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
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
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)
References
- 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
- Editors. (1960). FUEL DAMAGE IN WTR INCIDENT. Nucleonics (U.S.) Ceased Publication, Vol: 18, No. 9. https://www.osti.gov/biblio/4154609