Eng
Ukr
Print
2026 №05 (05) DOI of Article
10.37434/as2026.05.06
2026 №05 (07)

Automatic Welding 2026 #05
"Avtomatychne Zvaryuvannya" (Automatic Welding), #5, 2026, pp. 45-59

Reliability assessment of welded structures of absorbing elements of control and protection systems of WWER-1000 and WWER-440 nuclear reactors (Review)

O.S. Milenin, O.O. Makhnenko

E.O. Paton Electric Welding Institute of the NAS of Ukraine 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: asmilenin@ukr.net

To ensure the safety of nuclear power plants in Ukraine, a crucial role is played by the Control and Protection Systems (CPS) with absorber elements (AE) ‒ the rod cluster control assembly (RCCA) of the WWER-1000 reactor and the extensions of the emergency control cassettes (ECC) of the WWER-440 reactor. The complexity of the operational impact on the AE, which are welded structures, necessitates an in-depth study of the physical and technological processes to ensure their structure integrity and reliability. Currently, the methods for predicting the limit state and service life of the AE elements in the CPS are insufficiently developed. This makes it impossible to extend the limited term of safe operation of these elements, which was assigned during the design of the nuclear power units. 50 Ref., 3 Tabl., 14 Fig.
Keywords: nuclear reactors, WWR-1000, WWER-440, control and protection system, absorber rods, emergency control cassette extensions, welded joints, term of safe operation


Received: 21.05.2026
Received in revised form: 31.07.2026
Accepted: 30.09.2026
Posted online: 20.10.2026

