Three dimensional considerations in thermal-hydraulics of helical cruciform fuel rods for LWR power uprates

•We benchmarked the 4 × 4 helical cruciform fuel (HCF) bundle pressure drop experimental data with CFD.•We also benchmarked the 4 × 4 HCF mixing experimental data with CFD.•We derived new friction factors for PWR and BWR designs at PWR and BWR operating conditions from CFD.•We showed the importance of modeling the 3D conduction in HCF in steady state and transient conditions.

In order to increase the power density of current and new light water reactor designs, the helical cruciform fuel (HCF) rods have been proposed. The HCF rod is equivalent to a thin cylindrical rod, with 4 fuel containing vanes, wrapped around it. The HCF rods increase the surface area to volume ratio of the fuel and enhance the inter-subchannel mixing due to their helical shape. The rods do not need supporting grids, as they are packed to periodically contact their neighbors along the flow direction, enabling a higher power density in the core. The HCF rods were reported to have the potential to uprate existing PWRs by 45% and BWRs by 20%. In order to quantify the mixing behavior of the HCF rods based on their twist pitch, experiments were previously performed at atmospheric pressures with single phase water in a 4 by 4 HCF and cylindrical rod bundles. In this paper, the experimental results on pressure drop and mixing are benchmarked with computational fluid dynamic (CFD) using steady state the Reynolds average Navier–Stokes (RANS) turbulence model. The sensitivity of the CFD approach to computational domain, mesh size, mesh shape and RANS turbulence models are examined against the experimental conditions. Due to the refined radial velocity profile from the HCF rods twist, the turbulence models showed little sensitivity to the domain. Based on the CFD simulations, the total pressure drops under the PWR and BWR conditions are expected to be about 10% higher than the values previously reported solely from an empirical correlation based on the experimental data. The impact of 3D conduction in the HCF rods is shown to be negligible under steady state but significant under transient conditions.