  | JSC ChMP is the part of Russian Federation nuclear-power complex ( Corporation TVEL) |  |
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Zirconium is found in many places of the Earth as a mineral and now it became as the necessary material for nuclear application. This metal combined many attractive properties of other materials, such properties as durability, irradiative transparency, corrosion resistance, and others.
For construction material purpose zirconium is alloyed by special elements. These additives are changing zirconium properties and make it durable for many years in hard working conditions of nuclear reactors. These additives are introduced during zirconium melting and crystallization of manufactured alloys in the form of ingots. There are four companies in the world which produce zirconium:
- Chepetskiy Mechanical Plant,
- CEZUS, France,
- Teledyne Wah Chang, USA
- Westinghouse, USA. Zirconium ingot is the beginning of the production process of zirconium alloy items.
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Ingots
Size: Ingots 400 - 450 mm in diameter (ingot weight from 1000 to 3500 kg).
Marking: Zirconium ingots and zirconium alloys ingots are marked by stamping on the butt end of the ingot. The marking contains melt number, the year of the melt and the ingot weight. Ingots are packed in wooden boxes or in other packing, at customer's request.
Transportation: Transportation of ingots is allowed by any kind of transport. During transportation and storage of ingots it is necessary to avoid contact with corrosive liquids and atmosphere.
Tubes
Seamless cold-rolled channel tubes.
Tubes are manufactured from zirconium alloys of nuclear grade with Niobium texts 2.5%. The tubes are corrosion resistant. Tubes are supplied as vacuum annealed and with inner and outer surfaces pickled. At customer's request tubes can undergo special heat treatment in order to get pre-set mechanical properties, metal microstructure and other properties.
Geometrical dimensions of tubes and their tolerances (mm).
| Outer diameter |
Wall thickness |
Lenght |
|
| nominal |
limit |
nominal |
limit |
nominal |
limit |
|
| 88.0 |
+0.7
−0.1 |
from 3.0
to 4.6 |
±0.3 |
up to 8005.0 |
+20.0 |
|
| 89.0 |
+1.5 |
from 7.0
to 13.5 |
+1.5 |
up to 1950.0 |
+10.0 |
Inspection
Tubes are inspected by ultrasonic flaw-detector for the absence of defects on the outer and inner surfaces of the tubes and inside the metal of the tubes.
Overall non-straightness (bow) of the tubes is not over:
- 2 mm - for tubes with the outer diameter of 88 mm;
- 3 mm - for tubes with the outer diameter of 89 mm.
Packaging and marking.
Each tube with the outer diameter of 88 mm is packed in polyethylene film. Tubes with the outer diameter of 89 mm are packed in paper, placed on supporting cradle and packed in wooden or metal boxes orcontainers. The packaging of tubes makes it impossible for tubes to move inside the containers, to get contaminated, to have surfaces damaged, to have the shape of the tube changed. Transportation marking is transportation signs and the producer, net weight, gross weight, alloy designation, heat number (lot number), outer diameter of the tubes, customer's name and address.
Transportation and storage
Packed tubes can be transported by all kinds of transport. While transportation the tubes shall be protected from mechanical damage, contact with atmosphere moisture and corrosive chemical substances. Tubes must be stored as packed in closed storage place, which excludes mechanical damage of tubes, contacts with moisture and corrosive chemical substances.
Cladding cold-rolled tubes
Tubes are produced of zirconium alloys of reactor grade with Niobium texts 1%. At customer's request the mass weight of nitrogen, carbon, hydrogen, oxygen and copper in the tubes metal can be determined. Its texts is not over: nitrogen(N) - 60 ppm, carbon(C) - 200 ppm, hydrogen(H) - 15 ppm, oxygen(О) - 1000 ppm, copper(Cu) - 70 ppm. After manufacturing the tubes are annealed, outer and inner surfaces are pickled. At customer's request tubes can be supplied in recrystallized condition. Tubes are corrosion-resistant.