References

1. (1989) PNAE G-7 Codes for Strength Analysis of Nuclear Power Plant Equipment and Piping. Moscow, Energoatomizdat [in Russian].
2. Makhnenko, V.I. (2006) Safe service life of welded joints and assemblies of modern structures. Kyiv, Naukova Dumka [in Russian].
3. Shugailo, O., Banko, S., Brik, D. et al. (2023) Ensuring the operability of NPP components and structures during design and long-term operation (analytical studies and operational experience). Ed. by O. Shugailo. Kyiv, DNTTs YaRB [in Ukrainian]. DOI: https://doi.org/10.32918/978-966-2544-81-7
4. Kharchenko, V.V., Chirkov, A.Yu., Kobelskyi, S.V., Kravchenko, V.I. (2018) Calculation analysis methods in problems of strength of equipment elements of WWER reactor installations. IPS, Kyiv, Ukraine [in Russian].
5. Torop, V.M. (1998) Scientific and technical section: Monitoring of strength as a necessary condition of safe operation of the equipment of nuclear power plants. Pt. 1. Methodology and realization. Strength of Mater., 30(2), 107-113. https://doi.org/10.1007/BF02811275
6. Dewes, P., Roppelt, A. (2000) The role of cladding material for performance of LWR control assemblies. In: Experience, performance and perspectives. Technical committee meeting on control assembly materials for water reactors, 215-227.
7. Afanasiev, A. (2000) Experience of CR and RCCA operation in Ukrainian WWER-1000: Aspects of reliability, safety and economic efficiency. In: Experience, performance and perspectives. Technical committee meeting on control assembly materials for water reactors, 77-89.
8. Makarenko, A., Chaikovskyi, M., Mazurok, O., Zuyok, V., Mykhaylenko, O. (2024) Calculation analysis of VVER-1000 RCCA elements to justify lifetime extension. Nuclear and Radiation Safety, 3(103), 26-35. https://doi.org/10.32918/nrs.2024.3(103).03
9. Chopra O.K. (2010) Degradation of LWR core internal materials due to neutron irradiation. NUREG/CR-7027. ANL-10/11.
10. Zuyok, V.A., Tretyakov, M.V., Rud, R.O. (2023) Corrosion resistance of the produced by Ukrainian enterprises main structural materials for the primary circuit of pressurized water reactors to substantiate its application and further licensing. Chemical Technologies for Reconstructing Ukraine in the War and Post-War Periods, 92-116. https://doi.org/10.30525/978-9934-26-329-3-6
11. Risovanyi, V., Khudyakov, A., Ostrovsky, Z. (1998) Properties and structure of control rod dummies claddings made of EP-630U alloy and 08Cr18Ni10Ti steel after reactor irradiation. Proc. of SSC RF RIAR, 4, 81-90.
12. Chyrkov, O.Yu. (2020) Radiation creep in problems of mechanics of stress deformation of materials and structure elements. IPS, Kyiv, Ukraine [in Ukrainian].
13. Zuyok, V., Mazurok, O., Godun, O. et al. (2025) Justification of RCCAs lifetime extension at operating Ukrainian NPPs. Summary calculations. Nuclear Engineering and Design, 437, 114008. https://doi.org/10.1016/j.nucengdes.2025.114008
14. (2013) Guidelines for Integrity and Lifetime Assessment of Components and Piping in WWER Nuclear Power Plants (VERLIFE). Vienna, Int. At. Energy Agency.
15. Makhnenko, O.V., Kandala, S.M. (2022) Influence of residual process stresses on brittle fracture resistance of WWER- 1000 reactor baffle in case of an emergency. Technical Diagnostics and Non-Destructive Testing, 4, 12-16 [in Ukrainian]. https://doi.org/10.37434/tdnk2022.04.02
16. Kennard, M.W., Harbottle, J.E. (2000) LWR control assembly designs: A historical perspective. Experience, performance and perspectives. In: Technical committee meeting on control assembly materials for water reactors, 7-31.
17. Zuyok, V., Mazurok, O., Godun, O., Chaikovskyi, M., Tretyakov, M. (2024) Materials science analysis of RCCA structural materials and calculations for lifetime extension. Nuclear and Radiation Safety, 1(101), 38-48. https://doi.org/10.32918/nrs.2024.1(101).04
18. NP 306.2.141-2008. General Safety Provisions for Nuclear Power Plants [in Ukrainian].
19. NP 306.2.208-2016. Requirements for seismic design and seismic safety assessment of nuclear power plant units [in Ukrainian].
20. Paydar, A.Z., Balgehshiri, S.K.M., Zohuri, B. (2023) Advanced reactor concepts (ARC). Elsevier.
21. Kushtym, A.V., Zigunov, V.V., Grytsyna, V.M. et al. (2023) Characteristics of weld joints in absorbing rods made of 42CrNiMo alloy for VVER-1000 RCCA. Nuclear and Radiation Safety, 4(100), 38-48. https://doi.org/10.32918/nrs.2023.4(100).04
22. DSTU ISO 5817:2016. Welding. Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded). Quality levels for imperfections [in Ukrainian].
23. TUU 25.3-26444970-015:2020/12-1-060.00.00 TS. WWER-1000. Absorber rods. Technical specifications [in Ukrainian].
24. DSTU EN 10088-1:2019. Stainless steels. Pt. 1. List of stainless steels (EN 10088-1:2014, IDT) [in Ukrainian].
25. Balytskyi, O.I., Makhnenko, O.V., Balytskyi, O.O. et al. (2005) Fracture Mechanics and Strength of Materials: Reference Guide. Ed. by V.V. Panasiuk. Vol. 8: Strength of Materials and Durability of NPP Structural Components. Kyiv, Akademperiodyka [in Ukrainian].
26. TUU 25.3-26444970-022:2022. ARK Extension Unit. Technical Specifications [in Ukrainian].
