Fabrication of fuel and Zirconium products – NFC Capabilities R.N. Jayaraj Chief Executive Nuclear Fuel Complex Department of Atomic Energy Government of India Hyderabad 1
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Indian Three Stage Nuclear Power Program 95 90 90 86 84 84 (%) -----> 90 85 79 85 80 82 Availability/Capacity Factor 75 72 80 75 69 75 70 71 65 67 60 60 55 50 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 Stage – I PHWRs Stage - III Stage - II Thorium Based Reactors Fast Breeder Reactors • 17- Operating • 40 MWth FBTR - • 1 - Under construction • 30 kWth KAMINI- Operating • Several others planned Operating since 1985 • Scaling to 700 MWe Technology Objectives • 300 MWe AHWR- • Gestation period being realised Under Development reduced • 500 MWe PFBR- • POWER POTENTIAL POWER POTENTIAL IS Under Construction 10,000 MWe VERY LARGE • POWER POTENTIAL LWRs 350,000 Mwe Availability of ADS can • 2 BWRs Operating enable early introduction of • 2 VVERs under Thorium on a large scale construction 3
NFC Activities Core Fuel for Zircaloy Sub-assemblies for PHWRs & BWRs Structurals Breeders Nuclear NFC Non-nuclear Special Tubes Materials 4
Fuel Fabrication Activities at Nuclear Fuel Complex UCIL IREL Imported MDU Zircon Sand UF 6 Zirconium Natural Oxide Enriched UO 2 UO 2 Powder Powder Zirconium Sponge Natural UO 2 Enriched UO 2 Zr Alloying Pellets Pellets Fuel Tubes & Components Fuel assemblies Fuel Bundles for BWRs for PHWRs 5
Manufacturing Activities at NFC • Zircon – Nuclear Grade ZrO 2 – 19-element PHWR 220 Reactor Grade Zirconium Sponge – Zirc – 2, Zirc – 4, Zr-2.5% Nb, etc. • – MDU Nuclear and Sinterable Grade UO 2 powder – Sintered UO 2 fuel pellets – PHWR Fuel Bundles. 37-element • DU / DDU – Direct Calcination – PHWR 500 Reduction – Sintering – UO 2 Fuel Pellets – PHWR Fuel Bundles • UF 6 – Pyrohydrolysis – Reduction Zircaloy 2 clad 6x6 Enriched UO 2 Fuel – UO 2 Powder – UO 2 Pellets – Assemblies for Boiling Water Reactors (BWR) Zircaloy 4 clad Natural UO 2 Fuel BWR Fuel Assemblies. at Tarapur (TAPS 1&2) Bundles for Pressurised Heavy • Water Reactors (PHWR) Manufacturing and supply of core sub-assemblies for Fast Reactors. Stainless Steel (316/D-9) Hardwares for Fuel Assemblies & Core Components for FBTR & PFBR 6 Coolant & Calandria Reactivity Mechanisms Tubes
BWR Fuel Assembly for Tarapur Atomic Power Stations-1&2 ZIRCALOY AND OTHER COMPONENTS UPPER FUEL TUBES 14.27 OD; 0.88 Wt; 3879 L 35 Nos. NUT TIE PLATE 14.27 OD; 0.88 Wt; 469 L 8 Nos. LOCKING TAB WASHER SPACER ASSEMBLY 7 Nos. INCONEL AND SS COMPONENTS 114 Nos. NUMBER OF WELDS 622 Nos. SPRING UO 2 ENRICHED URANIUM OXIDE PELLET NO OF ENRICHMENTS 3 PELLETS - 12.27 9165 Nos. LENGTH OF FUEL ASSEMBLY 4245 mm SPACER GRID WEIGHT OF FUEL PELLETS 160 Kg ONE BWR CORE CONTAINS Zr 2 TUBE * FUEL ASSEMBLIES 284 Nos. - CONTAINED ENRICHED URANIUM OXIDE 45 Te * REPLACEMENT FOR EACH OUTAGE 100 Nos. - CONTAINED ENRICHED URANIUM OXIDE 16 Te DIMENSIONS IN “mm” FUEL ROD LOWER TIE-PLATE Indigenization Improvements - Fully annealed thick wall fuel sheath. - Short and Chamfered Pellets - Pre-Pressurization of Fuel Element 7
Second stage of India’s Nuclear power Program FUEL CLAD TUBES (6.6 x 0.45 x 2555 mm) BLANKET CLAD TUBES (14.33 x 0.56 x 2350 mm) CSR CLAD TUBES (22.4 x 1 x 1260 mm) DSR CLAD TUBES (21.4 x 0.7 x 1110 mm) REFLECTOR CLAD TUBES (44 x 1 x 3325 mm) IBC CLAD TUBES (44 x 1 x 3325 mm) TUBES FOR CORE STRUCTURALS 8
9 Cr 1 Mo Finished Tubes
D9 PFBR Fuel Clad Tube
PFBR FUEL PIN GRID ASSEMBLY 11
From Zircon Sand to Zirconium Alloy Ingots at NFC Compaction of Zr Sponge + Zircon Sand Hf-free ZrO 2 Powder Nuclear Grade Zr Sponge alloying elements Briquettes EB Welded Electrode Copper Mould Lock Valve Vacuum Arc Melting Furnace Electron Beam Welding of Briquettes Zirconium Alloy Ingot using Consumable Electrode to form Consumable Electrode Max. size: 350 mm dia x 2 m height
Major Activities of Zirconium Alloy Fabrication Plant at NFC Pilot Hole Expansion Press Hot Extrusion of Pilger Mill for Production of Zirconium Alloy Billets Zirconium Alloy Fuel Tubes Cold Swaging of Zirconium Alloy Bar Array of Zirconium Alloy Fuel Tubes Hot Rolling of Zirconium Alloy Sheets