Geometrical dimensions of tubes and their tolerances(mm).
| Outer diameter |
Inner diameter |
Wall thickness |
|
| nominal |
limit |
nominal |
limit |
nominal |
limit |
|
| 9.13 |
+0.06
−0.05 |
7.72 |
+0.07 |
not less 0.62 |
— |
|
| 9.15 |
±0.05 |
7.72 |
+0.08 |
not less 0.63 |
— |
|
| 10.3 |
±0.07 |
8.80 |
+0.10 |
not less 0.65 |
— |
|
| 11.2 |
±0.10 |
9.60 |
+0.10 |
not less 0.70 |
— |
|
| 12.6 |
±0.15 |
— |
— |
not less 0.85 |
±0.10 |
|
| 13.58 |
+0.05
−0.07 |
11.70 |
+0.10 |
not less 0.85 |
— |
Tube length is not over 4500 mm. The bow of the tube in 500 mm of length - not over 0,5 mm , and in the whole length - 1,5 mm.
Inspection
Tubes are inspected by ultrasonic and eddy current methods for the absence of defects on the outer and inner surfaces and inside of the metal of tubes. The coefficient of hydride orientation in the metal of tubes and also the texts of fluor on the surface of tubes are determined and certified. At customer's request the tubes may be subjected to metallographic inspection of metal microstructure on the cross section of the samples to define the real grain size.
Packaging and marking
Tubes are covered by paper, polyethylene film and placed in wooden or in receivable metal box. Tubes are packed so as to make it impossible for them to move inside the packing, to get contaminated, to getdamaged surfaces and changes in shape. Transportation marking is marking tare with transportation signs and producer, net and gross weights, alloy designation, lot number, tubes dimensions and customer's name and address.
Transportation and storage
Packed tubes can be transported by all kinds of transport. While transportation tubes should be protected from mechanical damages, contact with moisture and corrosive chemical substances. Tubes should be stored as packed in closed storage rooms. Storage life is 2 years from the date of dispatch.
Rods
Rods as well as tubes are necessary material in construction of fuel rods and fuel assemblies of nuclear reactors. They are used for producing end plugs for fuel rods and different elements of fuel assemblies.
The ChMP produces rods as cold-extruded, hot-extruded, cast, hot-pressed, cold-rolled, forged (by cold forging method) in diameter from 4,5 to 81 mm, up to 7400 mm long;
Rods are manufactured from zirconium alloys with niobium texts 1 % or 2,5 %, and from alloy Е635. Rods are corrosion resistant.
According to the precision level of manufacturing rods can be divided in two grades: standard and highly precision rods.
Geometrical dimensions of improved precision rods and their tolerances (mm)
| Diameter |
Lenght |
Tolerance of the rod generatrix per 1 m lenght |
|
| nominal |
limit |
nominal |
limit |
|
| 4.5 |
−0.10 |
from 500
to 1500 |
+5.0 |
5.0 |
|
| 9.0 |
+0.15 |
not less 1500 |
— |
1.5 |
|
| 9.6 |
+0.15 |
not less 200 |
— |
1.5 |
|
| 12.0 |
+0.30 |
7410 |
+50.0 |
— |
|
| 13.2 |
±0.20 |
not less 1500 |
— |
1.5 |
|
| 14.0 |
±0.15 |
кратна 200 |
+10.0 |
1.5 |
|
| 14.3 |
±0.20 |
not less 1500 |
— |
1.5 |
|
| 20.0 |
±0.20 |
not less 1500 |
— |
5.0 |
|
| 22.0 |
±0.15 |
not less 1500 |
— |
5.0 |
|
| 23.0 |
±0.30 |
not less 1500 |
— |
5.0 |
|
| 27.0 |
±0.30 |
not less 1500 |
— |
5.0 |
|
| 30.0 |
±0.30 |
not less 1500 |
— |
5.0 |
|
| 35.0 |
±0.30 |
divisible 380 |
+5.0 |
5.0 |
|
| 62.0 |
+3.0 |
2510 |
+30.0 |
unchecked |
|
| 80.0 |
±0.50 |
by the order |
+10.0 |
unchecked |
|
| 81.0 |
+2.50
−1.50 |
divisible 180 |
+10.0 |
unchecked |
Inspection
Rods undergo radiographic and ultrasonic inspection for the absence of any defects inside body of rod.
