For safe and economical spent fuel management, assessing the integrity of the cladding, which is the first barrier to the escape of radioactive material, is very important. For the sake of risk assessment, it is essential to calculate the probability of failure of the spent fuel rods loaded inside the cask during the transportation or storage. However, due to the large amounts of calculations required, it is not practical to analyze every detail of the spent fuel rods and assemblies. This study presents a methodology to perform a cask-level analysis by sequentially simplifying the fuel rods and spent fuel assemblies for the calculation of fuel rod failure probability. A simplified single fuel rod model was generated by considering the material properties of a high burnup fuel rod stored in dry storage for approximately 5 years and the interfacial bonding conditions of the cladding tube. The simplified model produces the same deflection as the detailed model at the critical moment that produces a fracture plastic strain of 1%. The developed single fuel rod simplified model is assembled in a CE 16×16 configuration, and a methodology is presented in which the CE 16×16 assembly model is once again replaced by a simplified model with a cuboidal shape. Compression analyses were performed on each part of the CE 16×16 model to obtain isotropic property data, and a simplified model was created based on those data and the cross-sectional second moment values of the parts. A cask drop analysis was performed to validate the similarity of the CE 16×16 model and the simplified model by comparing important structural responses such as impact acceleration. The 20 simplified fuel assembly models and one detailed model were loaded into a cask to perform the drop analysis. For the detailed model, the impact acceleration was extracted for different loading positions and the corresponding impact load and pinch load were derived. The spring force and contact force corresponding to the pinch load were extracted by applying a Python script technique to extract the maximum value of them exerted on each fuel rod. The vulnerability of spent fuel rods to bending loads and the failure criteria were considered during the simplification process of a single fuel rod. From the extracted impact and pinch loads, the probability of failure of the spent fuel rods as a function of impact acceleration can be calculated.

Post Irradiation Examination Facility (PIEF) is a test facility for nuclear fuel research and development and performance evaluation. From the past to the present, assemblies and fuel rods have been transported from nuclear power plants (NPP) several times, and various destructive and non-destructive tests have been performed. Among these, in the case of the 14×14 Westinghouse STD assemblies that are transported as a whole assembly, the top nozzle is connected to the guide tube by welding. Therefore, the fuel rods could not be removed from the assembly at the NPP, so the assemblies were transported to PIEF as is. Then, after cutting between the top nozzle and the guide tube in the pool, and the fuel rods were extracted and tested. In order to transport the assembly in the future, it is necessary to maintain stability by inserting the dummy rod into the unit cell from which the fuel rod is extracted. However, since the length of the dummy rod is almost 4 m and the diameter is about 10 mm, the dummy rod often bends while passing through the dimple spring of the grid. Additionally, when dummy rods are inserted into unit cells that are continuously empty after the fuel rods are extracted, there may be cases where the dummy rods are not inserted into the desired unit cell but are bent and incorrectly inserted into the next unit cell. The moment the dummy rods are inserted into the dimple spring of grid, a load is applied to the dummy rod due to the tension of the spring. If it can be inserted while offsetting the load, the work can be performed more smoothly. Accordingly, an underwater handling tool was developed that can be inserted while offsetting the tension of the spring. Using this handling tool applies a load to the dummy rod and rotates the dummy rod itself, offsetting the tension of the spring and allowing the dummy rod to be inserted without bending. This handling tool is equipped with a shock absorbing device to protect the dummy rod and spring, and a module to rotate the dummy rod. As a result of inserting the dummy rod using the developed handling tool, it was possible to easily insert the dummy rod into unit cells that were previously impossible to insert.

