ML19241C191

Responds to NRC 730703 Ltr Re Violations Noted in IE Insp Rept 50-267/73-04.Corrective Actions:Encl Corrosion Monitoring Program Was Established

ML19241C191
Person / Time
Site:	Fort Saint Vrain
Issue date:	05/23/1979
From:	Justin Fuller PUBLIC SERVICE CO. OF COLORADO
To:	Seyfrit K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
Shared Package
ML19241C187	List: ML19241C191
References
NUDOCS 7907300116
Download: ML19241C191 (17)

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s public service company e coactrado

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l P.O. Bo. 340, Denver, Colorado 80201

. ~in m J fiay 23, 1979 -

Fort St. Vrain Unit No. 1 P-79110 Mr. Karl V. Seyfrit, Director Nuclear Regulatory Commission Region IV Office of Inspection and Enforcement 611 Ryan Plaza Drive Suite 1000 Arlington, Texas 76012 Docket No. 50-267

SUBJECT:

I & E Inspection 73-04 Response

Dear Mr. Seyfrit:

This letter is to inform you of the results of the service water system evaluation identified in I & E Inspection Report 73-04.

A corrosion monitoring program was established in 1974 consisting of coupons being placed in the service water system at various locations.

The coupons after being exposed to the system were removed and analyzed in accordance with a procedure which meets the intent of NACE Standard TM-01-60, " Laboratory Corrosion Testing of Metals for the Process In-dustries." Coupon processing results reflect water corrosivity in the form of " mils per year" corrosion rates. (Refer to Attachment 1 for corrosion monitoring program details)

The result of the four year corrosion monitoring program indicate an average service water system corrosion rate of 1.5 mils per year. Such corrosion rates for a polyphosphate and zinc corrosion control system are well within acceptable industrial limits for open cooling water systems.

Based on the above information, we feel the corrosion monitoring program ~

has verified the acceptability of our service water system corrosion treatment program and no further action is required. I & E Inspection Report 73-04 has no remaining open items and is closed by submittal of the attachment document.

Very truly years,

, N. W . hd

/ J. K. Fuller, Vice PresiOnt Engineering and Planning JKF/vsm Attachment 7907800l/G &

O/3

ATTACHMENT I f._

RESPONSE TO I & E 73-04 CORROSION MONITORIN3 PROGRAM Service Water System --

Fort St. Vrain NUCLEAR GENERATING STATION Puolic Service Company of Colorado Platteville, Colorado

~4 85 Q76

G CONTENTS INTRODUCTIDN . . '

SYSTEM DESCRIPTION. . . . . . . . . 2 TEST PROCEDURES. . . - .....3 TEST RESULTS. . . . * * * -

CONCLUSIONS. . . . . . . . . . . 7 APPENDIX. * * -

485 0;q

INTRODUCTION r

In 1974, Public Service Company of Colorado (PSCC) established a corrosion monitoring program for the Service Water System (42) at the Fort St. Vrain Nuclear Generating Station located near Platteville, Colo-rado. The corrosion monitoring progrcm consisted of exposing mild steel specimens to the water at various locations within the service water system. At periodic intervals (generally 120 days) the specimens were removed, evaluated, and corrosion rates determined. New specimens were installed whenever exposed specimens were removed thus providing a continuous means of determining the corrosion rate.

From the initial data (July,1974) to the present, the fluctuation in corrosion rates represents the normal variation due to process vari-ables such as temperature and flow. The monitoring period covered by this report is from July,1974 through September,1978. During this period, the average corrosion rate for the service water system was 1.5 mils per year.

The corrosion rates varied somewhat during this p;.riod, but were less t.an 5.0 mils per year (mpy). For our system design and corrosion program an optimum corrosion rate of 3 mpy + 1 to 2 mpy is desirable.

It would appear that the current corrosion rates in this system are under control and well within acceptable limits.

485 07jt SYSTEM DESCRIPTION System 42 is a separate cooling water system that provides cooling ,

to a variety of equipment. Corrosion control is maintained by the addi-tion of polyphosphate and zinc solutions to levels of 30 ppm. The pH is controlled by sulfuric acid to a range of 6.8 - 7.0.

485 079

TEST PROCEDURES Test Coupons All coupons used in this program were prepared and supplied by the Nalco Chemical Company. Coupon evaluation after exposure was performed by Fo'rt St. Vrain chemistry personnel. The test coupons were 3/8" x 3" x 16 gage carbon steel, SAE 1010. Each coupon had been degreased and sandblasted to remove oxides and other surface contaminants. After this cleaning procedure, the coupons were weighed to the nearest 0.1 milligram.

The coupons were then carefully stored in an inhibited package until ready for exposure.

Test Probes Each test probe consisted of a mounting rod, packing gland, and pipe nipple suitable for attaching to a valve. A single test coupon was mounted to the rod in such a manner that it was electrically in-sulated from any other metallic components. This assured that galvanic (two-metal) corrosion was not present during the test.

