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Ermittlung dynamischer Kennwerte von Dämpferbeton für die Simulation des Beanspruchungsverhaltens
(2016)
Die Sicherheit und Integrität von Verpackungen radioaktiver Stoffe wird anhand von numerischen Berechnungen bewertet. Bei einem Anprall oder Absturz sind die mechanischen Beanspruchungen auf die Behälter auch von den Eigenschaften des Untergrunds abhängig. Um potentielle Gefahren während der Verladung zu minimieren, wird energieabsorbierender Dämpferbeton in den Handhabungsbereichen nuklearer Lager eingesetzt.
Zu einer umfassenden sicherheitstechnischen Analyse und Bewertung gehört die Berücksichtigung des Beanspruchungsverhaltens von Dämpferbeton. Hierfür ist ein numerisches Materialmodell notwendig, das in der Literatur bisher nicht vorlag. Die dafür notwendigen dynamischen Kennwerte sind in verschiedenen Druck- und Eindringversuchen ermittelt worden. Dazu wurden dynamische Druckversuche an würfelförmigen Prüfkörpern durchgeführt, sowie Eindringversuche mit unterschiedlichen Eindringkörpern und Dämpferbetonproben. Die experimentell ermittelten Kennwerte wurden verwendet, um ein Materialmodell für Dämpferbeton zu entwickeln und kritische Beanspruchungsszenarien numerisch zu berechnen. Um die Qualität des Materialmodells zu überprüfen, wurde ein realitätsnaher Fallversuch eines Behälters in Originalgröße auf ein lagertypisches Dämpferbetonfundament durchgeführt.
In dem Beitrag sollen die unterschiedlichen Untersuchungen zur Ermittlung dynamischer Kennwerte sowie deren Ergebnisse dargestellt werden. Gezeigt werden ebenso numerische Nachberechnungen einzelner Versuche sowie die ausführliche Berechnung des Fallversuchs im Originalmaßstab. Experimentelle und numerische Ergebnisse aus der Simulation werden hier gegenübergestellt.
The shock absorbing material damping concrete is for the foundation in dry interim storage facilities for radioactive waste in Germany. In case of a potential cask drop damping concrete minimizes the mechanical loads to the cask. In course of safety analyzes this accident scenario is considered by numerical simulations using the finite element method. To get reliable results of numerical simulations a suitable material model is needed to take the characteristics of damping concrete into account. Due to the lack of sufficient material knowledge a research project was started to characterize the material’s behavior under different load conditions. This paper presents the test program to analyze the material behavior of damping concrete which is characterized by large volume change and
strain rate hardening dependence. The determined Parameters were used to adapt an existing material model of the FE-code ABAQUS®. This model has to handle the mechanical damage behavior of damping concrete which occurs under compression and shear loads during a potential cask drop. To verify the material model numerical simulations are compared with dynamic penetration tests, which were conducted with specimens assembled similar to the real application of the damping concrete footings. The transferability of the material
model to a real accident scenario was verified by a drop test with a full-scale cask on a damping concrete footing.
The paper focuses on the preliminary determination of the bar length and the experimental performance of the 1m-puncture test in compliance with the guidelines of the IAEA under the given boundary conditions. Following aspects have to be considered concerning the determination of an appropriate length of the bar to obtain maximum damage to the specimen: the design of the package, its drop orientation and the impact point as well as a pre-damage of the package resulting from a previous 9m drop test. According to the Regulations the minimum length of the bar is defined as 20 cm, which has to be adapted to the outer surface of the package, especially to packages with large impact limiters.
In this context, two main aspects are important: First, the realisation of a maximum puncture load applied to the package while no other component of the package has contact with the impact target. Second, the reduction of the risk of buckling and maximising the stiffness of the bar by a length which is as short as possible. In order to optimize the bar length, finite element calculations are often done by simulating the global behaviour of the package during the puncture test. The evaluation of the conducted puncture test regarding IAEA compliance is done by analysing deceleration measurements. The paper presents a possible approach to determine the length of the bar and the construction of a form-fitted connection to the target showing various examples of puncture tests.
For disposal of the German research reactor of the Technical University Munich FRM II a new transport and storage cask design was under approval assessment by the German authorities. The Bundesanstalt für Materialforschung und -prüfung (BAM) assessed the mechanical and thermal package safety and performed drop tests. The activity release approaches and subjects of quality assurance and surveillance for manufacturing and operation of the package were assessed by BAM as well.