An important goal of dismantling process is the disassembling of a spent nuclear fuel assembly for the subsequent extraction process. In order to design the rod extractor and cutter, the major requirements were considered, and the modularization design was carried out considering remote operation and maintenance. In order to design the rod extractor and cutter, these systems were analyzed and designed, also the concept on the rod extraction and cutting were considered by using the solid works tool. The main module consists of five sub-modules, and the function of each is as follows. The clamping module is an assembly fixing module using a cylinder so that the nuclear fuel assembly can be fixed after being placed. The Pusher module pushes the fuel rods by 2 inches out of the assembly to grip the fuel rods. The extraction module extracts the fuel rods of the nuclear fuel assembly and moves them to the consolidation module. The consolidation module collects and consolidates the extracted fuel rods before moving them to the cutting device. And the support module is a base platform on which the modules of the main device can be placed. The modules of level 2 can be disassembled or assembled freely without mutual interference. For the design of fuel rods cutter, the following main requirements were considered. The fuel rod cut section should not be deformed for subsequent processing, and the horizontally mounted fuel rods must be cut at regular intervals. The cutter should have the provision for aligning with the fuel rod, and the feeder and transport clamp should be designed to transfer the fuel rods to the cutting area. The main module consists of 6 sub-modules, and function of each is as follows. The cutting module is a device that cuts the fuel rods to the appropriate depth for notching. The impacting module is a device that impacts the fuel rods and moves them to the collection module. The transfer module is a device that moves the fuel rods to the cutting module when the aligned fuel rods enter the clamp module. The clamping module is a device to clamp the fuel rods before moving them to the cutting module. The collection module is a container where the rod-cuts are collected, and the support module is a base platform on which the modules of the main device can be placed. The module of level 3 can be disassembled or assembled after the cutting module of level 2 is installed, and the modules of level 2 can be disassembled or assembled freely without mutual interference.

Korea Atomic Energy Research Institute (KAERI) has been operating the Post Irradiation Examination Facility (PIEF) for spent fuel. The facility has pools and hot cells for handling and examining fuel assemblies and rods. In the first hot cell, non-destructive tests such as visual inspection, defect detection, oxide layer thickness measurement, and gamma scanning are performed on a full-length fuel rod. Then, the fuel rod is transported to the next hot cell for measuring the rod internal pressure (RIP). After the RIP measurement, the fuel rod is cut by a cutting machine to make samples for destructive tests. Currently, the existing cutting machine is broken, so a new machine needed to be designed and manufactured. The major considerations for designing the cutting machine were convenience of remote handling and decontamination. The machine was modularized and its handling parts were designed to be easily controlled by manipulators. The cover was designed to prevent radioactive contamination of the surrounding area.

Korean MMTT project has been launched in order to clarify the vibration and shock loads under normal condition and transportation (NCT) in Korean geological and transportation conditions and to evaluate the integrity of SNF under such a transportation load. To evaluate the integrity of the SNF during normal land and sea transport tests, a representative SNF that represents the entirety of the different types of SNFs stored in the spent fuel pool of the power plant should be selected. And, it is necessary to make the test assembly to have a statically and dynamically similar behavior with the actual SNF. Therefore, in this project, we selected two types of fuel assembly that are expected to exhibit relatively conservative behavior under NCT, and these assemblies are being fabricated into surrogate test assemblies to have a similar characteristic as actual SNF based on the accumulated data from the poolside examination and the hot cell test so far. Tests were conducted for NCT conditions. In addition, a fatigue test was performed to integrity of the nuclear fuel rods under NCT conditions. Nuclear fuel assemblies are transported while being laid inside the cask under NCT, and are exposed to external shocks and vibrations. At this time, the fuel rod between the grid and grid is exposed to bending motion by this external force. For this simulation, a fixture was developed and used for static bending tests and bending fatigue tests. To simulate spent nuclear fuel rod specimens, hydrogen reorientation Zry-4 cladding was used and simulated pellets made of stainless steel were applied. And also, it was bonded using epoxy to give bonding conditions between the inside and the pellet. As a result of the test, cracks occurred due to the concentrated load between the pellets, resulting in damage to the fuel rod. The fatigue results showed a similar trend compared to the results performed by ORNL, and the lower bound fatigue curve presented by NUREG-2224 was also satisfactory.

