Bernhard Droste

SAFETY ANALYSIS OF CASKS UNDER EXTREME IMPACT CONDITIONS

Abstract The determination of the inherent safety of casks under extreme impact conditions has been of increasing interest since the terrorist attacks of 11 September 2001. For nearly three decades BAM has been investigating cask safety under severe accident conditionslike drop tests from more than 9 m onto different targets and without impact limiters as well as artificially damaged prototype casks. One of the most critical scenarios for a cask is the centric impact of a dynamic load onto the lid-seal system. This can be caused, for example, by a direct aircraft crash (or just its engine) as well as by an impact due to thecollapse of a building, e.g. a nuclear facility storage hall. In this context BAM is developing methods to calculate the deformation of cask components and — with respect to leak-tightness — relative displacements between the metallic seals and their counterparts. This paper presents reflections on modelling of cask structures for finite-element analyses and discusses calculated results of stresses and deformations. Another important aspect is the behaviour of a cask under a lateral impact by aircraft or fragments of a building. Examples of the kinetic reaction (cask acceleration due to the fragments, subsequent contact with neighbouring structures like the ground, buildings or casks) are shown and discussed in correlation to cask stresses which are to be expected.

Measurement techniques and preliminary results of drop tests with full scale spent fuel transport and storage casks

Abstract The experimental testing and quantitative stress analysis of new cask designs becomes more and more important with increasing size of casks and their impact limiters, in order to assess the safety margins as well as for calculation validation reasons. Full scale drop testing of spent fuel transport and storage casks is performed by the Federal Institute for Materials Research and Testing within the type B package approval procedure and for safety demonstration reasons respectively. In drop tests for demonstrating ability of a package to withstand normal and accident conditions of transport, the instrumentation of a specimen is an important tool to evaluate its mechanical behaviour during impact. Generally, the instrumentation incorporates the measurement of strains and accelerations at the package. Test results as deceleration–time and strain–time functions constitute a main basis for the validation of assumptions in the safety analysis, for the evaluation of calculations based on finite element methods and extrapolation of scale model testing on full sized package within approval design tests. Besides, all of the above mentioned instrumentation, the flatness of the sealing area and the circularity of the cask lid flange are determined by using three-dimensional coordinate measurements to evaluate the mechanical impact behaviour of the cask flange region after the drop test sequence. Indispensable are measurements concerning leak tightness of the closure lid system. Additionally, specific photogrammetric measurements are used to characterise the conditions of the closure lid system after drop test in more detail. The preparation and interpretation of the results is in progress and indicates possible correlations between the leak tightness rate and measures of the relative movement of the lid.

Drop test program with half scale model CASTOR® HAW/TB2

Abstract Federal Institute for Materials Research and Testing (BAM) is the competent authority for mechanical and thermal safety assessment of transport packages for spent fuel and high level waste in Germany. In context with package design approval of the new German high level waste cask CASTOR® HAW28M, BAM performed several drop tests with a half scale model of the CASTOR® HAW/TB2. The cask is manufactured by Gesellschaft für Nuklear Service mbH and was tested under accident transport conditions on the 200 tons BAM drop test facility at the BAM Test Site Technical Safety. For this comprehensive test program, the test specimen CASTOR® HAW/TB2 was instrumented at 21 measurement planes with altogether 23 piezo resistive accelerometers, five temperature sensors and 131 triaxial strain gauges in the container interior and exterior respectively. The strains of four representative lid bolts were recorded by four uniaxial strain gauges per each bolt. Helium leakage rate measurements were performed before and after each test in the above noted testing sequence. The paper presents some experimental results of the half scale CASTOR® HAW/TB2 prototype (14 500 kg) and measurement data logging. It illustrates the extensive instrumentation and analyses that are used by BAM for evaluating the cask performance to the mechanical tests required by regulations. Although some of the quantitative deceleration, velocity and strain values cannot be shown because of confidentially issues, they are provided qualitatively to illustrate the types of measurements and methodologies used at BAM.

Impact target characterisation of BAM drop test facility

Abstract BAM safety related research of containers for radioactive material focuses on advanced mechanical safety assessment methods for verification of the structural integrity and leak tightness under normal conditions of transport and hypothetical accident conditions during transport and storage. An essentially unyielding target with a rigid surface is required for impact tests performed for package approval according to IAEA regulations. In addition to specification of a target, e.g. with a combined mass more than 10 times that of the specimen for drop tests, unyielding target characteristics have been investigated with various package designs and different impact tests. The unyielding target of the BAM drop test facility, a reinforced concrete block together with an embedded and anchored mild steel plate, provides relatively large mass and stiffness with respect to the packages being tested. For monitoring reasons accelerometers and strain gauges are embedded in the concrete block of the foundation at several positions. Additionally, dynamic impact responses like vibrations and rigid body motion can be measured by seismic accelerometers. The mechanical characterisation of the targets rigidity is based on experimental results from various drop tests. Test containers with weights of 181 000 kg, 127 000 kg and 8010 kg hit the target with velocities up to 13˙5 m s–1 in the horizontal and vertical drop positions. The rigidity of the impact target can be demonstrated with experimental results confirmed by analytical approaches. Some conclusions can be drawn about experimental testing as well as analytical calculations in order to compare impact effects.

