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Methodological aspects for finite element modeling of lid systems for type B(U) transport packages
(2012)
The regulatory compliance of the containment system is of essential importance for the assessment
process of Type B(U) transport packages. The requirements of the IAEA safety standards for
transport conditions implies high loading on the containment system. The integrity of the
containment system has to be ensured in mechanical and thermal tests.
The containment system of German SNF and HLW transport packages usually includes bolted lids
with metal gaskets. The finite element (FE) method is recommended for the analysis of lid systems
according to the guideline BAM-GGR 012 for assessment of bolted lid and trunnion systems. FE
analyses provide more accurate and detailed information about loading and deformation of such
kind of structures. The results allow the strength assessment of the lid and bolts as well as the
evaluation of relative displacements between the lid and the cask body in the area of the gasket
groove.
This paper discusses aspects concerning FE simulation of lid systems for Type B(U) packages for
the transport of SNF and HLW. The work is based on the experiences of BAM Federal Institute for
Materials Research and Testing as the German competent authority for the mechanical design
assessment of such kind of packages. The issues considered include modeling strategies, analysis
techniques and the interpretation of results. A particular focus of this paper is on the evaluation of
the results with regard to FE accuracy, influence of the FE contact formulation and FE modeling
techniques to take the metallic gasket into account.
Packages for the transport of radioactive material are generally equipped with specific
structures (basket) to support the radioactive content in defined position. The safety function
of the basket depends on the kind of transported inventory. In case of transport cask for spent
fuel, the basket design has to ensure the subcriticality of the fissile material in all conditions
of transport in particular. Therefore the evaluation of structural integrity and neutron
absorption capability of the basket is an important part of complete safety analysis. Sufficient
heat transfer to maintain fuel assembly and cask temperature within allowable limits has to be
verified as well. Corrosion resistance is an additional requirement on basket materials owing
to contact with water during loading and unloading operations.
Computational and experimental methods or their combination along with additional material
and component tests can be used to analyse the mechanical and thermal basket behaviour
under transport conditions defined in IAEA regulations. By deciding between the analysis
methods, the design features (including material selection concept) as well as specific safety
function should be accounted.
In approval procedures of transport packages for radioactive materials, the competent
authority mechanical and thermal safety assessment is carried out in Germany by BAM. Some
questions of safety evaluation of basket designs are discussed in this paper based on the BAM
experience within approval procedures. The paper focuses primarily on the mechanical
behaviour of baskets with regard to the assumptions that have to be used in the criticality
safety demonstration. The state of the art methodologies for computational basket stress and
deformation analysis as well as for interpretation of drop tests results are presented.
BAM Federal Institute for Materials Research and Testing is the competent authority for mechanical safety assessment of transport packages for radioactive material in Germany. The further development of state-of-the-art technology concerning assessment methods is essential for a qualified work of involved designers and authority experts. The paper gives an example of current development done to improve understanding and modeling capabilities of wood filled impact limiter. In order to reduce the loads applied to the package containment, which result from regulatory drop tests, most packages are protected by energy dissipating impact limiter. Wood, encapsulated by steel sheets, is one of the materials typically used for energy dissipation in these impact limiter. Very often, mechanical safety cases regarding the 9 m drop test are performed computationally, where it is essential to use reliable and verified computational methods and models. In this context, the paper presents an approach for a finite element material model for wood. Thereby, the mechanical behavior of wood under compression loading is the focus of the development work. Additionally, material orientation as well as strain rate, temperature and lateral constraint may vary. A large number of experiments, particularly compression tests, was designed and performed to establish an adequate experimental database for modeling verification. The experimental results enabled the derivation of necessary requirements: The material model has to take into account strain rate and temperature dependencies as well as the anisotropic characteristics of the material, a proper yield criterion, flow rule and hardening law. Such a material model is currently not available in established commercial dynamic finite element codes. Thus it is necessary to create a user-defined material model considering the mentioned requirements. A first step was done by determining a yield surface as well as detecting flow and hardening mechanisms from experimental force-deflection curves. In a next step the LS-DYNA material model MAT_75 was altered according to conclusions of former BAM development work, regarding the modeling of post-peak softening as a function of lateral constraint. Future research will contain the further development, implementation and verification of a material model for wood.