The cask body is made of ductile cast iron and closed by two bolted lid systems with metal seals. The material of the lids is stainless steel. On each end of the cask a wood-filled impact limiter is installed to reduce impact loads to the cask under drop test conditions. In the cavity of the cask a basket for five spent fuel assemblies is arranged.
For the safety case a combination of experimental testing and analytical/numerical calculations were applied. In total, four drop tests were carried out at the BAM large drop test facility. Two tests were carried out as a full IAEA drop test sequence consisting of a 9m drop test onto an unyielding target and a 1m puncture bar drop test. The other two drop test were performed as single 9m drop tests and completed by additional analyses for considering the effects of an IAEA drop test sequence.
The main objectives of the drop tests were the investigation of the integrity of the package and its safety against release of radioactive material as well as the test of the fastening system of the impact limiters. Furthermore, the acceleration and strain signals measured during the tests were used for the verification of Finite-Element-Analysis (FEA) used for the safety analysis of the package design.
The finite-element models incorporated in the package design safety report include the cask body, the lid system, the inventory and the impact limiters with the fastening system. In this context special attention was paid to the modeling of the encapsulated wood-filled impact limiters.
Additional calculations using the verified numerical models were done by the applicant and assessed by BAM to investigate e.g. the brittle fracture of the cask body made of ductile cask iron within the package design approval procedure.
This paper describes the package design assessment from the view of the competent authority BAM including the applied assessment strategy, the conducted drop tests and the additional calculations by using numerical and analytical methods.
A new dual purpose cask design was developed for the safe transport and interim storage of spent fuel elements of German research reactors. In the framework of the safety assessment within the licensing procedure the Bundesanstalt für Materialforschung und –prüfung (BAM) as competent authority performed a series of drop tests according to the IAEA-Regulations [1]. The package consists of a cylindrical thick-walled ductile cast iron cask body closed by a double lid system with metallic seals. A lid and bottom sided impact limiter consisting of a wood/steel construction limit the mechanical impact loading. The full-scale test specimen was equipped with a basket and assembled with dummy-fuel elements. The package and test specimen, respectively have a total mass of approximately 24 metric tons.
The mechanical test program included three 9m free drop tests, in horizontal, vertical and oblique cask orientation onto the lid system. Additionally, a 1m-puncture drop test followed the horizontal drop test to consider an IAEA-test sequence. The horizontal and vertical drop tests were performed at a temperature of minus 40°C. During the oblique drop test the upper impact limiter was heated to +80°C. The tests were conducted onto an unyielding target, fulfilling the requirements of the IAEA regulations [1].
The test specimen was considerably instrumented with strain gauges and accelerometers. Transient strains at selected locations of the inner and outer container walls, of the primary and secondary lid, as well as of the corresponding lid bolts were measured during the drop tests. Furthermore, decelerations in different locations at the cask body and the lids were measured. The complex geometrical deformation of the impact limiters due to the impact were determined by optical 3d- measurements using the projected fringe method in combination with multi-image photogrammetry. Before and after the drop tests the leakage rate of the lid system was determined by helium leakage testing.
The experimental results contribute to the evaluation of the package response to mechanical tests, demonstrating safety under normal and accident conditions of transport. Especially to the verification of the dynamic finiteelement model of the package used in the package design safety report [2]. The paper describes the performance of the drop tests, selected test results focusing on the lid screws and the cask body and the deformation of the impact limiters as well as impact kinematics, respectively.