The damaged spent fuel rods must be stabilized by encapsulation or dry re-fabrication technologies before geological disposal. For applying the dry re-fabrication technology, we manufactured a vertical type furnace to perform the fuel material recovery from damaged fuel rods by oxidative decladding technology. As driving forces to accelerate oxidative decladding rate, magnetic vibration and pulse hammering generated by a pneumatic cylinder were used in this study. The oxidative decladding efficiency and recovery rate of fuel oxide powder with rod-cut length, oxidation temperature and time, oxygen concentration, and gas mixtures were investigated using simfuel rod-cuts in a vertical furnace for fuel material recovery and powder quality improvement. The oxidative decladding was performed for 2.5-10 h as following operation parameters: simfuel rod-cut length of 50-200 mm, oxidative temperature from 450 to 580°C, oxygen concentration of 49.5 or 75.6%, and gas mixtures in O2/Ar or O2/N2. In magnetic vibration, oxidative decladding was progressed only at bottom portion of fuel rodcut. Whereas, oxidative decladding in pulse hammering was occurred at both top and bottom portions of fuel-rod. In pulse hammering method, the oxidative decladding conditions to declad rod-cuts of 50- 200 mm in length were established to achieve both decladding efficiency of ~100% and fuel material recovery rate of > 99%. These conditions were as follows: oxidation temperature and time at 500°C and 2.5-10 h, oxygen concentration at 75.6% under O2/N2 gas mixtures. As operation conditions for a pneumatic cylinder, stroking, actuating, and waiting times were 0.5, 3, and 12 s.

Currently, as the saturation capacity of wet storage pool for spent nuclear fuel (SNF) of PWR in Korea has reached approximately 75%, Dry Storage Facilities (DSF) are necessary for sustainable operation of nuclear power plants. It is necessary to develop acceptance requirements for the delivery of SNF from reactor storage site to Centralized DSF. To do this end, the mechanical integrity of SNF is directly related to its repacking, retrieving, and transporting/handling performances. And also, this integrity is a key factor associated with the criticality safety that is connected to the damaged status of SNF. According to the NUREG/CR-6835, the NRC expects that the potential for nuclear fuel failures will increase because of the increase of the fuel discharge burnup and the degradation of fuel and clad material properties. Due to such damages and/or degradation, the fuel rods in the fuel assembly may be extracted and empty for following treatments (transportation, storage, handling etc). This condition can have a detrimental effect on the criticality safety of SNF. Thus, this study investigated whether extracted and empty of damaged SNF rod affects criticality safety. In this analysis, it is assumed that up to four fuel rods are missed. As a result of the analysis, As the number of fuel rods miss up to a certain number, the value of multiplication factor value of the fuel assembly increases. In addition, since the fuel rods located at the outermost layer contained relatively less fissile material than the fuel rods located center of the lattice, and neutrons were lost by the absorption material, the effective multiplication factor value gradually decreased. Nevertheless, the criticality safety was assessed to be maintained.

A rod internal pressure increased by fission gas release is major factor that causes degradation during dry storage of spent fuel. Because rod internal pressure is greatly affected by fuel design, operation power history, it is essential to perform complex calculation using performance code to accurately predict rod internal pressure as function of burnup. However, because it is difficult to apply a complex method into dry storage design and to determine rod internal pressure based on conservative way this study presents a simple correlation that can predict an approximate rod internal pressure as function of burnup For the development of simple correlation, rod internal pressure and fuel rod void volume data measured through about 400 PIE (Post Irradiation Examination) data were used. The developed simple correlation can cover various fuel rod arrays, discharged fuel average burnup, operation history, cladding type, burnup range, and information on Westinghouse type fuel rods such as Spain ENUSA, USA EPRI/ANL/ORNL/PNNL, WEC, etc. In this paper, the data of simple correlation determination is briefly introduced, and the data analysis process and results are summarized. Two correlations that can conservatively determine rod internal pressure and free void volume in fuel rod according to fuel rod average burnup were presented, and the effect of initial He fill pressure was evaluated. In particular, the results of Post Irradiation Examination for 46 fuel rods conducted in Korea are also included, so it is expected that newly presented correlations can be used easily in various ways in the domestic research, industry, and academia.

