[en] Detailed post irradiation examination was carried out on a PHWR fuel bundle irradiated at Kakrapar Atomic Power Station unit 2 (KAPS-2). The fuel bundle had failed early in life at a low burnup of 387 MWd/T. Non destructive and destructive examination was carried out to identify the cause of fuel failure. Visual examination and leak testing indicated failure in two fuel pins of the outer ring of the bundle in the form of axial cracks near the end plug location. Ultrasonic testing of the end cap weld indicated presence of lack of fusion type defect in the two fuel pins. No defect was found in other fuel pins of the bundle. Metallographic examination of fuel sections taken from the crack location in the failed fuel pin showed extensive restructuring of fuel. The centre temperature of the fuel had exceeded 1700 degC at this location in the failed fuel pin, whereas fuel centre temperature in the un-failed fuel pin was only about 1300 degC. Severe fuel clad interaction was observed in the failed fuel pin at and near the location of failure but no such interaction was observed in the un-failed fuel pins. Several incipient cracks originating from the inside surface were found in the cladding near failure location in addition to the main through wall crack. The incipient cracks were filled with interaction products and hydride platelets were present at tip of the cracks. It was concluded from the observations that the primary cause of failure was the presence of a part-wall defect in the end cap weld of the fuel pins. These defects opened up during reactor operation leading to steam ingress into the fuel, which caused high fuel centre temperature and severe fuel-cladding interaction resulting in secondary failures. A more stringent inspection and quality control of end plug weld during fabrication using ultrasonic test has been recommended to avoid such failure. (author)