One of the important components of a nuclear fuel cycle facility is a hot cell. Hot cells are engineered robust structures and barriers, which are used to handle radioactive materials and to keep workers, public, and the environment safe from radioactive materials. To provide a confinement function for these hot cells, it is necessary to maintain the soundness of the physical structure, but also to maintain the negative pressure inside the hot cell using the operation of the heating, ventilation, and air conditioning (HVAC) systems. The negative pressure inside the hot cells allows air to enter from outside hot cells and limits the leakage of any contaminant or radioactive material within the hot cell to the outside. Thus, the HVAC system is one of the major components for maintaining this negative pressure in the hot cell. However, as the facility ages, all the components of the hot cell HVAC system are also subject to age-related deterioration, which can cause an unexpected failure of some parts. The abnormal operating condition from the failure results in the increase of facility downtime and the decrease in operating efficiency. Although some major parts are considered and constructed in redundancy and diversity aspects, an unexpected failure and abnormal operating condition could result in reduction of public acceptance and reliability to the facility. With the advent of the 4th Industrial Revolution, prognostics and health management (PHM) technology is advancing at a rapid pace. Korea Hydro & Nuclear Power, Siemens, and other companies have already developed technologies to constantly monitor the integrity of power plants and are applying the technology in the form of digital twins for efficiency and safety of their facility operation. The main point of PHM, based on this study, is to monitor changes and variations of soundness and safety of the operation and equipment to analyze current conditions and to ultimately predict the precursors of unexpected failures in advance. Through PHM, it would be possible to establish a maintenance plan before the failure occurs and to perform predictive maintenance rather than corrective maintenance after failures of any component. Therefore, it is of importance to select appropriate diagnostic techniques to monitor and to diagnose the condition of major components using the constant examination and investigation of the PHM technology. In this study, diagnostic techniques are investigated for monitoring of HVAC and discussed for application of PHM into nuclear fuel cycle facilities with hot cells.

In the nuclear fuel cycle (NFC) facilities, the failure of Heating Ventilation and Air Conditioning (HVAC) system starts with minor component failures and can escalate to affecting the entire system, ultimately resulting in radiological consequences to workers. In the field of air-conditioning and refrigerating engineering, the fault detection and diagnosis (FDD) of HVAC systems have been studied since faults occurring in improper routine operations and poor preventive maintenance of HVAC systems result in excessive energy consumption. This paper aims to provide a systematic review of existing FDD methods for HVAC systems therefore explore its potential application in nuclear field. For this goal, typical faults and FDD methods are investigated. The commonly occurring faults of HVAC are identified through various literature including publications from International Energy Agency (IEA) and American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE). However, most literature does not explicitly addresses anomalies related to pressure, even though in nuclear facilities, abnormal pressure condition need to be carefully managed, particularly for maintaining radiological contamination differently within each zone. To build simulation model for FDD, the whole-building energy system modeling is needed because HVAC systems are major contributors to the whole building’s energy and thermal comfort, keeping the desired environment for occupants and other purposes. The whole-building energy modeling can be grouped into three categories: physics-based modeling (i.e., white-box models), hybrid modeling (i.e., grey-box models), and data-driven modeling (i.e., black-box models). To create a white-box FDD model, specialized tools such as EnergyPlus for modeling can be used. The EnergyPlus is open source program developed by US-DOE, and features heat balance calculation, enabling the dynamic simulation in transient state by heat balance calculation. The physics based modeling has the advantage of explaining clear cause-and-effect relationships between inputs and outputs based on heat and mass transfer equations, while creating accurate models requires time and effort. Creating a black-box FDD model requires a sufficient quantity and diverse types of operational data for machine learning. Since operation data for HVAC systems in existing nuclear cycle facilities are not fully available, so efforts to establish a monitoring system enabling the collection, storage, and management of sensor data indicating the status of HVAC systems and buildings should be prioritized. Once operational data are available, well-known machine learning methods such as linear regression, support vector machines, random forests, artificial neural networks, and recurrent neural networks (RNNs) can be used to classify and diagnose failures. The challenge with black-box models is the lack of access to failure data from operating facilities. To address this, one can consider developing black-box models using reference failure data provided by IEA or ASHRAE. Given the unavailability of operation data from the operating NFC facilities, there is a need for a short to medium-term plan for the development of a physics-based FDD model. Additionally, the development of a monitoring system to gather useful operation data is essential, which could serve both as a means to validate the physics-based model and as a potential foundation for building data-driven model in the long term.

