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The figures denoted by AECL Symbol
The figures denoted by 37000-fuel below form a "Historical and Pictorial Record of Canada's Power Reactor Fuel Bundle Design and Development", edited by R.D. Page and A.J. Langdon, photography by C. Baskin, CRNL. This pictorial record of Canada's power reactor fuel bundles was prepared to historically record the evolution of the power reactor fuel over the years. No one report issued over the years has been able to describe in detail the various changes that these pictures portray. It should be noted that the record does not include WR-1 type fuel or special irradiation of assemblies. "A picture speaks a thousand words".
Ron Page, email 2001.08.14 to WJG
AECL37000 Fuelfig000_AECL_Symbol_Pick_28.jpg1093 x 1293200 KB  
  
End-Plates of the First 3 Inch Diameter Fuel Bundles
This is a photo of the end-plates of the first 3 inch diameter fuel bundles. These were the first 19 element fuel bundles built in Canada and irradiated in the E-20 loop (now U-2) in the NRU reactor. They had to have a diameter of 3 inches to fit in the thick wall pressure tube installed in the E-20 loop to commission it. As the knowledge of the material properties of Zircaloy-2 was not well known at that time, the wall thickness was increased to be conservative. The bundles were assembled by screws as the method of welding the end-plates had not been developed. (circa 1959-60).
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig001_3_inch_end_of_19_el_bundle.jpg1402 x 782124 KB  
  
NPD-7 Element End View
This is an end view of one of the first NPD 7-element fuel bundles. They were assembled by riveting the elements to the thick end-plates. Later Tungsten-Inert-Gas (TIG) welding was used and later resistance welding to thinner end-plates, thus improving the neutron efficiency of the fuel.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig002_NPD_7_el_Riveted.jpg1224 x 1209154 KB  
  
NPD-7 Element Riveted
This NPD 7 element riveted bundle is in its classic autoclave black.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig003_NPD_7_el_Riveted_Long.jpg1396 x 108992 KB  
  
NPD-7 Element End View
This end plate on the NPD 7 is now assembled by TIG welding to a thinner end plate.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig004_NPD_7_end_welded.jpg832 x 89075 KB  
  
NPD-7 Element T.I.G. Welded
In some colour photos the rusty colour on the surface of fuel bundles is from endurance testing in the lab and comes from the iron oxide from the carbon steel piping, even though the bundles rested in a Zircaloy pressure tube.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig005_NPD_7_long.jpg1140 x 74471 KB  
  
NPD 19 Element End View
The end view of a NPD 19 element assembled by TIG welding.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig006_NPD_19_end.jpg1104 x 1099136 KB  
  
NPD 19 Element
The 19 elements are spaced by two wires wrapped around each elements and spot welded to the sheaths, one turn per length of element.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig007_NPD_19_element.jpg1384 x 67984 KB  
  
Douglas Point 19-Element Wire Wrap
The Douglas point 19 element bundles were wire wrapped but the helix around the element was doubled. Thicker wires were attached at each end to act as bearing pads so the bundles could slide through the pressure tubes with minimum wear to the tubes.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig008_Douglas_Point_19 el_wire_wrap.jpg1390 x 71087 KB  
  
Douglas Point 19-Element Wire Wrap
An example of the DP 19 element bundle covered in the iron oxide and showing the extra wire pads which are partially ground to a flat surface contoured to fit the pressure tube.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig009_DP_19_el_Colour.jpg1119 x 77668 KB  
  
NPD and DP 19 Element Wire Wrap
A comparison of the NPD & DP 19 element bundles. Note that the DP bundle now assembled by resistance welded of end plates to the elements.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig010_NPD-DP_19_Element.jpg1284 x 1103155 KB  
  
AMF Brazed Twisted Tape 19 Element
During the development of the wire wrapped 19 element bundles for Douglas Point, there was growing concern of the possibility of inter-element fretting of the thin .015 in. thick fuel sheaths. A study was launched to come up with different ways of spacing the elements and also to delete the end plates. The following bundles are an illustration of what were considered. The first example is the twisted tape bundle for so-called better mixing. The center element was made strong enough to take the fueling machine loads and the outer elements were recessed for the fueling machine side stops. Did not graduate.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig011_AMF_Twisted_Tape_Brazed_19_el.jpg1336 x 65180 KB  
  
Welded-Belly Banded AMF Bundle
Another design during this period was held together by belly bands and used welded spacers. Did not graduate. AMF stands for American Machine and Foundry who was contracted to produce Uranium metal fuel for NRX and NRU Research reactors at Chalk River. They were later bought out by Canadian Westinghouse.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig012_Welded_Belly_Band_AMF_bundle.jpg1411 x 789110 KB  
  