Fabrication of Seamless Pressure Tubes and Calandria Tubes through Pilgering Route Zr-2.5%Nb Pressure Tubes Zircaloy 4 Calandria Tubes Parent Metal Seamless Tube: Homogeneous Equiaxed Microstructure Heat Affected Zone Fusion Zone SEAMLESS SEAM WELDED Uniform and Welded tubes: Non-homogeneous Non uniform Residual negligible Residual Stress microstructure (3 distinct zones) Stress 14
Manufacture of Hexcans & Square Channels through Pilgering Route ROLLER MANDREL Roller Scheme for Hexagonal Tube Pilgering PILGERED HEXCAN ROLLER ASSEMBLY MANDREL ROLLER SCHEME FOR PILGERING OF SQUARE SECTIONS FINISHED SQUARE CHANNEL DIFFICULTIES ENCOUNTERED DURING FABRICATION Formation of twist 15 Formation of bow
Reactivity Control Mechanism Assemblies CLASSIFICATION OF 540 MWe PHWR REACTIVITY DEVICES 1) Flux Monitoring a) Vertical Flux Units – 26 Nos. b) Horizontal Flux Units – 7 Nos. 2) Regulation & Control a) Liquid Zone Control System – 6 Nos. b) Adjuster Rods – 17 Nos. c) Control Rods – 4 Nos 3) Shutdown a) Shut-off Rods – 28 Nos. b) Liquid Poison Injection System – 6 Nos. --------------------------------------------- TYPICAL VIEW OF 540 MWe PHWR CORE TOTAL NO. OF ASSEMBLIES : 94 HORIZONTAL FLUX UNIT ASSEMBLY OF 13 METER 16 LENGTH 3-COMPARTMENT LIQUID ZONE CROSS SECTTION OF LIQUID POISON CONTROL UNIT OF 13 METER LENGTH INJECTION UNIT
Cobalt Absorber Assemblies for PHWRs 17
MANUFACTURING FACILITIES AT NFC 18
Tube Manufacturing facilities at NFC • NFC produces seamless tubes using a combination of hot working and cold working operations. • Hot working facilities – 1200 T Vertical Piercing/Expansion press – 3780 T Horizontal hot Extrusion press 19
2 Roll Pilger Mill – Cold working facilities 3 Roller Pilger Mill 2 Roll Pilger mills(17 – 150mm OD) 3 Roller Pilger mills (4 – 30mm OD) 3/4 Roller Universal Pilger mill ( Square, Hexagonal and circular cross sections up to 160mm OD) Triple Tube Draw bench (up to 40mm OD) 20 Triple Tube Draw Bench
Heat treatment facilities LPG fired annealing furnace (1000kg/hr) Bright annealing furnace (250kg/hr) Tube finishing facilities • Cross roller tube straightners • Belt grinding stations • Cutting and deburring stations • Pickling and degreasing facilities High Vacuum Annealing Furnace (1000 0 C , 10 -6 torr ) 21
Indigenous Capability to Manufacture Process Equipment 22
High Temperature Sintering Furnace Calcination / Reduction Furnaces Integrate Spacer / Bearing Pad Special Purpose Resistance Welding Machine Welding Machine 23
Bearing Pad Welding Machine for PHWR Fuel Elements End Plate Welding Machine Vacuum Baking Furnace for Graphite coating of PHWR Fuel Tubes 24
Robotic end plate welding machine Conceptualized, procured and successfully qualified for production of 19 and 37 element PHWR fuel bundles Robot integrated welding stations with other work stations. The productivity has increased by 50% Provision for integrating another end plate welding machine 25
Quality Control Activities Gamma Ray Spectrometer Atomic Absorption Spectrophotometer Analytical Laboratory Inductively Coupled Plasma – Thermal Ionisation Mass Spectrometer Atomic Emission Spectrometer (TIMS) (Model: Ultima 2 CHR) Non-Destructive Testing Facilities Automated Ultrasonic 23 m long 9Cr-1Mo tubes Automated Eddy Current Testing Unit 26 Testing Unit under testing
Types of PHWR Bundles Manufactured at NFC 19-element wire-wrap Bundle 19-element split spacer Bundle 22-element split spacer Bundle 37-element split spacer Bundle 19-element Thoria Bundles 19-element RU Bundles 37-element RU Bundles 19-element SEU Bundles 27
Cumulative Production of PHWR Fuel Bundles at NFC Cumulative Production of PHWR Fuel Bundles at NFC 450000 CUM. QCC BUNDLES BUNDLES Q.C.Cleared: 4,27,457 400000 350000 300000 250000 200000 150000 100000 50000 0 YEAR 28
Product Range • Sizes: – OD: 4.7 mm to 250 mm – WT: 0.45 to 50 mm – Length : Up to 24 m • Shape : – Square cross section. – Circular cross section. – Hexagonal cross section. – Combination of all the above. • Materials: – All grades of SS-Austenitic , ferritic , martensitic & duplex, Zirconium and Titanium alloys, super alloys-Nickel base, Iron base, defence grades etc. • Specifications : – ASTM A 312, 213, 269, 789 etc with additional customer requirements for other than Titanium alloys. – AMS specification for Titanium alloys. 29
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