The Westinghouse Test Reactor Fuel Melt

Waltz Mill site, 20 miles southeast of Pittsburgh

April 3, 1960

A safety minute from whatisnuclear.com

Context

  • WTR was a pressurized tank-type water-cooled/water-moderated test reactor
  • Pressurized by head tank 250 ft. in the air
  • 60 MWt, designed to test materials and components
  • Privately owned
  • Each assembly had 200 grams of highly-enriched uranium in uranium-aluminum alloy
  • Fuel elements made of 3 concentric rings

What happened

  • A test was planned to reduce flow and see how the reactor operated
  • Power was 40 MW and flow was 15,000 gpm
  • Power was reduced to 30 MW and safety system setpoints were adjusted
  • Flow was reduced to 5250 gpm, power increased back to 37 MW and then back to 40 MW
  • At 8:35 pm, power unexpectely dropped to 17 MW
  • Automatic control rods withdrew to upper limit
  • Power started increasing again
  • Radiation alarms! ☢️😱
  • Personnel scramed and secured the plant and evacuated the area
Westinghouse Test Reactor core

Investigation

  • Gross fission product contamination of primary coolant
  • By April 9, the head was raised and scrubbed with carwash brushes
  • A three-inch thick shielded platform was constructed
  • Fuel was removed, but one assembly was stuck
  • It was melted
  • Coolant voiding around it explains the power reduction
Westinghouse Test Reactor opened up and cleaned

Root cause

  • Bonding defect from fuel fabrication over 1/2” found able to cause burnout
  • Inspections of spare fuel showed tons of big defects, up to 1”
  • Solution: improved fabrication tolerances and inspection
  • Blister tests insuffucient, ultrasonic inspection required
  • Cost increase of fabrication lower than cleanup costs

(Editors, 1960)

Failed fuel from the WTR

References

  1. Tardiff, A. N. (1962). SOME ASPECTS OF THE WTR AND SL-1 ACCIDENTS (No. IDO-19308; Issue IDO-19308). Division of Reactor Development, AEC. https://doi.org/10.2172/4828615
  2. Editors. (1960). FUEL DAMAGE IN WTR INCIDENT. Nucleonics (U.S.) Ceased Publication, Vol: 18, No. 9. https://www.osti.gov/biblio/4154609