Due to debris in the coolant against clad, fuel clad wear, fuel handling fault and so on, fuel rods maybe be damaged during the operation of nuclear power plants, in order that the fuel assemblies with damaged fuel rods are discharged before scheduled. If the damaged fuel assemblies are not reloaded into the core of the nuclear power plant, the fuel utilization decreases and the economy of the nuclear power plant is partly lost. For retrieving the loss of the economy, the damaged fuel assemblies can be repaired by replacing damaged fuel rods with dummy rods which don’t include fissile nuclides. Then, the repaired fuel assemblies can be reloaded into the core. As the repaired fuel assemblies are different with the normal fuel assemblies, especially the number of the damaged fuel rods is considerable, a whole quantitative analysis is very necessary to evaluate the effects from the reuse of the repaired fuel assemblies. In this paper, a full scope evaluation of reload design are performed including nuclear design, fuel design, thermal hydraulic design and safety evaluation, and some necessary improvements are done for the software system, design methods and progress which have been used in the normal reload design. As results, an integrated evaluation technique is developed to evaluate the feasibility and safety of reusing the repaired fuel assemblies, and the key effects due to the reuse of the repaired fuel assemblies are extracted, and the different effects are studied for the different materials of the dummy rods which can be used to conduct how to choose the proper material of dummy rods. In addition, this technique has been successfully applied in the engineering and the loss of economy due to the damage of fuel assemblies was retrieved partly. Therefore, the integrated evaluation technique has also important directive to other nuclear power plants if the repaired fuel assemblies are planned to reuse.

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