The domestic representative nuclear fuel cycle facilities are post-irradiation examination facility (PIEF) and Irradiated Examination Facility (IMEF) at KAERI. They have regularly operated since 1991 and 1993, respectively. Due to the long period of use, the facilities are ageing, and maintenance costs are increasing every year. The maintenance methods have mainly been breakdown maintenance (BM) and partially preventive maintenance (PM). They involve replacing components that have problems through periodic inspections by on-site inspectors. However, these methods are not only uncertain in terms of replacement cycles due to worker’s deviation on the inspection results, but also make it difficult to respond accidents developed through failures on the critical equipment that confines radioactive material. Therefore, an advanced operation and maintenance studied in 2022 through all of nuclear facilities operated at KAERI. Advancement strategy in four categories (safety, sustainability, performance, innovativeness) was analyzed and their priorities according to a facility environment were determined so a roadmap for advanced operation and maintenance could be developed. The safety and sustainability are higher importance than the performance and innovativeness because facilities at KAERI has an emphasis on research and development rather than industrial production. Thus, strategy for advancement has focused even more on strengthening the safety and sustainability. To enhance safety, it has been identified that immediate improvement of aged structures, systems, and components (SSCs) through large-scale replacement is necessary, while consideration of implementing an ageing management program (AMP) in the medium to long term is also required. Facility sustainability requires strengthening operation expertise through training, education, and cultivation of specialized personnel for each system, and addressing outstanding regulatory issues such as approval of radiation environment report on the nuclear fuel processing facilities and improvement work according to fire hazard analysis. One of the safety enhancement methods, AMP, is a new maintenance approach that has not been previously applied, so it had to be thoroughly examined. In this study, an analysis was conducted on the procedure and method for introducing an AMP. An AMP for nuclear fuel cycle facilities was developed by analyzing the AMP applied to the BR2 research reactor in Belgium and modifying it for application to nuclear fuel cycle facilities. The ageing management for BR2 has the objective to maintain safety, availability and cost efficiency and three-step process. The first step is the classification of SSCs into four classes to apply graded approach. Secondly, ageing risk is assessed to identify critical failure modes, their frequency and precursors. Final step involves defining measures to reduce the ageing risk to an acceptable level in order to integrate the physical and economic aspects of ageing into a strategy for inspection, repair, and replacement. Similar approach was applied to the nuclear fuel cycle facility. Firstly, the SSCs of nuclear fuel cycle facilities have been classified according to their safety and quality classifications, as well as whether they are part of the confinement boundary. The SSCs involved in the confinement boundary were given more weight in the classification process, even if they are not classified as safety-class. A risk index for ageing was introduced to determine which prevention and mitigation measure should be chosen. By multiplying the health index and the impact index, the ageing risk matrix provides a numerical score that represents guidance on the prevention and mitigation of ageing effect. The health index is determined by combining the likelihood of failure and engineering evaluation of the current condition of SSCs, whereas the impact index is calculated by taking into account the severity of consequences and the duration of downtime resulting from a failure. This ageing management has to be thoroughly reviewed and modified to suit each facility before being applied to nuclear fuel cycle facilities.

The dimensioning machine installed in the hot cell has been used for 20 years. It has been used for a long time so it was often malfunction due to aging and radiation. In addition, some parts of apparatus were discontinued and there were a lot of problems in maintenance and repair. In the old measuring system, the operator’s subjectivity was much involved. The process of control the focal length (distance between lens and specimen) by operator’s sense is a good example. The existing dimensioning machine was the Kh-7700 of Hirox Co., Ltd. As the equipment had been used for a longtime, additional utilities such as jigs, lighting module and servo motors have been customized and used. The same company’s apparatus was selected for the reasons that it did not need to manufacture a new utility so it could save the cost of radioactive waste disposal for existing utilities and its radiation resistance which has been used for 20 years in radiation environment. Lighting, standing, stage, controllers, cables and so on had been customized to provide remote control in hot cell. The installation was completed in March of this year in hot cell and has been successfully used until now. Through the improvement of dimensioning machine, an auto-focusing and multi-focusing were available. Therefore, they made it possible to produce high quality data and improve the accuracy of data. And this research could be a good example of how hot cell devices can be built and customized to achieve remote control.

The skeleton of fuel assembly is composed of top nozzle, bottom nozzle, grids, and guide tubes. In the reactor core, all the parts of the fuel assembly suffer degradations due to the condition of high temperature, pressure and water environment. Therefore, many material properties of high temperature mechanical strength, corrosion and irradiation resistance have been considered to choose the material for fuel assembly parts in the fuel development stage. The guide tubes have important roles to connect each parts and support the load of fuel assembly while the fuel is lifted. In Westinghouse 14×14 standard fuel assembly, Zircaloy-4 was used for the material of the guide tubes. Zircaloy-4 has a resistance to water corrosion and maintain good mechanical properties after the discharge from the core, so this alloy is also utilized for a fuel rod cladding material although the microstructure is slightly different due to the heat treatment difference. Thus, it is expected that there is no issue regarding the guide tube integrity after the discharge and during the storage in the pool, especially in case of low burn-up. However, the surface oxidation and resultant hydrogen pick-up can affect to the embrittlement to the Zr alloy. So, it is needed to know the actual status of spent fuel assembly by performing post-irradiation examination. In this study, the degradation level of the guide Tubes in low burn-up spent fuel assembly was investigated using the KAERI PIE facility in order to make some data which can be utilized to the baseline for evaluating the integrity of the spent fuel skeleton.