: ........
X: (f)
u 3:
........
3: I-

><
::J
100 5
:r:
1500
_j
LL 0
w
I- a:
a: 0
w I-
:r: (f)

50 1000

0 500+-------~--------~------~-------"
0 5 10 15 20 TI ME 5

Fig. 17 Thermal behavior of rods achieved by

modifying heater rod power
 - 31 -

"iOO

.LlQO ~Rod Power: FueL Rod

X Rod Power: FRS-No.4

:::E 300
u
'
::;:::

0:::
LU
::;:::
0
CL 200
0
0
a:

100

0+----K--~------.-------,-------~
0 5 10 15 20 TI ME S

Fig. 18 Fuel rod power and modified heater rod power

 - 32 -

1250 [!] CLad Temperature: FueL Rod

<!> CLad Temperature: FRS-No.S
Ymax. Temperature: FRS-No.S

1000

u
w
a:
:::> 750
1-
a:
a:
w
Q_
:1:
w
1-
500

250+-------~--------.--------,-------,-
0 5 10 15 20 TI ME 5

200 2500 · C!J Heet FLux: FueL Rod

<!>Heat FLux: FRS-No.S
I Stored Heat: FueL Rod
Y Stored Heat: FRS-No.S

150 2000
('\J L
): u
):
L
u
'
(f)
3:

'
3: 1-
X 100 ~ 1500
::::> :r:
_.J
lL 0
w
1- a:
a: ~
w 1-
:r: (f)

50 1000

0 500+-------~--------.--------,--------,
0 5 10 15 20 TI ME 5

Fig. 19 Fuel rod power and modified heater rod power

 - 33 -

500

1.!00 ~Rod Power: Fuel Rod

~Rod Power: FRS-No.5

~ 300
u
'
3:

a:
w
3:
~

CL 200
D
~
a:

100

0+---~--~------.------.------~
0 5 10 15 20 TI ME 5

Fig. 20 Fuel rod power and modified heater rod power

 - 34 -

1,4

1,2

1,0

X 0,4
ro

0,2

0 200 400 600 800 1000 1200 1400

heated length [mml

c 5
0
..0
..0
·c
1:>1 4
..c.
.,_,
"1-
0 3
..c.
.....
"0
3. 2

0 200 400 600 800 1000 1200 1400

heated length [mml

Fig. 21 Axial power profile of HALDEN - reactor and

corresponding width of helical conductor of a
fuel rod simulator
 - 35 -

Fig. 22 Radiograph of a fuel rod simulator with

helical conductor of variable width
 w
0'\
I

Fig. 23 Cross sections of fuel rod simulators with empty tubular conductor
respectively with MgO filled helical conductor