ML18190A166

R. E. Ginna - 03/09/1976 Steam Generator Inspection Final Report

ML18190A166
Person / Time
Site:	Ginna
Issue date:	03/09/1976
From:	Rochester Gas & Electric Corp
To:	Office of Nuclear Reactor Regulation
References
Download: ML18190A166 (22)

Text

0 Ginna Station Steam Generator lns ection Final Re ort March 9, 1976 Rochester Gas and Electric Corporation performed a planned inspection of Ginna Station steam generators from February 15, 1976 r

through February 27, 1976 in accordance with the Inservice Xnspection Program requirements as part of the annual refueling and maintenance outage.

A 100% inspection of unplugged tubes in both steam generator inlets and outlets was performed to evaluate the effect of the All Volatile Treatment water chemistry control program instituted in November 1974 and to verify the acceptability of the steam generators for continued operation.

The inspection program just completed is detailed in Figures (1) through (4) and included eddy current examination at 400 KHZ of 100% in both steam generator inlets and outlets.

Each tube was examined from at least the first support through the tube sheet, with approximately 200 tubes in each steam generator being examined over the U-bend section; and for dent, evaluation approximately 600 tubes in the "A" inlet, 450 tubes in the "A" outlet and 200 tubes in'both the "B" inlet and outlet were examined from the sixth tube support through the tube sheet.

The examination of approximately 160 tubes in both steam generator inlets and outlets at 25 KHZ was performed to determine sludge profiles on the secondary side of the tube sheets.

The "A" steam generator was inspected prior to secondary side washing and the "B" steam generator after secondary side washing.

Results of these examinations are given in Figures (5) through (7) which includes the "A" inlet and the "B" inlet and outlet, respectively.

There is not a figure for the "A" outlet due to the Page 1 of 22

fact that there were not, any indications 20%.

Table (1) of this report is included for comparison of the last four steam generator examinations.

All of the eddy current indications were within the first few inches of tubing directly above the tube sheet.

These indications, with the exception of three, are postulated to be due to wastage, based on growth rates.

The excepted three tubes, in the "A" inlet.,-

due to their larger growth rates compared to the mean, may have been caused by concentration of caustics.

Confirmation of. this is not possible since the eddy current examination method cannot differ-entiate between indications resulting from either wastage or stress corrosion cracking, but can accurately measure the maximum defect penetration to within normal statistical variation.

The indications are seen only in those areas where indications have been previously noted.

There has been no expansion of the indication region to other areas of the steam generators.

This inspection confirmed that the tube leak found in January 1976 was a random failure as reported in Reportable Occurrence 75-13.

Several things are noted from a comparison of results shown in Figures (5) through (7).

First the A inlet, with 39 tubes 40%

indications (present pluggable defect size) has shown only a

5% average growth rate over the past year considering tubes which had indications

>20% for the last two inspections.

Figure (8) is a histogram of the growth rate.

Similarly, the "B" inlet has shown only small changes in degradation with, the average growth rate over the past year, fog tubes>

20$, of a negative 1.72% and 2 pluggable tubes.

A histogram for the "B" inlet indications is shown in Figure (9).

This negative mean for changes in indication magnitude is attributed to statistical variations in the eddy current examination Page 2 of 22

N method.

The "A" outlet continues to be in excellent condition with only 10 indications of <20% and no reportable

(

>20%) indica-tions.

The "B" outlet has a large number of indications<

20%.

This large number is due to the increased number of inspected tubes and the differences in interpreters of the eddy current examination results.

There were two indications

>20% with both

<25%.

The dent evaluation program performed on bath steam generators, leads to the conclusion that there is not a denting problem in either steam generator.

Those dents which were identified are probably the result of original fabrication, due to their insignificant size

(

<5 mils).

The small number of tubes in both inlets which have experienced deterioration, inconsistent with the average, are believed to have deteriorated from the concentration of residual phosphates in the secondary side sludge deposits.

These concentrations of phosphates are caused by the remaining traces of sludge deposits formed during the period of phosphate control of the secondary system water chemistry before the conversion to AVT chemistry control in November 1974.

Removal of residual phosphates from the secondary side over the past 18 months of operation has been accomplished by continuous steam generator blowdown and high pressure water lancing.

The high pressure water lancing performed on the. secondary side is designed to remove as much of the sludge as possible, which contains the undesirable residual phosphates and/or caustics.