For economic and safe management of Spent Nuclear Fuel (SNF), it is very important to maintain the structural integrity of SNF and to keep the fuel undamaged and handleable. The cladding surrounding nuclear fuel must be protected from physical and mechanical deterioration. The structural evaluation of SNF is very complicated and numerically demanding and it is essential to develop a simplified model for the fuel rod. In this study, a simplified model was developed using a new cladding failure criterion. The simplified model was developed considering only the horizontal or lateral static load utilizing the cladding material properties of irradiated Zirclaoy-4, and applicability in horizontal and vertical drop impacts was investigated. When a fuel rod is subject to bending, a very complicated 3D stress state is generated within the vicinity of the pellet–pellet interface. A very localized stress concentration is observed in the area where the edges of the pellets contact the cladding. If the failure strain criteria obtained from the uniaxial tension test or biaxial tube test is applied, failure is predicted at the beginning stage of loading with premature through-thickness stress or strain development. The localized contact stress or strain is self-limiting and is not a good candidate for the cladding failure criteria. In this work, a new cladding failure criterion is proposed, which can account for the localized stress concentration and the through-thickness stress development. The failure of the cladding is determined by the membrane plus bending stress generated through the thickness of the cladding, which can be calculated by a process called stress linearization along the stress classification line. The failure criterion for SNF was selected as the membrane plus bending stress through stress linearization in the cross-sections through the thickness of the cladding. Because the stress concentration in the cladding around the vicinity of the pellet–pellet interface cannot be simulated in a simplified beam model, a stress correction factor is derived through a comparison of the simplified model and detailed model. The applicability of the developed simplified model is checked through horizontal and vertical drop impact simulations. It is shown that the stress correction factor derived considering static bending loading can be effectively applied to the dynamic impact analyses in both horizontal and vertical orientations.

Prior to the investigations on fuel degradation it is necessary to describe the reference characteristics of the spent fuel. It establishes the initial condition of the reference fuel bundle at the start of dry storage. In a few technology areas, CANDU fuels have not yet developed comprehensive analysis tools anywhere near the levels in the LWR industry. This requires significantly improved computer codes for CANDU fuel design. In KNF, in-house fuel performance code was developed to predict the overall behavior of a fuel rod under normal operating conditions. It includes the analysis modules to predict temperature, pellet cracking and deformation, clad stress and strain at the mid-plane of the pellet and pellet-pellet interfaces, fission gas release and internal gas pressure. The main focus of the code is to provide information on initial conditions prior to dry storage, such as fission gas inventory and its distribution within the fuel pellet, initial volumes of storage spaces and their locations, radial profile of heat generation within the pellet, etc. Potential degradation mechanisms that may affect sheath integrity of CANDU spent fuel during dry storage are: creep rupture under internal gas pressure, sheath oxidation in air environment, stress corrosion cracking, delayed hydride cracking, and sheath splitting due to UO2 oxidation for a defective fuel. To upgrade the developed code that address all the damage mechanisms, the first step was a review of the available technical information on phenomena relevant to fuel integrity. The second step was an examination of the technical bases of all modules of the in-house code, identify and extend the ranges of all modules to required operating ranges. Further improvements being considered include upgrades of the analysis module to achieve sufficient accuracy in key output parameters. The emphasis in the near future will be on validation of the in-house code according to a rigorous and formal methodology. The developed models provide a platform for research and industrial applications, including the design of fuel behavior experiments and prediction of safe operating margins for CANDU spent fuel.

In general, if a nuclear fuel cladding tube is damaged during reactor operation, it is called fuel failure. If the cladding tube is damaged, the function of sealing the nuclear fuel material is lost, and the fission products accumulated inside the nuclear fuel rod may leak into the coolant. The causes are the most damage caused by foreign substances in a coolant such as small iron wires, and GTRF (Gridto- Rod Wear) due to a grid, end-plug welding defect, PCMI (pellet cladding mechanical interaction), and oxidation corrosion damage. In this study, a device of simulating friction damage and debris induced damage between grid-fuel rods, which are the main causes of cladding tube damage, was developed. An air vibrator was installed as a function to induce vibration of the nuclear fuel rod. Sandpaper was installed between the grid and the fuel rod to induce friction between the grid-fuel rods. Saw teeth were installed on the grid to induce damage to foreign substances. It is believed that the simulated damaged nuclear fuel rod can be manufactured through on-study to provide the simulated damaged nuclear fuel rod necessary for the stabilization study of the damaged nuclear fuel rod.