Early Brazed - AMF 19 Element
Another design using brazing of the ferrule spacers to the elements were tried. Again did not graduate. But Zr-Be brazing was introduced.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig013_Early_AMF_Brazed_Bundle.jpg1371 x 45059 KB  
  
Domed End Cap Brazed AMF Bundle
To reduce the amount of Zircaloy in the end caps of the elements, thin domed end caps brazed to the sheath were tried. They had insulating pellets inside. The bundle was assembled with two planes of fixed spacers and bearing pads on the outside elements. All brazed to the sheath using both resistance heating and induction heating to melt the braze alloy.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig014_Domed_End_Cap_Brazed_AMF_Bundle.jpg1363 x 89491 KB  
  
Domed End Cap End View
The end view of the above bundle with fixed brazed spacers and domed end caps.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig015_Domed_End_Cap_End_View_with_fixed_brazed spacers.jpg1130 x 1108107 KB  
  
2 Fixed Plane Resistance Brazed 19 Element AMF
This bundle has two planes of spacers. The domed end caps have been replaced by normal solid ones to better survive the fueling machine side stop loads and remove the need of brazing the elements ends. The bearing pads were now standard.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig016_Two_Fixed_Plane_Brazed_AMF_19el_Bundle.jpg1375 x 75781 KB  
  
2 Fixed Plane Brazed AMF 19 Element End View
The end view of the same bundle. The chamfer on the end caps was to accommodate the chamfer on the side stops.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig017_End_View_2_Fixed_Plane_Brazed_19 el.jpg1091 x 106094 KB  
  
D.P. Replacement Brazed Split Spacer
After a number of defects during irradiation in NRU the design was abandoned and end plates were reintroduced. This bundle had no spacing and was not irradiate.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig018_DP_Brazed_Dev_Replacement_Bundle.jpg1367 x 72798 KB  
  
D.P. Development Brazed Split Spacer
The design of the replacement bundle for Douglas Point and NPD was slowly beginning to make progress. The fixed plane was dropped and replaced with a split spacer and a small pad in the center plane only. Thus the elements could now expand independently.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig019_DP_ Dev_small_mid_plane_Bearing_Pads.jpg1383 x 88489 KB  
  
Tube in Shell
Whilst all this development was going on a radical bundle design was tried. It was called the Tube-in Shell bundle. Instead of passing the heavy water coolant over and around the fuel, it was decided to try passing the cooling water through the fuel. This bundle was filled with vibratory compacted UO2 powder, thus it had relatively low Uranium density compared to the sintered pellets. It was all brazed in assembly which was very difficult. After two defects during irradiation the design was dropped from further development. It had a major weakness with respect to heat transfer, the coolant tubes had excellent heat removal but the eccentric outer annulus was very poor.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig020_Tube-in-Shell_Vib_Compacted_Bundle.jpg1386 x 75065 KB  
  
End View Tube in Shell
This an end view of the Tube-in-Shell bundle. The traces of the braze alloy are evident around the tube ends.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig021_End_View_Tube-in-Shell.jpg1171 x 1129134 KB  
  
D.P. Replacement Brazed Split Spacer
The design has now matured and the spilt-spacers are now canted to prevent interlocking and a full length bearing pad has been added in the center plane. This bundle has seen endurance testing in the Sheridan Park loop and the braze alloy has a higher corrosion rate than the normal Zircaloy, thus the white appearance at the joints of the bearing pads.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig022_DP_Brazed_Split_Spacer_Development_Bundle.jpg1134 x 78476 KB  
  
Douglas Point 19-Element End View
This is a Westinghouse made bundle after they took over from AMF. Note the grounding electrode marks on the end caps from resistance welding of the end plate to the elements.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig023_DP_19_el_End_View.jpg1213 x 1128130 KB  
  
Development Bundles
These end views are of two CGE development bundles where the use of welded bearing pads and spacers were tried. Also a variant of the end plate in two pieces. Note that the inner element caps are flat. This design did not go into production.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig024_CGE_Development_bundles.jpg1404 x 856126 KB  
  
D.P. Production Brazed Split Spacer
The final production bundle was a brazed split spacer design with three planes of bearing pads. This design of bundle was used as replacement fuel for both Douglas Point and NPD power reactors in Canada. It was also used in Kanupp, Pakistan and Rapp I & II, India.
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig025_DP_Production_Brazed_split_spacer.jpg1397 x 75779 KB  
  
NPD-7, D.P. 19 Wire Wrap and D.P. 19 Brazed Split Spacer
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig026_NPD_7-19-DP_Brazed_Split_Spacer.jpg1297 x 991118 KB  
  