Blowdown samples taken during normal operation indicated only small amounts of phosphates

present, although phosphates in the sludge could revert back into PO"= and concentrate on the tube surfaces which, depending on the molar ratio, would result in'acidic or caustic Page 3 of 22

attack of the tub'e.

That the degradution was caused by pockets in the sludge is supported by the fact that 33 of the 39 pluggable tubes in the "A" inlet which deteriorated to > 40% indications were in adjacent areas within the historical sludge kidney area.

Figures (10) through (13) illustrate the sludge profiles for this most recent inspection.

Ginna Station adherence to AVT chemistry control has generally been within specifications during the past year as illustrated on Figures (14) and (15).

The AVT chemistry specification for normal power operation and the limiting conditions are given on Table (2).

The series of modifications performed on the steam generators in March 1975 to decrease the area of the tube sheet which is sus-ceptible to low flow conditions and sludge buildup have reduced the average sludge depth but has not significantly changed the area of the sludge deposition.

The corrective action taken to ensure the continued reliability of the steam generators includes the following:

a

~

All tubes with eddy current indications of wall penetration b.

greater than or equal to 40% were plugged.

A thorough lancing of the secondary side of the tube sheets was performed in both steam generators to remove as much as possible any remai,ning phosphates and/or caustics contained within the sludge.

Sludge lancing of both steam generators will,be continued in an effect to keep sludge content to a minimum.

The lancing, coupled with blowdown during startup and normal operation, should considerably reduce the probability of significant tube degraduation during the plants'ub-sequent operation.

Page 4 'of 22

0

~

c.

In addition, a modification of the plant's secondary condensate system is under construction which is designed to insure that the feedwater entering the steam generators will be of the highest purity.

This modification will add in-line demineralizers to the condensate

system, and is scheduled to be placed in service following the next refueling outage in March 1977.

Because it has been established that all but 41 tubes from both steam generators had less than 40$ defect indications; because there were only a few tubes which experienced comparatively rapid degradation; and because sludge 3,ancing should further reduce the probability of phosphate and caustic pockets forming, the steam generators are considered acceptable for uninterrupted use until the planned refueling outage in the Spring of 1977, approximately 1 year from the expected date of return to service of Ginna Station.

An eddy current examination of the steam generators in accordance with the Inservice Inspection Program shall be performed during the 1977 refueling outage.

Page 5 of 22

TABLE ill STEAM GENERATOR POS XTION XNDXCATION SIZE (%)

FEB.

1974 EXAMINATIONDATE NOV. 1974 MAR. 1975 FEB.

1976 IIAII 1lALET 420 20-24 25-29 30-34 35-39 40-44 45-49

/50 329 63 50 36 14 24 12 17*

631 59 46 31 25 14 52*

655 109 63 38 27 22+

14*

10*

230 59 47 50 31 19*

8*

12*

TOTAL "A" INLET TUBES EXAMXNED AT EACH INSPECTION 3260 1655 2174 3192 STEAM GENERATOR POSITION IIAII OUTLET INDICATION SIZE(%)

C20

)20 58 0

NOV.

278 0

EXAMINATIONDATE MAR. 1975 FEB.

197 10 0

TOTAL "A OUTLET TUBES EXAMINED AT EACH INSPECTION 516 430 442 3192 STEAM GENERATOR POSITION INDICATION SXZE FEB.

97 NOV 197 MAR.

975 EXAMINATXONDATE FEB 1976 IIBII INLET (20 20-24 25-29 30-34 35-39 40-44 45-49

+50 21 4

2 0

0

'0 0

0 490 3

4 1

1 0

0 0

411 13 10 9

5 1*

0 10*

764 25 8

9 3

1*

0]*

TOT L B

INLET TUBES EXAMINED AT EACH INSPECTION 10/8 675 1931 3247 STEAM GENERATOR POSXTION IIBII OUTLET XNDICATION SIZE (20

>20 EXAM FEB.'1974 NOV. 1974 NATION DATE MAR. 1975 FEB 1976 1003 2

TOTAL ".B" OUTLET TUBES EXAMINED AT EACH INSPECTION 516 39 442 3247 NOTE:

Two tubes in the "B" steam generator were explosively plugged in January 1976.

These tubes are not shown in the above table.