Spent Fuel Transport Associated With Other Dangerous Goods in Regular Train Units — Assessment of Hypothetical Explosion Impacts

Abstract Continental railway transport regulations (RID) do not exclude the transport of spent fuel casks in a regular train unit that also contains wagons with other hazardous materials. In the case of a train accident the release or reactions of those dangerous goods could potentially give significant accidental impacts on to the spent fuel casks. The assessment of fires from inflammable liquids and the explosion impacts from pressurised inflammable gases (like LPG) is well known from other studies which have usually revealed sufficient safety margins to the robust spent fuel cask designs. A new problem to be assessed is the potential impact from a detonation blast wave from explosives transported in the same train unit as a spent fuel cask. BAM is assessing this problem by developing a numerical model to calculate the effect of the dynamic pressure of a external shockwave on the cask construction. The calculation results show that the integrity of a robust monolithic cask with a screwed lid closure system is preserved after the effect of a 21 tonne (equivalent weight of TNT) explosive detonation in the regular transport configuration with a distance of 25 m between the centre of the explosion and the front of the cask.

Dynamic crushing characteristics of spruce wood under large deformations

An extensive series of large deformation crushing tests with spruce wood specimens was conducted. Material orientation, lateral constraint and loading rate were varied. Regarding material orientation, a reduction in the softening effect and the general force level was observed with a higher fiber-load angle. A comparison with characteristics gained by application of Hankinson’s formula showed discrepancies in compression strength and the beginning of the hardening effect. Lateral constraint of the specimens caused a multiaxial stress state in the specimens, which was quantified with the applied measuring method. Further, a higher force level compared to specimens without lateral constraint and significant hardening effect at large deformations resulted. Thus, the influence of a multiaxial stress state on the force level could be determined. An increase in the loading rate led to higher force levels at any displacement value and material orientation.

Mechanical design assessment approaches of actual spent fuel and HLW transport package designs

Abstract In recent years, BAM Federal Institute for Materials Research and Testing finalised the competent authority assessment of the mechanical and thermal package design in several German approval procedures of new spent fuel and high level waste package designs. The combination of computational methods and experimental investigations in conjunction with materials and cask components testing is the most common approach to mechanical safety assessment. The methodology in the field of safety analysis, including associated assessment criteria and procedures, has evolved rapidly over the last years. The design safety analysis must be based on a clear and comprehensive safety evaluation concept, including defined assessment criteria and constructional safety goals. In general, for new package designs, the implementation of experimental package drop tests in the approval process should be obligatory. Additionally, pre- and post-test calculations as well as components or material testing could be important. The extent to which drop tests are necessary depends on the individual package construction, the materials used and identified safety margins in the design.

Testing of type B packages in Germany to environments beyond regulatory test standards

Abstract For >30 years at BAM, type B packages have been tested to non-regulatory test environments in different research and regulatory assessment projects. The aims of these projects were the identification of package safety margins beyond regulatory standards, and the consideration of accident scenarios that are not covered by the IAEA transport regulations. The present paper will address the following BAM experiments and computations: drop tests of type B packages from a height of 200 m, including a 1 : 2 scale model of a TN 8/9 spent fuel cask; 19·5 m drop test of a full scale spent fuel cask, the CASTOR Ic, onto a highway target; 13 m drop test of the CASTOR Ic cask onto a HEXCEL shock absorber; 14 m drop test of a CASTOR VHLW cask with artificial flaw onto steel rails; BLEVE impact involving a CASTOR THTR/AVR cask; aircraft crash tests and FEM calculations; prolonged fire test (3 h, 10 min) with a Pu nitrate package after 200 m drop test; FEM calculations of external pressure from TNT explosions at a distance of 25 m. Briefly addressed will be other tests performed in Germany (GNS drop tests of waste packages from 800 m in height; and a 1 : 3·4 scale model of a former GDR spent fuel cask C 30 dropped from 25·5 m onto a concrete building structure).

Internal cask content collisions during drop test of transport casks for radioactive materials

Abstract In transport casks for radioactive materials, significantly large axial and radial gaps between cask and internal content are often present because of certain specific geometrical dimensions of the content (e.g. spent fuel elements) or thermal reasons. The possibility of inner relative movement between content and cask will increase if the content is not fixed. During drop testing, these movements can lead to internal cask content collisions, causing significantly high loads on the cask components and the content itself. Especially in vertical drop test orientations onto a lid side of the cask, an internal collision induced by a delayed impact of the content onto the inner side of the lid can cause high stress peaks in the lid and the lid bolts with the risk of component failure as well as impairment of the leak tightness of the closure system. This paper reflects causes and effects of the phenomenon of internal impact on the basis of experimental results obtained from instrumented drop tests with transport casks and on the basis of analytical approaches. Furthermore, the paper concludes the importance of consideration of possible cask content collisions in the safety analysis of transport casks for radioactive materials under accident conditions of transport.

Mechanical safety analysis for high burn-up spent fuel assemblies under accident transport conditions

Abstract Transport packages for spent fuel have to meet the requirements concerning containment, shielding and criticality as specified in the International Atomic Energy Agency regulations for different transport conditions. Physical state of spent fuel and fuel rod cladding as well as geometric configuration of fuel assemblies are, among others, important inputs for the evaluation of correspondent package capabilities under these conditions. The kind, accuracy and completeness of such information depend upon purpose of the specific problem. In this paper, the mechanical behaviour of spent fuel assemblies under accident conditions of transport will be analysed with regard to assumptions to be used in the criticality safety analysis. In particular the potential rearrangement of the fissile content within the package cavity, including the amount of the fuel released from broken rods has to be properly considered in these assumptions. In view of the complexity of interactions between the fuel rods of each fuel assembly among themselves as well as between fuel assemblies, basket, and cask body or cask lid, the exact mechanical analysis of such phenomena under drop test conditions is nearly impossible. The application of sophisticated numerical models requires extensive experimental data for model verification, which are in general not available. The gaps in information concerning the material properties of cladding and pellets, especially for the high burn-up fuel, make the analysis more complicated additionally. In this context a simplified analytical methodology for conservative estimation of fuel rod failures and spent fuel release is described. This methodology is based on experiences of BAM acting as the responsible German authority within safety assessment of packages for transport of spent fuel.