At each " probe location" in the subject water system, four valves were provided for corrosion test coupon probes. Therefore, at each location, four coupons were being exposed simultaneously. Since the mounting rod was " retractable", it was possible to insert and/or re-trieve each test coupon through the valve without shutting down the water system. When inserted, each corrosion coupon was perpendicular to the water flow.

485 ggg

Test Probe Locations Six (6) test probe location (not consecutively numbered) were estab-lished in the service water system being monitored. Figure 1 (appendix) schematically shows the system and the relative locations of the six test probes.

The locations for the test probes were selected to provide the best overall evaluation of corrosion rates throughout the particular water system. Probes were positioned downstream of heat exchangers to detect the affect of head load on the corrosivity of the water. Low velocity sections were also monitored to verify the inhibitor's effectiveness in these sections.

Coupon Evaluation Each corrosion test coupon was removed after a specified time period, approximately 120 days. They were then visually examined, cleaned (in-cluding an acid wash), dried, and reweighed. The procedures used for coupon evaluation were those of Nalco Chemical Co.

The actual corrosion rate was calculated for each specimen using the f Olowing formula:

mils per year (mpy) = Factor x weight loss (mg) exposure time (days) 485 .gg; The factor for these specimens was 1.11, based' on the standard coupon size, corrections for units, and the density of SAE 1010 steel. .

This is a slight modification of the formula specified in NACE Standard TM-01-69 and basically reflects the standardization of coupon size, coupon material, and a slight relaxation of the accuracy of the calculated surface area.

After a group of test coupons was removed, a new set was installed.

Corrosion rates were calculated in " mils per year" based on the actual exposure period. Tharefore, the reported data is in increments of three months. For a given time period, the reported rate is the average of four (4) coupons.

485 082

TEST RESULTS All corrosion rates were calcule.ted and reported as " mils per year" ,

(mpy), based on the exposure period for any particular coupon. These corrosion rates, therefore, represent the average corrosion rate during the exposure period (approximately 120 days). Uithin that exposure period, the actual corrosion rate at any one time (instantaneous) may have been higher or lower than what was finally calculated. However, the intent of this program was to monitor the long term trends of the corrosion rates rather than the short term variations. '

The six corrosion probe locations were established in this water systems see Fig. 1). The corrosion rates are given in Table I and graphically presented in Figures 2A and 28 (appendix).

During the monitoring period between July,1974 and September,1978, the average corrosion rates at each probe lc, cation were as follows:

Probe 1 - 0.7 mpy Probe 3 - 1.0 mpj Probe 4 - 2.0 mpy Probe 5 - 1.6' mpy Probe 6 - 1.3 r,y Probe 2 - 1.6 mpy The overall average of r11 six probes in the system was 1.5 mpy. All probe locations exhibited similar patterns as the corrosion rates varied.

485 083 6-

CONCLUSION r

The Service Water System (System 42) corrosion rate of 1.5 mpy -

certainly falls within the expected corrosion rates for an inhibited, open cooling water system. There were periods when the corrosion rates fluctuated, but this is not abnormal for a cooling water system that is subject to system variation for heat load and flow.

A review of Figures 2A and 2B reveal t.a corrosion trends which are typical in power plant cooling water systems. The first is a cyclic corrosion rate whose period is approximately one year. The cycle is a result of atmospheric temperature changes associated with seasonal vari-a ti ons . The second is a gradual increasing trend which starts in the later part of 1976. It would appear that the corrosion rate trend some-what follows or is related to the power output of the plant since the in-creasing trend starts at approximately the same tir.e Fort St. Vrain first generated power. This correlation is very feasible since corrosion rates increase with increasing temperatures. This gradual increasing trend appears to in:rease the 1976 to 1978 seasonal Ligh by about one mil per year which it acceptable frc, a system corrosion viewpoint.

During t,e period of monitoring the corrosion rates, the most sig-nificant upset in corrasion rates occurred at probe location No ".

Upsets of this sort are not uncommon when changes in plant operation can affect the temperature and/or velocity in a cooling water system. In addition, changes in the water treatment program that were made for long 42iP:7 084 term improvement of the system can sometimes cause short term upsets. More recent data indicates the corrosion rate of location .4 is below 3.0 mpy.

Typical cooling water systems that are treated with colyphosphates, zinc and under good pH control can be expected to have corrosion rates in the range of 2.0 - 3.5 mpy. The corrosion rates indicated for System 42 fall within the acceptable ranges for the type of treatment being used.

With the exception of occasional system upsets, it would appear that the service water system at the Fort St. Vrain station is under acceptable corrosion control.

085

APPEtlDIX ,-

Figure 1 Schematic of Service Water System Table I Corrosion Rates, Service Water System Figure 2A & 2B Graphs, Corrosion Rate vs Time, Service Water System ..