NPD-7 W.W., NPD-19 Douglas Point-19 W.W. D.P. 19, 3 Fixed Plane DP-19 Split Spacer
Ron Page, email 2001.08.19 to WJG
AECL37000 Fuelfig027_NPD_7-19_DP_19_and_spilt_spacer_bundle.jpg1392 x 643112 KB  
  
Wire Wrap 28 Element - Development
During the development of the replacement D.P. design there were two other reactor fuel projects being developed. They were fuel bundles for Pickering A and Gentilly - 1 Boiling Light Water (BLW) reactors. Both these reactors were going to use 4 inch diameter pressure tubes vs the 3.25 inch of D.P. & NPD. Keeping the same size of elements as the D.P. 19 and .050 inch spacing between elements, the 28 element Pickering design was developed. CGE still preferred the wire warp rather than the toxic Beryllium braze. This wire wrap design was not favoured.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig101_Early_wire_wrap_28_el.jpg1351 x 98596 KB  
  
Wire Wrap 28 Element End View
The end plate for the 28 element Pickering bundle took many forms which are illustrated in the following photos.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig102_End_view_28_el_wire_wrap.jpg1236 x 1113117 KB  
  
28 Element Development Bundle Flexible Spacer
CGE tried very hard to come up with a satisfactory design using only welding as the means of assembly. The angled bearing pads were welded at two points. The flexible spacer did not survive irradiation or endurance testing. The lack of redundancy in the bearing pads received a negative point in the design review. The end plate design changed again.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig103_28_el_dev_bundle_Flexible_spacers.jpg1322 x 94498 KB  
  
28 Element Development Bundle
28 element with welded spacers and bearing pads. Note that one of the pads welds have failed and the pad is missing. Note two piece end plate.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig104_28_el_welded_Dev_Bundle.jpg1325 x 92486 KB  
  
28 Element Development Bundle End View
A close up of the two piece end plate on the welded 28 element development bundle.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig105_28_el_dev_bundle_end_view.jpg1305 x 1219128 KB  
  
28 Element Development Bundle Welded Bearing Pads
CGE still trying to develop the welded 28 element bundle, now with welded straight pads and more than one plane of inter-element spacers. Single piece end plate.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig106_CGE_28_el_straight_welded_bearing_pads_dev_bundle.jpg1380 x 98592 KB  
  
Pickering 28 Element
Westinghouse came up with the final production design of the Pickering 28 element bundle. It had brazed spacers and bearing pads and a classical simple end plate design proposed by an accountant.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig107_28_el_Pickering_production_bundle.jpg1232 x 72295 KB  
  
28 Element Development Bundle
GE was now using brazed pads and spacers and again a different end plate design. CGE traded wire wrap technology with Westinghouse for brazed technology.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig108_CGE_28_el_brazed_pad_dev_bundle.jpg1360 x 92592 KB  
  
28 Element Pickering Production in P.T.
A closeup of the classical Pickering 28 element end plate with the bundle inside a Zr-Nb 2.5% pressure tube. Note the thickness of the pressure tube. The hoop stress on pressure vessels is directly proportional to diameter; hence the small diameter pressure tube walls can be much thinner than the thick walls required for a PWR pressure vessel. Thin Zr walls do not absorb many neutrons; hence the moderator can be placed outside the fuel area in a low pressure calandria. This is the essence of pressure tube reactor design vs. pressure vessel reactor design.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig109_Pickering_28_inside_a_PT.jpg1356 x 1085128 KB  
  
Gentilly-1 with CST
The fuel for the Gentilly-1 was maximized by large diameter elements with a central structural tube to hold the 10 bundles in the vertical pressure tubes. The fuel worked well but, with the success of Pickering proven by the mid 70's, the 10 % (approximately) lower TUEC of BLW-type reactors was not big enough to warrant continued operation nor to justify the funding of continued development. In addition, G-1 experienced control problems (related to coolant voiding and the use of direct cycle heat transport system) and serious service water system corrosion problems. Hence, the plant was shut down and decommissioned.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig110_Gentilly-1_BLW_18_el_CST.jpg2444 x 1643488 KB  
  
Early Wire Wrap 37 Element
As a backup design to the 28 element Pickering bundle, a 37 element was proposed. This was a hand built solid steel bundle with mechanical wire wrap. The 37 element was later developed for the Bruce and 600 Mwe reactors.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig111_Early_37_el_bundle.jpg1267 x 1124118 KB  
  
Gentilly-1
B&W of Gentilly -1 Boiling Light Water 18 element fuel bundle.
Ron Page, email 2001.08.20-21 to WJG
AECL37000 Fuelfig112_Gentilly-1_BLW_18_el.jpg1387 x 75380 KB  
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