• TUBES WERE EXPLOSIVELY PLUGGED page 6 of 22

TABLE (2)

AVT CHEMISTRY SPECIFICATIONS Blowdown Analysis Characteristic Normal Power Operation Expected Value Control Value pHQ25 C

Cation Conductivity (p. Mhos/cm) r Fre e Hydroxide (ppm a s Ca CO3)

NH (ppm)

Na (ppm)

Cl (ppm)

8. 5 - 9. 0

<0. 15

<0. 25

<0. 10

<0. 15 8.5 - 9.0

2. 0

0. 15 Si02 (ppm)

Suspended Solids (ppm)

Blowdown Rate (gpm/SG)

<1.0

< l. 0 Continuous as Required to Maximum Limiting Conditions Blowdown Analysis Characteristic Two Weeks 24 Hours Immediate Shutdown Maximum Recommended 0 eratin Period Before Shutdown pH@ 25 C

Cation Conductivity (PMhos/cm)

Free Hydroxide (ppm CaCO

)

Blowdown Rate

8. 5

9. 2

<8. 5 or >9. 2

>2. 0 Jut <5

60. 15

)5 but C7 W0.15 but ( l. 0 Maximum Available Capacity

)7 page 7 of 22

X -25Khz to 1st support O -400Khz to 6th support "A" S/G INLET Pjg-400Khz over U-bend All tubes not marked-400Khz to 1st support 92908886 8482807876 7472 7068666462 60585654 525048464442 40 38 3634 3230 2826 24 22201816141210 8

6 4

2 91 89 87 85 83 79 77 75 73 71 69 67 65 63 61 59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21

~ 19 17 5

I 13 1

9 7

5 3

1 45 43

-4 37 35

-31 S

m.

27

.24 2'2 21 19 18 17

.16'5 8

7 6

4 3

2 NOZZLE FIGURE (1)

X-25Khz to 1st support 6 <<400Khz to 6th support "A" S/G 0UTLET All tubes not marked-400Khz to 1st support COLUNN5 92908886 848280 7876 7472 7068666462 60 585654 525048464442 40 38 3634 3230 282624 22201816141210 8

6 4

2 91 89 87 8 83 8 79 77 75 73 71 69 67 65 63 61 59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 17 15 13 ll 9

7 5

3 NNMAY NOZZLE 45 44 37 36 35 34 32 30 28 27 26 25 23 22 21 19 17 15 16

.14 13 11 8

7 6

5 4

3 1

2 ROMS FIGURE (2)

g -25Khz to 1st support 6 -400Khz to 6th support "B" INLET Pjg-400Khz even 0-bend All tubes not marked-400Khz to 1st support 92908886 848280 7876 7472 7068666462 60585654 52504846 4442 40 38 3634 3230 282624 22201816141210 8

6 4

2 91 89 87 85 83 81 79 7 75 73 71 69 6 65 63 61 59 57 55 53 51 49 47 45 43 41 39 373533 31 9 27 25 2

21 191 7 513 11 9

7 5

3 1

45 44 MANMAY NOZZLE 43 41 39 37 36 34 32 30 28 27 26 25 24 23 22 21 19 18 17 16 15 13ll 9

7 6

4 3

2 1

ROMS FIGURE (3)

IlgIl PUTLET X -25Khz to 1st support

-400Khz to 6th support All tubes not marked-400Khz to 1st support COLOSS 9290888684828078767472 7068666462 60585654 525048464442 40 383634 3230 282624 22201816141210 8

6 4

2 91 89 87 8 83 81 79 77 75 7 71 69 67 65 63 61 59 57 55 53 51 49 45 43 41 3

37 35 33 31 29 27 25 23 21:19 17 15 13 5

3 1

oth NANMAY NOZZLE 45 4S 41 39 37

- 36 35 34 31 30 29 27 24 23 22 21

]9 18 17 15 n

10.

8.

7 6

4 3

2 1

ROMS FIGURE (4)

X 20% to 39%

40% to 59%

"A" INLET EDDY CURRENT INDICATIONS Q60% to 79%

80%

to 90%

92908886 8482807876 7472 7068666462 60585654 525048464442 4038 3634 323028262422201816141210 8

6 4

2 91 89 87 85 83 81 79 77 75 73 71 69 67 65 63 61 59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 2

27 25 23 21 19 17 15 13 11 9

7 5

3 1

45 39 38 37 36 35 34 33 32 30 29 27 6

25 23 22 21 18 17 15 16 11 8

7 6

4 3

2 NNAY

. NOllLE ROllS FIGURE (5)

g 20% to 39%

40% to 59%

"B" INLET EDDY CURRENT INDICATIONS dh 60% to 79%

Q 80% to 90%

COLUYNS 92908886 848280 7876 7472 7068666462 60 585654 525048464442 40 38 3634 3230 282624 22201816 141210 8

6 4

2 91 89 87 85 83 81 79 77 75 73 71 69 67 65 63 61 59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 17 15 13 11 9