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TURBIllE BUILDIllG FORT ST. VRAIN fiUCLEAR GEffERATING PLAtlT SERVICE WATER, SYSTEM 42 CORROSION TEST SPEC!t4EN LOCATIONS FIGURE '_1

l TABLE 1 SERVICE WATER SYSTEM 42 PROBES 1, 3, 4, 5, 7 and C Average Rates: Probe 1: 0.7 mpy Probe 5: 1.6 mpy -

Probe 3: 1.9 mpy Probe 7: 1.3 mpy CORROSION RATE, moy_ Probe 4: 2.0 mpy Probe 2: 1.6 mpy DATE PROBE 1 PROBE 3 PROBE 4 PROBE 5 PROBE 7 PROBE 2 July 1974 0.5 1.5 1.6 1.7 2.1 1.0 Aug. 1974 0.4 1.4 1.5 1.3 1.0 0.8 Sept.1974 0.4 1.4 1.5 1.3 1.0 0.8 Oct. 1974 0.5 1.2 2.1 1.5 0.8 0.9 f- Nov. 1971 0.5 1.2 2.1 1.5 0.8 0.9 "

Dec. 1974 0.9 1.6 3.3 2.5 1.1 1.4 Jan.1975 1.1 2.4 3.8 3.1 1.4 1.8 Febr.1975 1.1 2.4 3.8 3.1 1.4 1.8 Ma r. 1975 0.9 1.8 2.5 2.4 1.9 1.3 Apr. 1975 0.5 0.8 0.9 1.0 1.3 0.7 May 1975 0.5 0.8 0.9 1.0 1.3 0.7 June 1975 0.2 0.5 0.3 0.7 0.8 0.4 July 1975 0.2 0.4 0.2 0.8 1.0 0.3 Aug. 1975 0.2 0.5 0.2 0.9 1.0 0.3 Sept.1975 0.2 0.6 0.3 0.7 1.0 0.4 Oct. 1975 0.2 0.8 0.5 0.7 0.6 0.5 Nov. 1975 0.2 0.9 0.7 0.7 0.4 0.7 Dec. 1975 0.2 1.0 0.9 0.6 0.3 0.8 Jan. 1976 0.3 1.2 1.0 0.6 0.3 0.8 Febr.1976 0.3 1.0 1.1 0.6 0.3 0.8 Mar. 1976 0.4 1.3 1.3 0.6 0.3 1.0 Apr. 1976 0.4 1.4 1.6 0.6 0.4 1.1 May 1976 0.4 1.5 1.9 0.6 0.5 1.4 June 1976 0.4 1.9 2.3 0.7 0.5 1.8 July 1976 0.5 2.1 2.1 0.8 0.5 2.1 Aug. 1976 0.5 2.4 2.5 1.0 0.5 2.5 Sept.1976 0.6 2.4 2.4 1.2 0.6 2.5 Oct. 1976 0.5 2.2 2.2 1.3 0.7 2.2 Nov. 1976 0.5 1.9 2.5 1.2 0.7 1.9 Dec. 1976 0.6 1.6 2.0 1.1 0.8 1.5 Jan. 1977 0.6 1.5 1.7 1.1 0.9 1.4 Febr.1977 0.6 1.5 1.7 1.0 0.9 1.3

, Mar. 1977 0.7 1.6 1.4 1.3 0.9 1.3 Apr. 1977 0.8 1.6 1.5 1.5 1.0 1.5 May 1977 0.8 1.6 1.6 1.8 1.2 1.9 f-- June 1977 0.9 2.3 1.9 2.0 1.7 2.1 July 1977 0.9 2.5 2.0 2.0 1.9 2.3 Aug. 1977 0.9 2.4 2.4 1.9 2.3 2.2 Sept.1977 1.0 2.8 2.7 1.8 2.4 2.4 Oct.1977 1.1 2.9 2.7 1.9 2.1 2.4 Nov. 1977 1.2 2.8 2.9 2.0 2.0 2.2 Dec. 1977 1.2 3.1 2.9 2.1 1.7 2.6 4 8

088

l TABLE 1 (continued)

CORROSION RATE, moy DATE PROBE 1 PROBE 3 PROBE 4 PROBE 5 PROBE 7 PROBE 2 Jan. 1978 1.2 3.1 3.1 2.2 1.6 2.7 Febr.1978 1.3 2.9 3.3 2.4 2.7 2.9 Mar. 1978 1.4 3.2 3.6 3.1 2.9 3.3 Apr.1978 1.6 3.4 3.7 3.2 3.1 May 1978 3.4 1.7 3.2 3.6 3.3 3.0 3.2 June 1978 1.6 3.2 3.4 3.1 1.7 '0 July 1978 1.4 2.8 2.9 2.6 2.6 .6 Aug. 1978 1.3 2.4 2.7 2.4 2.0 Sept.1978 2.4 1.1 2.2 2.4 2.2 2.1 1.9 I

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