The crush test for light weight and low density type B packages was introduced for the first time into the 1985 edition of the International Atomic Energy Agency (IAEA) transport safety regulations. In the early 1970s, the need for an additional mechanical test besides or instead of the well known 9 m drop test was deliberated. Various authors and test facilities, including BAM and Sandia National Laboratories (SNL), were able to prove that the level of safety provided by IAEA drop and puncture tests in the regulations did not protect against dynamic crush forces to smaller packages. As early as the third PATRAM symposium held in 1971 (Richland, WA, USA), Robert F. Barker asked for '... a more strenuous crushing test for protecting small, light weight packages ...' BAM developed from research activities a proposal as to which types of packages should be subject to crush tests and how the crush tests should be performed, which was presented at the 5th PATRAM symposium held in 1978 (Las Vegas, NV, USA). At the IAEA, the possible need for a crush test was first mentioned in 1977. The subject for a discussion, besides the principal need for this test, was also the development of suitable set of crush test boundary conditions. It took more than four years of discussion until a dynamic crush test similar to today's test was recommended by experts to the IAEA regulatory revision panel. Finally, after a rigorous evaluation process in which also the boundary conditions were determined, the crush test was proposed to be incorporated into the IAEA regulations. BAM and SNL participated in the crush test development and implementation process right from the beginning in the early 1970s until its implementation in the IAEA regulations in 1985. Today, BAM performs crush test procedures according to para. 727(c) of TS-R-1, which have not been changed since their first implementation. Crush tests performed in 2002 at BAM will be discussed. These approval design tests were performed on birdcage pellet transport containers under normal and accident conditions according to the IAEA regulations.
In the approval procedure of transport packages for radioactive materials, the mechanical and thermal safety assessment is carried out in Germany by competent authority BAM. In recent years BAM was involved in several licensing procedures of new spent fuel and HLW package designs, where the cask body was made of Ductile Cast Iron (DCI). According to IAEA regulations package designs have to fulfill requirements for specific conditions of transport. Type B(U) packages must withstand the defined accident conditions of transport. The temperature range from -40°C up to the operational temperature has to be considered. For the cask material DCI, it is necessary to determine the brittle fracture behavior. The German guideline BAM-GGR 007 defines requirements for the fracture mechanics of DCI. Due to complex structure of the cask body and the dynamic loading a fracture mechanical assessment in an analytical kind is not always possible. Experience of recent design approval procedures show that the application of numerical calculations are applicable to determine the fracture mechanical load in the cask body. At the first step a numerical analysis has to be done to identify the loading state at the whole cask body. Secondly an analysis of a detail of the cask body is made considering the displacement boundary conditions of the global model. An artificial flaw is considered in this detailed model to calculate the fracture mechanical loading state. The finite element mesh was strongly refined in the area of flaw. The size of the artificial flaw is characterized by the ultrasonic inspection used for the quality assurance of the package. The applicant developed additional analysis tools for calculation of stress intensity factor and/or J-Integral. The assessment approach by BAM led to the decision to develop own tools to the possibility for independent check of the results.
The paper describes the authority assessment approach for the DCI fracture mechanics analysis. The validation procedure incl. the development of own tools is explained. BAM developed a post-processor called JINFEM to determine the fracture mechanical loads. The regulatory 1 m puncture bar drop test is used to give an example of the assessment procedure.
The moisture content of wood is known to have a significant influence on the woods mechanical properties. Using wood as an energy absorber in impact limiter of packages for the transport of radioactive material, it is of particu-lar importance to ensure the moisture content and thus relevant mechanical properties to be in specified limits. The paper surveys the influence of wood moisture content on the mechanical properties of wood. Different measuring methods are discussed with respect to in-situ applicability, accuracy and effort. The results of an experimental ana-lysis of the accuracy of hand-held moisture meters using the electrical resistance method are discussed. Conclu-sions are drawn regarding the measurement of moisture content of wood upon delivery as well as of complete im-pact limiter assemblies. Requirements for quality surveillance during manufacturing of wood filled impact limiter are derived and it is exemplified how to meet them. Construction, manufacturing and inspection of impact limiter encapsulation with regard to leak-tightness are addressed.