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 Februaryr 15, 1976 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 greater than or equal to 40% were plugged.

b. 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

c. In addition, 0 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 XNDXCATION EXAMINATION DATE POS XTION SIZE (%) FEB. 1974 NOV. 1974 MAR. 1975 FEB. 1976 420 329 631 655 230 20-24 63 59 109 59 I IAII 25-29 50 46 63 47 30-34 36 31 38 50 1lALE T 35-39 14 25 27 31 40-44 24 14 22+ 19*

45-49 12 5 14* 8*

/50 17* 2* 10* 12*

TOTAL "A" INLET TUBES 3260 1655 2174 3192 EXAMXNED AT EACH INSPECTION STEAM GENERATOR INDICATION EXAMINATION DATE POSITION SIZE(%) NOV. MAR. 1975 FEB. 197 IIAII C20 58 278 10 OUTLET )20 0 0 0 TOTAL "A OUTLET TUBES 516 430 442 3192 EXAMINED AT EACH INSPECTION STEAM GENERATOR INDICATION EXAMINATXON DATE POSITION SXZE  % FEB. 97 NOV 197 MAR. 975 FEB 1976 (20 21 490 411 764 20-24 4 3 13 25 IIBII 25-29 2 4 10 8 30-34 0 1 9 9 INLET 35-39 0 1 5 3 40-44 '0 0 1* 1*

45-49 0 0 0 0

+50 0 0 10* ]*

TOT L B INLET TUBES 10/8 675 1931 3247 EXAMINED AT EACH INSPECTION STEAM GENERATOR XNDICATION EXAM NATION DATE POSXTION SIZE  % FEB.'1974 NOV. 1974 MAR. 1975 FEB 1976 IIBII (20 1003 OUTLET >20 2 TOTAL ".B" OUTLET TUBES 442 516 39 3247 EXAMINED AT EACH INSPECTION 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 Normal Power Operation Blowdown Analysis Expected Control Characteristic Value Value pHQ25 C 8. 5 - 9. 0 8.5 - 9.0 Cation Conductivity (p. Mhos/cm) 2. 0 r

F r e e Hydroxide (ppm a s Ca CO3) <0. 15 0. 15 NH (ppm) <0. 25 Na (ppm) <0. 10 Cl (ppm) <0. 15 Si02 (ppm) <1.0 Suspended Solids (ppm) < l. 0 Blowdown Rate (gpm/SG) Continuous as Required to Maximum Limiting Conditions Maximum Blowdown Analysis Recommended 0 eratin Period Before Shutdown Characteristic Immediate Two Weeks 24 Hours Shutdown pH@ 25 C 8. 5 9. 2 <8. 5 or >9. 2 Cation Conductivity (PMhos/cm) >2. 0 Jut <5 )5 but C7 )7 Free Hydroxide (ppm CaCO ) 60. 15 W0.15 but ( l. 0 Blowdown Rate Maximum Available Capacity page 7 of 22

"A" S/G INLET X -25Khz to 1st support Pjg-400Khz over U-bend O -400Khz to 6th support 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 I

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 13 1 9 7 5 3 1 45 43 -4 37 35

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2 NOZZLE FIGURE (1)

"A" S/G 0UTLET X-25Khz to 1st support All tubes not 6 <<400Khz to 6th support 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 45 44 37 36 35 34 32 30 28 27 26 25 23 22 21 19 17 16 15

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1 ROMS NNMAY NOZZLE FIGURE (2)

"B" INLET g -25Khz to 1st support Pjg-400Khz even 0-bend 6 -400Khz to 6th support 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 43 41 39 37 36 34 32 30 28 27 26 25 24 23 22 21 19 18 17 16 15 13 ll 9

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ROMS MANMAY NOZZLE FIGURE (3)

I lg I l PUTLET X -25Khz to 1st support All tubes not marked-400Khz to 1st support

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"A" INLET EDDY CURRENT INDICATIONS X 20% to 39% Q60% to 79%

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2 ROllS NNAY .

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"B" INLET EDDY CURRENT INDICATIONS g 20% to 39% dh 60% to 79%

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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 e

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2 0 ROllS th HANAY NOZZLE FIGURE (6)

"B" OUTLET EDDY CURRENT INDICATIONS g20% to 39% + 60% to

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"20 -18 -1 6 -14 10 "8 "6 I "4 - 0 2 8 0 2 4 16 1 20 E . CHANGE IN EDDY CURRENT READINGS (%)

"A" S/G INLET SLUDGE PROFILE Q = 2 inches 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 I

91 89 87 85 83 81 79 77 75 73 7'1 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 1 I

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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 I

I 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

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36 35 34 33 31 Q

30 29 27 26 25 g

22 21 19 18 g

17 15 13 14 11 9

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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 I  !

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17 14 9

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1 ROMS HA%AY NOZZLE 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 I

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 7 5 3 1 45 4

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2 ROMS NNMAY NOZZLE FIGURE (13)

I R. E. GINNA STATlON 1975 "A" STEAM GENERATOR CHEMISTRY JASUAST TCSSUASY UASCN A>>AIL SAY JVIIC JULY AVCVSI St>>ICV515 OCIOSCA IIOYCVSCS D 101 ~ 5055 5 101 ~ 5055 S 10. IS>>50

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R. E. GZNNA STATION 1975 "B" STEAM GENERATOR CHEMISTRY Ei 2

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