Packaging and marking.
Rods are packed in wooden or metal box or container. Rods packaging makes it impossible for them to move inside the box or container, to get contaminated, to have surfaces damaged, to change shape. Transportation marking is all transportation signs and producer, net weight, gross weight, alloy designation, lot number, rods diameter, customer's name and address.
Transportation and storage.
Packed rods can be transported by all kinds of transport. During transportation rods are protected from mechanical damaging, contact with moisture and corrosive chemical substances. Rods must be stored as packed in closed storage rooms, which excludes mechanical damaging, contact with moisture and corrosive chemical substances.
Crystal-bar zirconium
Crystal-bar zirconium with pseudocrystalline surface appearance (Van Arkel rods) are a special kind of products. It is the most pure zirconium. It is manufactured by iodide refining method of zirconium metal turnings.
Dimensions
Length - max 1400 mm, diameter - max 25 mm.
Marking
The marking is made by water-proof paint on top of the box. The marking consists of the name of the product, lot number, net and gross weights, the producer, customer's name and address.
Packaging and transportation
Rods are packed in wooden boxes, 500 kg per a box. The lot is not over 1000 kg. Packed crystal-bar zirconium can be transported by all kinds of transport. While transportation the rods should be protected from mechanical damaging, atmosphere moisture and corrosive chemical substances.
Cold-drawn zirconium alloy wire
Zirconium alloy wire is necessary for production of channels and fuel elements of nuclear cores. In channel manufacturing wire is used as filling wire during the weld of tubular channel parts. Such kind of wire is produced from zirconium alloys with niobium texts 1% or 2,5%. Special spring alloy C2M wire is used for fuel elements manufacturing. All kinds of wire are manufactured by cold drawing method from 0,9 mm to 3,0 mm in diameter;
Zirconium alloy wire with niobium texts 1% or 2,5% is supplied in annealed condition with pickled surface. The material of wire is corrosion resistant and is tested for porosity absence.
Geometrical dimensions of the wire and their tolerances (mm)
| Diametr |
Lenght |
Method of processing |
|
| nominal |
limit |
nominal |
|
| 0.9 |
−0.10 |
not less 200 |
drawing |
|
| 2.0 |
−0.04 |
|
| 2.5 |
−0.05 |
|
| 3.0 |
−0.05 |
When agreed by the customer and the producer the wire can be manufactured in other diameters. Non-roundness of the wire is within the diameter tolerance.
Spring zirconium alloy C2M wire
is supplied after vacuum annealing with pickled surface. The material of the wire is corrosion resistant.
Geometrical dimensions of the wire and their tolerances (mm)
| Diameter |
Lenght |
Method of processing |
|
| nominal |
limit |
nominal |
|
| 1.0 |
−0.05 |
not less 2000 |
drawing |
|
| 1.2 |
|
|
| 1.5 |
not less 10000 |
|
| 1.8 |
When agreed between the customer and the producer wire can be manufactured in other diameters. Wire non-roundness is within the diameter tolerances.
Packaging and marking.
Wire coils are covered in paper and packed in a wooden box, covered with polyethylene film from inside. Wire packaging makes it impossible for wire to move inside the tare, to get contaminated, to have damaged surfaces and changed shape. Transportation marking is showing all transportation signs and producer, net and gross weights, alloy designation, lot number, customer's name and address.
Transportation and storage.
Packed wire can be transported by all kinds of transport. While transportation wire is protected from mechanical damaging, contact with moisture and corrosive chemical substances. Wire must be stored as packed in closed storage rooms, which excludes its mechanical damaging, contact with moisture and corrosive chemical substances.
