Stress and fatigue analysis of fuelling machine housing of 500 MWe PHWR

One of the most appealing features of the Pressurised Heavy Water Reactors is the online refuelling capability. For this a fuelling machine is used. This machine opens a reactor channel by removing a seal plug and a shield plug and then does the necessary fuelling by pushing fuel bundles from a fuel magazine by rams. After necessary fuelling the machine closes the channel automatically. One of the most important parts of the fuelling machine is its pressure housing which becomes a part of the reactor channel during refuelling operation. It houses the fuel magazine, separators and rams. Beside channel pressure and other mechanical loads, the pressure housing experiences thermal transients during refuelling. The housing consists of two cylindrical shells having one end-closer in each. They are connected with each other by a large sized coupling. There are many holes on both the end-closers to accommodate ram movement, separators and magazine drive mechanisms. Some of these holes intersect with each other in the housing end-closures and hence end-closures are reinforced accordingly. This also makes the end-closures nonsymmetric. In the following sections the various analysis done to compute general stress distribution, stress concentration factors near to various holes, temperature transients during refuelling and also allowable fatigue cycles for pressure housing of fuelling machine for the proposed 500 MWe are described