A new dual purpose cask design was developed for the safe transport and interim storage of spent fuel elements of German research reactors. In the framework of the safety assessment within the package approval procedure the Bundesanstalt für Materialforschung und –prüfung (BAM) as competent authority performed a series of drop tests according with the IAEA Transport Regulations. The package consists of a cylindrical thick-walled ductile cast iron cask body closed by a bolted lid system with metallic seals. A lid and bottom sided impact limiter consisting of a wood/steel construction limit the mechanical impact loading. The full-scale test specimen was equipped with a basket and assembled with dummy-fuel elements. The package and test specimen, respectively have a total mass of approximately 24 metric tons. The mechanical drop test program included three 9m free drop tests, in horizontal, vertical and oblique cask orientation onto the lid system. Additionally, a 1m-puncture bar drop test followed the horizontal drop test to consider an IAEA-drop test sequence. The horizontal and vertical drop tests were performed at a temperature of minus 40°C. During the oblique drop test the upper impact limiter was heated up to +80°C. The tests were conducted onto an unyielding target, fulfilling the IAEA requirements. The test specimen was considerably instrumented with strain gauges and accelerometers. Transient strains at selected locations of the inner and outer container walls, of the primary and secondary lid, as well as of the corresponding lid bolts were measured during the drop tests. Furthermore, decelerations in different locations at the cask body and the lids were measured. The complex geometrical deformation of the impact limiters due to the impact were determined by optical 3D- measurements. Before and after the drop tests the leakage rate of the lid system was determined by helium leakage testing. The experimental results contribute to the evaluation of the package response to mechanical tests, demonstrating safety under normal and accident conditions of transport and especially to the verification of the dynamic finite-element model of the package used in the package design safety report.
Damaged spent nuclear fuel (DSNF) can be loaded in German dual-purpose casks (DPC) for transport and interim storage. Encapsulations are needed to guarantee a safe handling and a tight closure, separated from the package enclosure. These encapsulations shall be durable and leak-tight for a long storage period, because they are usually not accessible within periodical inspections of the DPC. Due to the general design of DPCs for standard fuel assemblies, specific requirements have to be considered for the design of encapsulations for DSNF to ensure the loading in existing package designs. Especially the primary lid system of a DPC is designed for maximum loads due to the internal impact of the content during drop test conditions. The main difference of encapsulations for damaged spent nuclear fuel is that they have usually a much higher stiffness than standard fuel assemblies. Therefore the design of an internal shock absorber, e.g. at the head of an encapsulation is required to reduce mechanical loads to the primary lid system during impacts.
BAM as part of the German competent authority system is responsible for the safety assessment of the mechanical and thermal package design, the release of radioactive material and the quality assurance of package manufacturing and operation. Concerning the mechanical design of the encapsulation BAM was involved in the comprehensive assessment procedure during the package design approval process. An internal shock absorber was developed by the package designer with numerical analyses and experimental drop tests. Experimental drop tests are needed to cover limiting parameters regarding, e.g. temperature and wall thickness of the shock absorbing element to enable a detailed specification of the whole load-deformation behavior of the encapsulation shock absorber.
The paper gives an overview of the assessment work by BAM and points out the main findings which are relevant for an acceptable design of internal shock absorbers. The physical drop tests were planned on the basis of pre-investigations of the applicant concerning shape, dimension and material properties. In advance of the final drop tests the possible internal impact behavior had to be analyzed and the setup of the test facility had to be validated. The planning, performance and evaluation of the final drop tests were witnessed and assessed by BAM. In conclusion it could be approved that the German encapsulation system for damaged spent nuclear fuel with shock absorbing components can be handled similar to standard fuel assemblies in existing package designs.
BAM acts as authority and for service in safety assessment of packages for transport and storage of radioactive materials. We offer extensive test capabilities and application of analytical methods for design verification and simulation for all types of packages for the transport and storage of radioactive materials according with the international IAEA Regulations for the safe transport and for national storage acceptance criteria. BAM operates several test facilities for drop and stacking testing, leak testing and thermal testing. The large drop test tower allows dropping full-scale specimens up to 200,000 kg in any drop orientation as requested. The comprehensive test facilities combined with long-term experience, newest equipment and measurement devices according to the latest state-of-the-art technology ensures realisation of complex test campaigns for package safety evaluation.
Beyond that, non-destructive and destructive material test devices and experts are available. Equipment and application of all kinds of typical measurement categories can be offered for testing campaigns.
In recent years we performed testing of full-scale type B package models with complex handling and preparation procedures. The results were contributed for different package design approval procedures. Type A packages mainly designed for medical related transport purposes, were continuously tested according to the transport regulations over recent years as well. Moreover, we work on research topics with relevance to package safety. The mechanical behaviour of lid closure systems under transport and storage conditions and the thermal behaviour of impact limiters were recently of special importance for the assessment competencies of BAM and were investigated under use of our test facilities.
The paper describes the test facilities and capabilities for package design safety evaluation at BAM and shows examples from our recent work.