Cold-rolled zirconium alloy sheets
Sheets are manufactured from zirconium alloys of nuclear grade with niobium texts 1.0% or 2.5%. After cold rolling of the sheets they are annealed, and their surfaces are pickled. The sheets are corrosion resistant. Zirconium alloys sheets serve as a material for fuel assemblies shrouds (channel) of nuclear reactors. They can also be used for manufacturing of shells and bodies for vessels of chemical reactors in chemical industry.
Sheets geometrical dimensions and their tolerances (mm)
| Thickness |
Widht |
lenght |
|
| nominal |
limit |
nominal |
limit |
nominal |
limit |
|
| 1.5 |
+0.15 |
250 |
+5.0 |
2775 |
+10.0 |
|
| 1.5 |
+0.20 |
418 |
+10.0 |
3680 |
+10.0 |
|
| 2.0 |
±0.15 |
250 |
+5.0 |
2775 |
+10.0 |
When agreed with the customer sheets of other dimensions can be manufactured, but not over 420 mm wide, 3800 mm long and from 0,5 mm to 5,0 mm thick.
Sheets are supplied with even, sheared or shaved edges.
Non-straightness tolerance:
- 3 mm for 1 m of length - for sheets not over 300 mm wide;
- 5 mm for 1 m of length - fro sheets 300 mm wide and over.
Camber of sheets is not over 5 mm for the whole length.
Packaging and marking.
Every sheet is covered by paper and placed in wooden or metal box or containers). The packaging of sheets makes it impossible for them to move inside the box or containers, to get contaminated, to have damaged surfaces and changed shape.
Transportation marking is showing all transportation signs and producer, net and gross weights, alloy designation, lot number, the sheets designation, customer's name and address.
Transportation and storage.
Packed sheets can be transported by all kinds of transport. While transportation sheets are protected from mechanical damaging, contact with moisture and corrosive chemical substances.
Sheets must be stored as packed in closed storage rooms, which excludes mechanical damaging of sheets, contacts with moisture and corrosive chemical substances.
Zirconium Compounds
Besides being used as a construction material, zirconium can build oxides, zirconium dioxide in a stable form. Zirconium dioxide can be used as an additive in glass production, in production of refractory ceramics, and if we use the so called stabilization of zirconium dioxide with other metals oxides, for example ferrous oxide, yttrium, we can use it for production of especially hard ceramic items for special purposes, for example, for production of electrochemical power generators, pumps for oil industry, refractory materials, and grinding bodies, in the form of balls in ball grinding mills for grinding of highly pure products.
The ChMP starts production of the following zirconium compounds:
- zirconium dioxide (monocline);
- zirconium dioxide (stabilized with yttrium oxide);
- zirconium carbonate;
- zirconium sulphate;
- grinding bodies on the basis of zirconium dioxide;
- ceramic items.
The more detailed to look here
Zirconium-steel welded joints
The production of bonding strength and leak-proof special zirconium-steel welded joint for RBM-K nuclear reactor fuel channels, was started by ChMP in 1971. This joint differs greatly from mechanical joint, used for channels of Canadian HPWR CANDU, by its improved strength, leak-proof ness and long life time.
The inner part of a welded joint is made from zirconium alloy, the outer part is made from the stainless steel. The joint is a special connection of two bushings, one inside the other which are welded together by diffusion welding. The tension of the connecting line, which is due to the difference between the quotients of thermal expansion of steel and zirconium, is secured by a special design of bushings, which cares for the working condition of the joint, helps to avoid cracking in the place of weld.
The ChMP can manufacture welded joints of such kind at customer's request not only for nuclear application, but also for another applications, for example, in chemical industry.
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Other Zirconium products
ChMP has an ability to produce the items of various shapes by machining and welding: fittings, flanges, parts of pipe lines, parts of pumps, plasma spraying cathodes and various equipment (filters, tanks etc.).
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