7 5

3 1

45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15

13 e

40 38 36 34 32 30 28 26 24 22 20 18 16 10 8

6 4

2 0th HANAY NOZZLE ROllS FIGURE (6)

g20% to 39%

Q40% to 59%

"B" OUTLET EDDY CURRENT INDICATIONS

+ 60% to 79%

'Q 80% to 90%

COLlRHS 92908886 848280 7876 7472 7068666462 60 585654 525048464442 40 38 3634 3230 282624 22 201816141210 8

6 4

2 91 89 87 85 83 81 79 77 75 73 71 69 67 65 63 61 59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11 9

7 5

3 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15

13 38 36 34 32 28 26 24 22 18 16I 8

6 4

2 NNAY NOZZLE ROMS FIGURE (7)

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READINGS

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"A" S/G INLET SLUDGE PROFILE Q

= 2 inches I

7 5

3 1

51 49 47 45 43 41 39 37 35 33 31 29 27 25 23/21.19 17 15 13 I

85 83 81 79 77 75 73 7'1 69 67 65 63 61 59 57 55 53 11 9

91 89 87 COLlMS 92 90 88 86 84 82 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8

6 4

2 45

~

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"-18 17 14 9

6 5

3 2

1 NNAY NOZZLE FIGURE (10)

"A" S/G OUTLET SLUDGE PROFILE Q = 2 inches 92908886 8482807876 7472 7068666462 60585654 5250484644424038 3634 3230 282624 22201816 141210 8

6 4

2 91 89 87 85 83 81 79 77 75 73 71 69 67 65 63 61 59 57 55 53 51 49 47 45 43 41 39 37 35 33 I

31 29 27 25 23 21

~ 19 17 15 13 11 9

I 7

5 3

1 45 Q

39 37 35 36 34 33 Q 31 30 29 27 26 25 g 22 21 19 18 17 g 15

14 13 11 9

7 6

5

~-

3 NNAY N012LE FIGURE (11)

B" S/G INLET SLUDGE PROFILE Q

= 2 inches COt.UlOS 92908886 8482807876 7472 7068666462 60585654 525048464442 40 38 3634 3230 282624 22201816 141210 8

6 4

2 91 89 87 85 83 81 79 77 75 73 71 69 67 65 6 3 61 59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 i

I 21 19 17 15 13 ll 9

7 5

3 1

HA%AY NOZZLE 45 43 (y 39 37 36 34 33 Q 31 29 27 25 23 22 18 17Q 14 9

6 5

1 ROMS FIGURE (12)

"B" S/G OUTLET SLUDGE PROFILE Q = 2 inches COLUNNS 92908885 8482807876 7472 7068666462 60585654 525048464442 40 38 3634 3230 282624 22201816141210 8

6 4

2 91 89 87 8 83 81 79 77 75 73 71 69 67 65 63 61 59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21.19 17 15 13 11 9

I 7

5 3

1 45 4

43 41

~

39 37 36 35 33 Q 30 29 27 25 23 22 21 (y 18

. 17 -Q6 7

5 3

2 NNMAY NOZZLE ROMS FIGURE (13)

R. E.

GINNA STATlON 1975 "A" STEAM GENERATOR CHEMISTRY I

JASUAST D 101 ~ 5055 TCSSUASY 5

101 ~ 5055 UASCN S

10. IS>>50 CS

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A>>AIL 5

IO IS 5015 SAY

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10 15 5055 AUOINT 5 10155055, 5

10 I~ 5055 SCSTCUSCS OCTOSCS IO 15 50 AS NOYCUSCS 5 N I~

OCCCINCS FIGURE (14)

R. E.

GZNNA STATION 1975 "B" STEAM GENERATOR CHEMISTRY Ei 2

JANVAAY 0

10 IS 202S YCSSUASY

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Io I~ 20 20 JANUAIIY 0

IO I~ 20 2 ~

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10 lc. 20 NASCN 0

lo IS 20 22 ASS IL Io IS 20 22 NAT

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Io IS 20 JUNC 0

lo I~ 20 ES JULY 0

lo 1$ 2022 AUOULT Io IS 20 ES S EST CN SR 0

lo IS 20 ES OC'IUSCA

~

10 IS 20 0

NOYCNSR

~

Io IS 20 22 DCCCNSR 0

FIGURE (15)