27. Votinov, S.N., Maksymkin, O.P. (2002) On the question of the role of the energy of the packing defect in the change in the structure and properties of metals and alloys as a result of radiation and thermal exposure. Questions of Atomic Science and Technology, 3, 23-30 [in Russian].
28. Sorokin, A.A., Margolin, B.Z., Kursevych, I.P. et al. (2011) Effect of neutron irradiation on the mechanical properties of materials of WWER-type reactor cores. Questions of materials Science, 2(66), 131-151 [in Russian].
29. Smirnov, V.I., Margolin, B.Z., Lapin, A.N., Kokhonov, V.I., Sorokin, A.A. (2012) Neutron irradiation effect on the fracture toughness of 18Cr10NiTi steel and metal of its welds. Inorganic Mater.: Appl. Res., 3, 534-545. https://doi.org/10.1134/S2075113312060093
30. Mills, W.J. (1987) Fracture toughness of two Ni-Fe-Cr alloys. Eng. Fract. Mech., 26(2), 223-238. https://doi.org/10.1016/0013-7944(87)90199-8
31. Pokhmurskyi, V., Hnyp, I., Lychkovskyi, E. (2001) Materials science aspects of the reliability of NPP unit equipment. Proc. of the Shevchenko Scientific Society, 6, 22-42 [in Ukrainian].
32. Timofeev, B.T., Bazaras, Zh.L. (2007) Low-cycle fatigue of welded joints of 08Kh18N10T steel. Physicochemical Mechanics of Materials, 1, 104-109 [in Russian]. https://doi.org/10.1007/s11003-007-0013-4
33. Krasnorutsky, V.S., Petelguzov, I.A., Hritsina, V.M. et al. (2010) Investigation of the influence of VCR on corrosion processes in materials of the active zone of WWER reactors. Questions of Atomic Science and Technology, 5, 58-66 [in Russian].
34. Karpyuk, L.A., Savchenko, A.M., Leontyeva-Smirnova, M.V. et al. (2020) Steel cladding for WWER fuel pins in the context of accident-tolerant fuel. Prospects. Atomic Energy, 128, 218-222. https://doi.org/10.1007/s10512-020-00679-3
35. (2013) Guidelines for integrity and lifetime assessment of components and piping in WWER nuclear power plants (VERLIFE). Annex G to Appendix C. Swelling of RVI Materials, 63-64.
36. Margolin, B.Z., Murashova, A.I., Neustroev, V.S. (2012) Analysis of the influence of type of stress state on radiation swelling and radiation creep of austenitic steels. Strength Mater., 44(3), 227-240. https://doi.org/10.1007/s11223-012-9376-3
37. Zuyok, V., Gann, V.V., Zigunov, V.V. et al. (2024) Cooling of control rods and specification of critical temperatures to justify safe operation. In: Problems of Atomic Sci. and Technol., 40-48. https://doi.org/10.46813/2024-152-040
38. Garner, F.A. (2012) Radiation damage in austenitic steels. Comprehensive Nuclear Mater., 4, 33-95. https://doi.org/10.1016/B978-0-08-056033-5.00065-3
39. Zinkle, S.J., Tanigawa, H., Wirth, B.D. (2019) Radiation and thermomechanical degradation effects in reactor structural alloys. In: Structural Alloys for Nuclear Energy Applications, 163-210. https://doi.org/10.1016/B978-0-12-397046-6.00005-8
40. Rossini, N.S., Dassisti, M., Benyounis, K.Y., Olabi, A.G. (2012) Methods of measuring residual stresses in components. Materials & Design, 35, 572-58. https://doi.org/10.1016/j.matdes.2011.08.022
41. ISO 21432:2019. Non-destructive testing - Standard test method for determining residual stresses by neutron diffraction.
42. (2003) ASTM E837-01e1. Standard test method for determining residual stress by the hole drilling strain gauge method. In: ASTM Standard Book, 694-703.
43. Lobanov, L.M., Pivtorak, V.A. (1990) Holographic methods of research of stress-deformed composites and quality control of welded structures. In: Problems of welding and special electrometallurgy. Kyiv, Naukova Dumka, 47-51 [in Russian].
44. Ueda, J., Murakawa, H., Nakacho, K., Ma, N.X. (1995) Establishment of computational welding mechanics. Trans. of JWRI, 24(2), 73-86.
45. Harrison, R.P., Loosemore, K., Milne, J., Dowling R. (1980) Assessment of the integrity of structure containing defects. Report R/H R6- Rev. 2 of Central Electricity Generating Board. Bekeley.
46. Orynyak, I.V., Torop, V.M. (1991) Two-criterial evaluation of the limiting state of a cracked body under a nonsymmetric loading. Strength Mater., 23(11), 1177-1184. https://doi.org/10.1007/BF00780093
47. Dmytrakh, I.M., Tot, L., Bilyi, O.L. et al. (2012) Fracture Mechanics and Strength of Materials: Refer. Manual. Ed. by V.V. Panasyuk. Vol. 13: Serviceability of Materials and Structural Elements with Sharp-Notch Stress Concentrators. Lviv, Spolom [in Ukrainian].
48. Hobbacher, A. (2002) Recommendations for fatigue design of welded joints and components. Doc. IIW XIII-1539 96 / XV-845-96.
49. Horn, R.M., Kass, J.N., Rangantath, K. (1984) Evaluation of the growth and stability of stress corrosion cracking in sensitized austenitic pipings. J. Pressure Vessel Technol., 106(2), 201-208. https://doi.org/10.1115/1.3264329
50. Lobanov, L.M., Makhnenko, O.V., Milenin O.S. et al. (2025) Computer software for modeling a circumferential welded joint. The Paton Welding J., 8, 55-67, https://doi.org/10.37434/tpwj2025.08.06
This article is licensed under a Creative Commons Attribution Non-Commercial 4.0 International (CC-BY-NC).

Suggested Citation

O.S. Milenin, O.O. Makhnenko (2026) Reliability assessment of welded structures of absorbing elements of control and protection systems of WWER-1000 and WWER-440 nuclear reactors (Review). Automatic Welding, 05, 45-59. https://doi.org/10.37434/as2026.05.06

Advertising in this issue: