ML17157A421

Analysis of Pitting Corrosion Failures in ESW Sys RHR Lube Oil Coolers & RCIC Pump Room Unit Coolers at Susquehanna Steam Electric Station.

ML17157A421
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Site:	Susquehanna
Issue date:	08/31/1990
From:	THOMAS M. LARONGE, INC.
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NUDOCS 9011190331
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ThomosM.Laronge,In(-.10439N.E.FOURTHPLAINROA0~P.O.BOX4448~VANCOUVER, WA98662~(206)254-1213~FAX(206)896-2106September 10,1990ORIINALENTBYFEDERALEXPRESPENNSYLVANIA POWER&LIGHTCOMPANYTwoNorthNinthStreetAllentown, PA18101-1179 Attention:

Mr.RaymondS.Tombaugh, ProjectEngineer

SUBJECT:

REQUESTED REVISIONS TOFINALREPORTONESWRHRLUBEOILCOOLERFAILUREANALYSIST.M.L.197-90-002

DearMr.Tombaugh,

Wearepleasedtoprovidetheattachedreplacement pagesforourreportT.M.L.197-90-002, containing theeditorial corrections andsuggestions providedbyyouandyourco-workers duringourmeetingonSeptember 7,1990.Bestregards,.~c.c<ArthurJ.Freedman,

~Executive VicePresident (ThomasM.Laronge,President AJF/TML:dh Enc:A/S9011190331 PDRADOCKP901i1205000337PDC4Quo,lityforIndustryWeappreciate yourinputandhopethatthereport,ascorrected, willbesatisfactory.

Pleasedonothesitatetocallifyouhaveanyfurtherquestions.

ThomasM.Laronge,Inc.AKNWLEDEMENTTheworkdescribed inthisreport,particularly theworkon-siteandatPP&L's.HazletonLaboratory andAllentown ofQces,couldnothavebeenaccomplished withoutthewholehearted supportandcooperation ofPP@Lpersonnel.

Thewriterswishtoexpresstheirappreciation forthetime,effortandcourtesies extendedtousduringthisproj'ect.

Wealsowishtoexpressourspecialthankstothefollowing individuals, listedinalphabetical order,fortheirextrahelpbeyondthecallofduty:D.P.DunnD.J.MorganT.J.PensockW.J.RhoadesR.S.TombaughL.E.WillertzPagei ThomosM.Laronge,Inc.TABLEFNTEAcknowledgement TableofContentsIntroduction Conclusions ResultsofInspections ListofInspected Equipment Inspection MethodsPhysicalMeasurements andObservations RHRLubeOilCoolersRCICPumpRoomUnitCoolersESWSupplyLinetoRCIClE-228BOtherInspections Discussion ofMeasurements andInspections AnalysesofDepositsandMetalSurfacesAnalytical MethodsICAPandChemicalAnalysesofDepositsSEM/EDSAnalysesofDepositsMicrobiological AnalysesDiscussion ofAnalytical ResultsESWSystemChemistry andOperations ESWChemistry ESWandRHRPumpOperations SystemOperations TheESWSprayPondESWandRHRPumpRunTimesRHRLubeOilCoolingWaterFlowVelocities 666881214141517171820232527272828293032Pageii

ThomasM.Laronge,Inc.RootCauseFailureAnalysisSummaryPitInitiation PitPropagation EffectsofSulfur,IronandManganese inDepositsComparison ofRHRCoolers(Copper)andRCICCoolers(Cupronickel)

AppendixBibliography ListofTablesListofFiguresListofPhotographs Preliminary Report3535363738404243456192Pageiii

ThomosM.Loronge,Inc.INTRDTINOnMay28,1990,aleakoccurredintheRHR2E-217CMotorOilCooleratthePennsylvania PowerandLight(PP&L)Susquehanna SteamElectricStation(SSES).ThisleakforcedashutdownofUnit1andadelayinstartupofUnit2untilallRHRmotoroilcoolingcoilscouldbereplaced, othercriticalheatexchangers usingemergency servicewater(ESW)forcoolingcouldbeinspected, therootcauseoftheproblem.determined andthepotential forsimilarfailuresinrelatedequipment evaluated.

ThomasM.Laronge,Inc.wascontracted byPP&LtoidentifytherootcauseoftheRHR2E-217Cmotoroilcoolerfailureandtoinspectequipment atotherlocations intheplantcooledbytheESWsystem.Weworkedon-siteandinPP&L'sHazleton, Pennsylvania Laboratory andAllentown, Pennsylvania officesfromFriday,June8throughTuesday,June12,1990inclusive.

Duringthistime,weinspected thefailedcooler,severalotherRHRmotoroilcoolercoils,andothercoolers,heatexchangers andaccessible pipingservicedbytheESWsystem.Weranon-sitemicrobiological assaysatsixlocations forthepresenceofsulfate-reducing bacteria(SRB)andacid-producing bacteria(APB)thatcancausemicrobiologically influenced corrosion (MIC),andwetooksamplesofheatexchanger tubes,wateranddepositsforlateranalysis.

WeworkedcloselywithPP&L'smetallurgists andotherstaffmembers.Wejointlyinspected

failures, pits,metalsurfacesanddepositsunderthelightmicroscope andscanningelectronmicroscope (SEM)inthe'Hazleton Laboratory.

Wereviewedplantandcorporate engineering officerecords,including technical specifications, procedures, heatexchanger inspection reports,ESWwaterchemistry andoperating conditions, andotherrelatedinformation.

PP&Lprovidedaccesstoallrecordsandinformation pertinent tothisprojecttoassistusinourwork.Page1 ThomasM.Laronge,Inc.~~~~OnJune12,1990,intheAllentown office,wecompleted apreliminary reportofourfindings.

Subsequently, wecarriedoutthefollowing work:~We,carefully inspected sectionsofRHRlubeoilcoolercoilsandRCICpumproomunitcoolerheatexchanger tubesremovedduringoursitevisit.~Weanalyzedwaterandde'positsamplesandranscanningelectronmicroscope (SEM),electrondiffraction spectroscopy (EDS)andX-raydiffraction (XRD)analysesondepositsfromspecificlocations, i.e.,insidepits,onselectedtubespecimens.

~Weranfurthermicrobiological studiesonselectedtubestoassistincharacterizing thenatureofthecorrosion.

~WestudiedplantESWsystemoperating recordsandotherpertinent plantrecordsindetail.~Wereviewedourownextensive filesandcarriedoutaliterature reviewoncausesofwaterside pittingcorrosion ofcopperandcopperalloyheatexchanger tubes.ThisAnalreportincludesallessential information fromourJune12,1990preliminary report,allnewdataobtainedsinceJune12,1990andourconclusions.

Ourpreliminary reportisincludedintheAppendixandshouldbeconsidered aspartofthiscompletereport.Page2 ThomosM.Laronge,Inc.NLINTheRHRlubeoilcoolersandtheRCICpumproomunitcoolersfailedbyacombination ofmicrobiologically inducedcorrosion (MIC)andconventional chemicalpittingcorrosion mechanisms.

2.TheESW,asmeasuredattheinlettoRCIClE-228B,ismicrobiologically veryactiveandcontainshighlevelsofsulfatereducingbacteria(SRB)andacidproducing bacteria(APB).3.TheESWAandBloopshavebeenstagnant(notrunning)between65and75percentofthetimesince1987.Duringthesestagnantperiods,depositsformedontheinternal(waterside) surfacesoftheRHRandRCICcoolercoilsandtubes.Anaerobic conditions underthesedepositsallowedSRBtogeneratesulfidesthatdestroyed theprotective, passiveQlmonthecopper(RHR)coilsandattackedthe90:10cupronickel (RCIC)tubes.4.MICdidnotcontinueatahighrateunderthesedepositsbecauseofthetoxiceffectsofcopper,ions.Instead,conventional under-deposit oxygenconcentration cellcorrosion becamethedrivingforceforcontinuing pittingattack.5.SulQdesprobablycontinued toplayaroleinthecorrosion process,evenafterpitinitiation.

Continuing presenceofSRBinthesystemallowedsulfidestoformawayfromthecorroding coppersurfaces.

Thesesulfidesthendiffusedwiththewaterandwereabletoattackpassivefilmsonthemetal.Bothdeep.sharp-edged pitscharacteristic ofconcentration cellcorrosion andshallower, roundedpitscharacteristic ofsulQdeattack,werefoundintheRHRlubeoilcoolingcoils(seePhotographs).

SEM/EDSelementmapsshowsulfurpresentinallpits,butatvariouslocations, usuallynotnexttothemetalsurface.6.Manganese playedadualroleinthecorrosion process.InthemostseverelycorrodedRHRlubeoilcoolercoils,e.g.,thefailedcooler,2E-217C,nocontinuous protective depositswereobserved.

Rather,thedepositappearstohaveformedasaseriesofdiscretelayers,perhapsassociated withperiodsofflowandnoflow,waterchemistry changes,etc.CoolerRHR1E-217Bshowedsimilardeposits.

Thesedepositscontained onlysmallamountsofmanganese.

Manganese probablyactedasanelectrontransferagentinthesedepositstocatalyzethecorrosion reactions.

Page3

'v Thomos7.M.Laronge,Inc.TheRHRlubeoilcoolersintheworstcondition (2E-217Cand1E-217B)takewaterfromtheESWBloopandthecoolersinthebestcondition (lE-217A, 2E-217AandlE-217D)areallontheAloop.Thereasonsforthiscannotbepositively definedfromtheavailable data,butsomefactsareclear.PriortoJune1989theESWAloopranmorefrequently andcarriedmorewaterthantheBloop,butata20percentlowerflowvelocitythroughtheRHRcoils.Substantially higherlevelsofmanganese werefoundintheAloopcoils,comparedtotheBloop.Thedifferent flowpatternsintheAloopmayhaveallowedmoremanganese todepositinthesecoilsandtoformcontinuous filmsratherthandiscrete',

porousdepositsasdescribed inConclusion 7.Theveryhighlevelsofmanganese foundinconnecting elbowsfromcoilslE-217Aand2E-217B(oneoneachloop)remainunexplained.

Theseelbowswerenot-corroded inanyway.8.TwoRHRlubeoilcoolercoils,2E-217B(examined inourlaboratories) andlE-217B(examined byDr.WillertzofPP&L)showedheavierdepositsandpittinginthetop(wateroutlet)layersofcoilsthaninthebottom(waterinlet)layers.Othercoilsmayalsoshowthiseffectbutwerenotexaminedinthisway.Theseobservations suggestatemperature effect,butthetemperature riseacrosstheRHRlubeoilcoolers(8'F)doesnotseemtobesufficient toproducethesedifferences.

Also,theRHRpumpsonlyoperatedbetween5and10'percent ofthetimeeachyear,sothatverylittleheatwasavailable fromthissource.9.OtherthantheRHRlubeoilcoolers,mostofthecoolingequipment intheESWsystemcontains90:10cupronickel tubes.TheRCICpumproomunitcoolersarecorrodedatleastasseriously, astheRHRroomcoolers.Wefoundone90percentthrough-wall pitinRCIC1E-228Bandone60percentthrough-waQin1E-228A.Weexaminedsectionsfromonlyonetubefromeachcooler.Thesetubesshowedlowmanganese levelsandheavy,scalydepositssimQartothosefoundinRHR2E-217C,thefailedRHRlubeoilcoolercoil.RCIClE-228Bshowedthehighestlevelofmicrobiological contamination ofallcoolerstestedduringthisstudy.10.Copperand90:10cupronickel arebothhighlyresistant tocorrosion incleanfiowingwater,butinbiologically activesystems90:10cupronickel issometimes moresusceptible tobiofouling andMIC.Duringouron-siteinspections, weexaminedseveral90:10cupronickel coolersinthedieselgenerator systemandfoundlittleornopitting.Wealsoexaminedthe2E-297AGRDXcondenser butcouldnot'etermine thecondition ofthemetalinthesetubesbecauseofthelargeamountofdepositpresent.Page4 ThomasM.Laronge,Inc.11.ESWwaterchemistxy datashowaconsistent downwardtrendinconductivity andcalciumlevelsduring1989and1990.Langelier Indexvaluesareoftenabove,+0.5 andoccasio'nally approach+1.0.Somecalcium,presumably ascalciumcarbonate, wasfoundinmostoftheRHRandRCICcoolerdeposits.

Page5

ThomasM.Laronge,Inc.RELFINPENLitfIneEuimnDuringourworkon-siteandinourlaboratory, weinspected heatexchanger tubesand/orESWpipingfromthefollowing units:2.4,5.6.7.8.9.10.12.13.lE-217AlE-217B1E-217C2E-217A2E-217B2E-217C2E-217D1E-228A1E-228B2E-297AOE-505E1,2D OE-507DOE-533DRHRlubeoQcoolercoil.RHRlubeoilcoolercoil.RHRlubeoQcoolercoil.RHRlubeoilcoolercoil.RHRlubeoQcoolercoil.RHRlubeoilcoolercoil.RHRlubeoQcoolercoil.RCICpumproomunitcooler.RCICpumproomunitcooler.ESWGRDXsystemcondenser.

Dieselgenerator intercooler.

Dieselgenerator jacketwatercooler.Dieselgovernorcooler.InsInMthoIndoingouron-siteinspections, weusedthefollowing methods:~Visualinspection oftubesanddepositsaswesawtheminplaceorastheywerepresented tous.~Videoprobe inspections oftubesinplace.~Visualinspections witha15Xmagnifying lensoftheinteriorsurfaces'f coolingcoilsandtubesthathadbeensplitlongitudinally.

Page6 ThomasM.Laronge,Inc.~Microscopic examination

.ofselectedspecimens inthePALHazletonLaboratory.

~Microbiological culturesofdepositsfromcoilsandtubes,usingmediaspecificforsulfate-reducing andacid-producing bacteria(SRBandAPB).Inourlaboratory,

• wedidsubstantial additional inspection andanalytical work.Thesedataaresummarized inTablesandFiguresforeasycomparison ofspecimens:

~Carefulvisualobservation ofthenatureofthedepositsandcorrosion oneachspecimen, withphotographic documentation (Tables1and12andPhotographs 1through41).Physicalmeasurements, i.e.,size,wallthickness, etc.'Table2).~Depositweightdensitymeasurements (Tables3and12).~Pitdepthmeasurements (Tables4and12).~Waterchemistry studies(Table9andFigures4,5and6).~Chemicalanalysesofdeposits(Tables5and6andFigure2).X-raydiffraction analysestoidentifycompounds indeposits(Table7).Microbiological analysesofsamplecultureson-site(Table8andFigure3).SEM/EDSanalysestoidentifyelementsindeposits(Table6,Figures9through22andPhotographs 42through49).Page7

Thomo,sM.Laronge,Inc.PleaserefertotheseTablesandFiguresinconnection withthefollowing discussion.

Thephotographs arearrangedinageneralorderofincreasing magniQcation, sothatbyperusingthephotographs, thereadercangainanincreasingly detailedcomparison ofthenatureofthepittingonthevariousspecimens mcaznined.

PhsiMurmnrvtionFigure1isaschematic diagramofanRHRpumpmotor,showingthearrangement ofthelubeoilcoolingcoQs.Thecoilsarearrangedinastackofsixlayers,withfourturnsineachlayer.ForidentiQcation purposeswehavenumberedthecoilsfromtoptobottomandletteredtheturnsfromtheinsideout,asshowninFigure1.Thus,coil3Bisthesecondfromtheinsideturninthethirdlayerfromthetop.Physicalmeasurements areshowninTable2.'urmeasurements showthattheRHRlubeoilcoolingcoilsandtheRCICroomcoolertubesaregenerally withinspecifications.

Deviations aresmallandcanbeattributed toproblemsinwallmeasurements ontubescontaining depositsandtosomedeformation thatmustoccurwhencoppertubingisformedtomaketheRHRcoils.Thereisnoevidencewhatsoever fromthesemeasurements thatanyappreciable thinningoftubewallsduetogeneralcorrosion hasoccurred.

TheRHRlubeoilcoolingcoilsarereportedly madefromtypeKcopper,andtheRCICroomcoolertubesfrom90:10cupronickel.

Nowetchemistry testsweredonetoverifythesecompositions, butEDSanalysisonagallededgeofonetubefromRCIC1E-228Aconfirmed 90:10cupronickel inthistube.A.RHRLubOiller1.RHRlE-217AWeinspected sectionscutfromcoils2and5inthiscooleron-site(seeFigure1).Thesesectionsweresimilar.Bothcontained aPage8 ThomasM.Laronge,Inc.light,smoothlayerofblackdeposit.Veryslight,irregular pittingwas1observedunderthis'deposit.

Therewasnovisibletuberculation.

Wejudgethiscoiltobeamongtheleastcorroded(pitted)ofalltheRHRcoQsthatwestudied.Wealsoexaminedseveral90degreeelbowsthatconnected thelayersinthelE-217Acoil.Theseelbowsappeartobemadefromadifferent alloythanthecoppercoil,perhapsabrass.Theseelbowscontained asubstantial amountofablack,powderydeposit.Somebaremetalwasvisible.Wemeasuredthedepositweightdensityat15.4mg/ft2.Novisiblecorrosion couldbeseenintheseelbows.However,pittingwasclearlyvisibleinthecoppertubeconnected tooneelbow(Photographs 37,38and39).2.RHRlE-217B'Wedidnotinspectthiscoilon-site.Inourlaboratory, weinspected layer3B.(seeFigure1)fromthiscoil.Wefoundalargeamountofdepositmixedwithtubercles rangingupto0.25inchinbothdiameterand'height (seedescription inTable1).Thedepositweightdensity,measuredat31.7gm/ft2,wassecondonlytothedensitymeasuredinRHR2E-217C(seeTable3).Pitdensitywaslowerthanfoundinthe1Cand2CRHRlubeoilcoolers,butsubstantially higherthaninthelAand2Acoolers(Table4).Themaximumpitdepthmeasuredonourspecimenwas0.025inch,or35percentwallpenetration (Table4).Thiscompareswith0.042inchmeasuredbyDr.WillertzofPP&Lonadifferent sectionfromthesamecoil.ThenatureanddepthofpittingintheRHRlE-217BcoilcanbeseeninPhotographs 20through23.3.R~RR13-217Thiscoolerwasnotinspected on-site.Inthelaboratory, thisspecimenwas.foundtohavethehighestmeasureddensityofpitting,butnotthehighestpitdepthorwallpenetration (Table4).Thedepositweightdensity,at24.1gm/ft2,wasinthehighestgroupPage9 ThomosM.Lo,ronge, inc.measured(Table3).Depositsweresmoothandbrowntoblackin~~~~color,withmanybrightgreen,redandsilvercoloredcrystalsaroundandinsidepits.Pits,mostlycoveredbytubercles, werelarge,shallowandhemispherical.

'IhedepositsandpittinginthisspecimencanbeseeninPhotographs 28through31;thecrystalsareapparentinSEMPhotograph 47.4.RHR1E-217DFortherecord,wenoteherethatnospecimens fromRHRlE-217Dwereprovidedforourinspection.

Dr.Willertzreportedonlylightdepositsandtuberculation, andverylittlepitpenetration inthis'ube.

5.RHR2E-217AThiscoilwasnotinspected on-site.Inthelaboratory, thistubesectionwaslike1E-217A.ThebrowndepositwassimilartothatinlE-217B,butmuchsmallerinquantity(Table3).Tubercles wereminorandtherewasnovisiblepittingorgeneralcorrosion.

6.RHR2E-217BOn-sitewefoundthiscoiltobeintermediate incondition between1E-217Aand2E-217C.Thespecimenweexaminedcontained stringyblackdepositsthatcoveredpart,butnotallofthesurface.NosigniQcant tuberculation waspresent,butpitdepthswerequitesevere.Laboratory inspections confirmed theseobservations.

Wewereabletoexaminespecimens fromthesecondcoilfromthetop(2E-217B-2)andthesecondcoilfromthebottom(2E-217B-5),

asshowninFigure1andTable1.Theentire2E-217B-2 coilwassenttoourlaboratory.

Photograph 10showsthiscoilassplitforinspection.

Thecentertubewasmcaminedindetail.Page10 ThomasM.Loronge,Inc.Thedifferences indepositweightdensity,pittingdensityandpitpenetration between2E-217B-2 and2E-217B-5 (Tables3and4)confirmsimilarobservations madebyDr.Willertzonthe1E-2178coQ,usingX-rayexamination.

Depositcharacteristics, tuberculation andpittingintheuppercoil(2E-217B-2) weremuchlikethefailedcoil2E-217C.(seebelow)exceptthatpitsin2Bweremostlyhemispherical.

Deposition andpittingin2E-217B-5 wereverylight;thissectionappeared,

visually, muchlikelE-217Aand2E-217A.Photographs 32,33and34showthenatureofthepittingin2E-217B.Unfortunately, thesephotographs donotdistinguish betweenthe2B-2andthe2B-5coils.Weexaminedfour90degreebendsfrom2E-217B.Thesebendsappeared,

visually, tobemadefromcopperandseemedtobequitedifferent fromthebendsinthe1E-217Acoil(seeabove).Depositweightdensities wereintheintermediate rangeandnopittingorgeneralcorrosion wasobserved.

Seealsothediscussion ofchemicalanalysesofdeposits, (Page19.andTable5,Page50).7.~2E-217Itwasathrough-wall failureinthiscoilthatalertedtheplanttothepittingcorrosion problemintheRHRlubeoilcoolers.andotherheatexchangers servedbytheESWsystem.On-site,wefoundtheinteriorsurfaceofthe2E-217Ccoilcoveredwithathick,dense,layeredscalydeposit,quitedifferent inappearance fromtheothercoils.However,thetubewesawhadbeenremovedfromthesystemseveraldaysbeforeourvisit,sothatthedepositswerequitedrywhQeothertubeswerewet.On-site,wefoundlargetubercles coveringnumerousrandompitsovermostofthesurface.Thesepitsvariedgreatlyinsize,shapeanddepth.Bothhemispherical andirregularly-shaped pitswereobserved, asopposedtothemostlyhemispherical pitsfoundinother1coils.Someofthepitsin2E-217Cweresharp-edged andquitedeep.Page11 ThomasM.Laronge,Inc.Laboratory inspections conflrmed theseverityofcorrosion anddeposition inthiscoil.ThedepositweightdensitywasthehighestmeasuredinanycoiltTable3)andpitdensityanddepthwerealsoamongthehighestmeasured(Table4).Photographs 17,18and19showtheheavydepositsanddeeppitsfoundinthiscoil.Anearthrough-wall pitcanbeclearlyseeninthelowersawededgeofthetubeinPhotograph 17.8.2E-217DThiscoilwasnotexanQnedon-site.Inthelaboratory, wefoundthedepositweightdensitytobehighat27;3gm/ft2,comparable todepositsincoilslE-217Band1E-217C.Pitdensitywaslessseverethanineitherofthesetubes.Pitpenetration in2E-217Dwassimilarto1E-217Candlessseriousthanin1E-217B.Thedepositsweretypically browntoblackwithgreenedgesaroundsmalltubercles.

Pitsweresmallandhemispherical.

Photographs 24through27comparedtoPhotographs 17,18and19showthedifferences betweenthedepositsfoundin2E-217Dand2E-217C.RRIPumRmniIr1E-22AnlE-22BTheRCICcoolersarereportedly tubedwith,90:10 cupronickel tubes,asexplained above.Thetubesarestraightandinstalled horizontally inthecoolers.Thenominaltubediameteris0.5inch(Table2).ThismeansthattheRCICtubesmaybemoresubjecttolossofflowduetopartialtubeblockagethantheRHRlubeoilcoolersifdepositsshouldforminthesetubes.TheRCIClE-228Acoolerwasopenedinourpresenceduringourinspection visitsothatwewereabletoexaminetheinternaldepositsimmediately uponexposuretoair.Thisisimportant becauseanaerobic bacteriathatcanberesponsible formicrobiologically influenced corrosion (MIC)tend-tobecomeinactiveuponexposuretooxygen.Page12

ThomosM.Lo,ronge, Inc.ThetubesinRCIClE-228Acontained loose,browndeposits.

MostofthesedepositsseemedtobeintheformofwellQocculated solidswithclearwater.Thetubemetalappearedtoberelatively cleanduringouron-siteinspection.

Weunderstand thattheRCICIE-228AcoolerisservedbytheESWAloop.PP&LinformedusthattheRCICpumproomunitcoolerswerecle'anedaboutthreeyearsagoandthatlargeamountsofblackdeposit,presumably manganese, wereremovedatthattime.The1E-228Bcoolerhadbeenopenedandcleanedforseveraldaysbeforeourinspection.

Onetubehadnotbeencleaned,andwefoundthispipetocontainalargeamountofloose,blackdeposit.Weunderstand thatthelE-228BcoolerisservedbytheESWBloop.OnetubefromeachoftheRCICcoolerswassenttoourlaboratory forinspection.

Visually, thetubefromRCIClE-228Atcontained lessdepositandfarfewerpitsthantheIE-228Btube.Whenmeasured, however,depositweightdensities inthesetubesweveroughlythesame(Table3)andpitdensityseemedtobe.higherin1E-228AthaninlE-228B(Table4).TheAcoolershowedthedeepestsinglepitmeasuredduringthisentirestudy;0.05inch,corresponding to91percentwallpenetration.

ThelE-228Bcoolershowedamaximumof0.036inchpitdepthwith60percentwallpenetration.

Thesedifferences maynotbesigniQcant, sinceonlyonesmallportionofonetubefromeachunitwasexamined.

Also,theverticalandhorizontal splitsdescribed inTables3and4arequestionable becausetubeorientation couldnotbemaintained precisely duringremovalfromtheunitandduringcutting.Photographs 14,15and16showthenatureanddensityof,depositsandpittingin1E-228A,andPhotographs 40and41showaclose-upviewofonepitfromthistube.Thetypicalgreen,redandbrowndepositsfoundinbothDxeRHRandRCICcoolerscanbeclearlyseeninthesephotographs.

Page13 p~l.'i ThomasM.Loronge,Inc.GESWSu1LinRIlE-22BDuringouron-siteinspections, wewereabletoexaminetheESWBsupplylinetoRCIClE-228B.Weunderstand thatthisismildsteelpiping.Thislinewasheavilycorrodedandcoveredwithauniformlayerofbrownscalerangingupto3/16inchinthickness.

Notubercles wereseenandnopittingcouldbefoundunderthedeposit,asfaraswecouldreachintothisline.Seebelowforadiscussion ofmicrobiological testinginthispipe.Thispipe,aswesawit,wastypicalofmildsteelpipeexposedtocorrosive waterformanyyearswithnochemicaltreatment.

Theheavylayersofcorrosion-produced scaleareprobably, atthispoint,providing somecorrosion protection tothepipe.Webelievethatthecondition ofthispipeissimilartothatofmostoftheESWpipingexposedtosimilarflowconditions.

D.thrIninDuringoursitevisit,weinspected severalcoolersandcondensers thatcouldnotbedismantled forsubsequent laboratory examination.

Theseinspections aredescribed indetailinourpreliminary report(Appendix);,

theinformation issummarized brieflybelow.l.OE-7DDiInrtorackWrpierTubesinthiscoolerwerereportedtobe90:10cupronickel.

Previouseddycurrent(ET)testingofthiscoolerhadidentified onetubewithatleast60percentwallpenetration.

Weinspected thistubeinplace,usingfiberscope equipment, andfoundmanypitsthatappeared, throughthefiberscope, tobeverydeep.Thepitswererandomlydistributed andirregular inshape.Thecoolerhadbeencleanedbeforewearrivedsothatwedidnotseethedepositsinplace.Page14 Thomo,sM.Lo,ronge, Inc.2.E-DDi1vrnrIrWeexaminedthissmall90:10cupronickel singletubecooleraftercleaning.

Onlyminorpittingcouldbeseeninthistube.3.OE-505E12DDies1nrorIntrpolerThetubesinthis90:10cupronickel coolerweretoosmalltopermitentranceofthefiberscope.

Thetubeendswerecleanandcontained manysmallpits.Nootherobservations couldbemade.4.2E-27AWRDXmnnr~Thisexchanger wasopenedjustbeforeourinspection.

Thetubesandtubesheetswerecoveredwithheavydepositsthatmadeviewingthetubesimpossible.

Thedepositsseemedtoincludecorrosion

products, scaleandloose,slimymaterial.

Microbiological activityinthisdepositwaslow(Table8,Page54).e'iDiscussion ofMeasurements andInsectionsTable12summarizes theinspection information fromTable1through4andgroupsthecoolersbyESWloop.BasedonthesedataweranktheRHRlubeoilcoolersinthefollowing way,fromworsttobest:PitDensity~pi~inkWorst1C25-3002C1-2001B5-502B-24-502D52B-512ANM1DNMtBestlANMNM=NotMeasured.

DeepestPitInihe~2C0.0281B0.0252B-20.0252D0.0151C0.0132B-50.0072ANM1DNMlANMDepositWt.Densitygm~~f2C37.901B31.732D27.251C24.072B-213.212B-56.882A5251DNM1ANMPage15 0hl~1y'),V Thoma,sM.Loronge,Inc.tTheprecision ofthedatashownaboveisprobablystatistically unjustiQed, sinceonlyonesectionoftubefromeachcoilwasexaminedforeachdatapoint.Nevertheless, sometrendsareapparent.

First,RHRlubeoilcoolersontheESWBloopseemtobeinworsecondition thanthoseontheAloop.Withthepossibleexception ofRHR2E-217D,alloftheRHRBand"Ccoolers,usingESWBwater,showsubstantially higherpitdensities anddepthsandhigherdepositweightdensities thantheRHRAandDcoolersontheESWAloop.Inspiteoftherelatively highplaceofRHR2E-217Dinthisranking,pitdensities andpitdepthsforthiscooleraremoreliketheAlo'opcoolersthantheBloop.OnlythedepositweightdensityforRHR2E-217Dseemstobeinordinately high.However,itisinteresting thatDr.Willertz's rankingoftheRHRcoolersisalmostexactlythesameasourrankingbasedondepositweightdensity.Thefactthatbothdeposition andpittingweremoresevereinthetophalvesofRHRlubeoilcoolingcoils1E-217B(fromDr.Willertz's report)and2E-217B,comparedtothebottomhalves,suggeststhattemperature maybeasigniQcant factorinthisproblem.However,thetemperature riseacrosstheRHRlubeoilcoolersisreportedtobeonly8'F.Also,theRHRpumpshaveoperatedlessthan10percentofthetimesince1987,sothatheatgenerated bythesepumpsdoesnotseemtobesi~ificant.

SeethesectionofthisreportdealingwithESWsystemoperations beginning onPage27forfurtherdiscussion ofthissubject.Thephysicalcondition oftheRCICpumproomunitcoolersdoesnotseemtobeafunctionoftheESWloops.Wheninspected on-site,lE-228BseemedtobemoreheavilyfouledthanlE-228A,butmeasureddepositweightdensities areaboutthesame.BothtubesareheavQypitted.Page16 ThomasM.Laronge,Inc.ANALYEFDEPIANDALRFAEAniMhAvarietyofinstrumental andwetchemicalanalytical methodswasusedtoassistinidentifying elementsandchemicalcompounds presentinthedepositsintheRHRlubeoQcoolers,theRCICpumproomunitcoolersandtheESWGRDXcondenser 2E-297A.Thesemethodsincluded:

Inductively coupledargonplasmaspectroscopy (ICAP)combinedwiththermalandwetchemicalmethodsto.,deflnetheoverallelemental composition ofthedeposits.

Scanningelectronmicroscopy (SEM)andelectrondiffraction spectroscopy (EDS)toidentifyelementspresentinmicrolayers inandaroundspeciQcpitlocations.

X-raydiffraction (XRD)todefinespecificchemicalcompounds presentinselectedpits.On-sitemicrobiological cultureteststodetectsulfatereducingbacteria(SRB)andacidproducing bacterial (APB)thatcancausemicrobiologically influenced corrosion (MIC).Directexamination ofcleanedmetalsurfacestohelpidentifymorphological featurescharacteristic ofMICandgeneralunder-deposit pittingcorrosion.

Allofthisworkispresented anddiscussed inthissectionofthereport.Page17 ThomasM.Laronge,Inc.hmilTable5presentstheresultsofICAP,thermalandwetchemical.analyses ofdeposits.

ThegreenandsomeofthereddepositsreportedinTable1andshowninthephotographs correspond tocoppercompounds, probablycorrosion products.

Thisisconfirmed bythehighlevelsofcopperfoundinalltheRHRandRCICdeposits.

Itisentirelypossible, however,thatthesehighcoppervaluesalsoincludecoppermetalscrapedfromthetubesduringthesamplecollection process.ThetwoanalysesreportedforRHR2E-217Crepresent different samplesrunbyseparatelaboratories.

Agreement isexcellent exceptforcopper,discussed above,andsodium,averycommoncontaminant.

TheRHRlubeoilcoolerdatafromTable5areplottedinFiguret2.ThisFigurecomparescoolers1Band2C(heaviest depositsanddeepestpits),cooler1C(highpitdensitybutintermediate pitdepthanddepositweightdensity)andcooler1A(leastdepositsandpit:tingofallcoolersexamined).

Thedifferences amongtheseanalysesarestriking:

~Coolers1Band2C,intheworstcondition, showlowlevelsofiron,manganese andcalcium,andrelatively highlevelsofsulfur.~Cooler1Cshowshighironandmanganese, slightlyhighercalciumandroughlyhalfthesulfurofcoolers1Band2C.~CoolerlA,inthebestoverallcondition, showsverylowsulfur,thehighestmanganese andanintermediate ironlevel.Baseduponexperience withthecombustion andthermaltdecomposition methodusedtodetermine totalsulfurinthedepositsamples,ourlaboratory estimated thatmostofthesulfurinthePage18 gIII~4<

ThomasM.Laronge,Inc.depositsfromRHRlE-217Aand2E-217Cwasprobablypresentas~~sulfate.Thisis,ofcourse,notaquantitative determination, butwereportedsulfateinTable5onthatbasisfordiscussion.

Sincemanyinorganic sulfatesaresolubleitmightseemunreasonable toexpectsulfatesindepositsofthistype.Infact,however,sulfatesarecommonlyfoundinwater-formed

deposits, e.g.,inrecirculating coolingwatersystems.Eventhoughsimplesulfatesaltsoftenhaveappreciable solubility, complexinorganic andorganicsulfatesexistthatarelesssoluble.Also,thesulfateion,becauseofitshighchargedensity,adsorbseasilyonmanysubstrates alongwithappropriate cationsforchargebalance..Finally, mostflocculant hydroxides, including hydroxides ofiron,aluminum, copper,nickelandmanganese amongothers,wQIreadilyoccludesulfatesaltsastheyprecipitate.

Manycorrosion productsprecipitate firstasthehydroxide andthendehydrate andcrystallize toformoxidesandotherinsoluble complexcompounds.

Substantial amountsofsulfatecanbeheldonametalsurfaceinthisway.Nofirmconclusions canbedrawnfromtheseICAPdataalone,buttheobvioustrendsmustberecognized.

Itiswellknownthatmanganese canactasacorrodant oracatalystforcorrosion, or,underdifferent circumstances, asafilm-forming inhibitor.

Iron,particularly irontransported tothecorrosion siteinthewaterratherthanformedinplaceasacorrosion product.canalsoprovideprotection.

SulfuriscommonlyfoundatenhancedlevelsindepositsformedbyMIC.SeetheRootCauseFailureAnalysissectionofthisreportforbackground information andreferences onthebehaviorofmanganese, ironandsulfurincorrosion processes.

Curiously, thedepositsintheRHRlE-217Aand2E-217Belbowsarealmostidentical toeachotherandverydiQ'erent fromtheotherRHRcoolerdeposits.

Theelbowscontainmuchlesscopper,moreiron,veryhighlevelsof,manganese andasignificant amountofzinccomparedtotheRHRlubeoilcoolertubesthemselves.

These.dataindicatethattheelbowsfromboth.coils.may,infact,bemadePage19 ThornosM.Lo,ronge, Inc.fromsomeformofbrass(seetheinspection discussions above).Thehighmanganese levelsintheelbowdepositsconfirmtheblackdepositsfoundduringinspection, butthereisnoreadyexplanation forthepresenceofhighermanganese intheelbowsthaninthecoils.TheanalysisoftheRCICpumproomunitcooler1E-228Bdeposit(Table5)isdifferent fromtheRHRlubeoilcoolerdeposits.

Thiscupronickel tubeshowedoneofthedeepestpitsmeasuredduringthisstudy(Table4)andtheanalysisshowstheexpectedcopperandlowlevelofnickelinthedeposit.TheironlevelismoderatecomparedtotheRHRcoolerdepositsandthemanganese levelisverylow.Thisseemstoparallelthedeeppittingandlow<manganese depositcontentobservedinRHR1E-217Band2E-217C.However,in'contrast totheRHRcoolers,thesulfurcontentintheRCIClE-228Bdepositisverylow.Finally,thedepositintheDX2E-297-Acondenser isentirelydifferent fromthedepositintheRHRandRCICcoolercoils.Thisisamuchmore'typical waterside corrosion andfoulingdeposit,highinironandsilica,verylowinmanganese, copperandsulfur,andwithasignificant lossonignitionindicating thepossiblepresenceoforganicmaterial.

Wewereinformedthatourinspection represented thefirst.timethe2E-297Aheatexchanger hadbeenopened,sothe'a'ccumulation ofwater-borne solidsisnotsurprising.

Thisexchanger mustbecleanedtorestoreperformance, andatthattimeitwillbeimportant toinspectthetubesforpossiblecorrosion damage.SEM-EDSAnIfDeEDSspectraofselectedpitsfromtheRHRlubeoilcoolercoilsandRCICpumproomunitcoolertubesarepresented inFigures9through22,alongwiththerespective elemental compositions

~calculated fromstandardlessanalysis(inwhichthedataareinterpreted mathematically withouttheuseofphysicalstandards).

'hecorresponding SEMphotographs appearasNumbers42through-49.Elementmapsforsulfur,chlorine, ironandmanganese areshownPage20 In ThomasM.Larongl,Inc.asFigures23through29.Allofthesedataaresummarized forediscussion inTable6.EDSspectraweretakenattwoselectedmicrolocations ineachdeposit.Forwimple,referring toTable6,Photograph 42showsaspeciQcpitinRHRlubeoilcooler1E-217B-3B.

Figure9showstheEDSspectrumtakeninthemiddleofthedepositinthispitandFigure10showsthespectrumofthedepositatthebaseofthepit,nexttothemetal.Thecorresponding elementmapforthispitappearsasFigure23.Considering theheterogeneous natureofthedepositsandthespecificity oftheEDSspectra,theagreement betweentheEDSdataandtheICAPresultsinTable5isquitegood.TheEDSanalysesforchlorine(chloride) andsulfurareparticularly interesting becausetheseelementsareoftenfoundnearactivecorrosion sites.Chlorides accumulate inunder-deposit pittingcorrosion cellsbyiontransport mechanisms, whilesulfuroftenappearsatMIClocations throughmicrobial metabolism.

ThechlorideandsulfurdatainTable6donotshowanyconsistent pattern.Consider, forexample,theEDSspectrafromthreediferentpitsinRHRlubeoQcoolercoillE-217B-3B aslistedinTable6.~FiureLocation~ChloridRHRlE-217B-3B 9,10Insidepit16.42Pitbase6.75Sulf'urNoneNone11,1213,14InsidepitNonePitbaseNoneInsidepit15.93Pitbase0.246.1213.353.57NoneThesedifferences may.represent heterogeneous depositsortheymaybeadditional evidencethatmorethanonecorrosion mechanism Page21 Thomo,sM.Laronge,Inc.tmaybeinvolvedinthepittingattackintheRHRandRCICcoolers.Dr.WillertzransimilarSEM/EDSanalysesontheRHRcoilsandfoundthesamevariations, bothonpitsfromthesamecoilandamongdifferent coils.Agreement betweenthetwosetsofanalysesseemstobegoodwiththepossibleexception thatDr.Willertz's datashowmoreelementsandespecially moresulfurinsomecasesthandoourresults.Inanefforttoidentifyspecificchemicalcompounds inthedeposits, weranX-raydiffraction studiesonselecteddepositsfromRHRlubeoilcoolerslE-217B-3B, RHR2E-217Canda90degreebendfromRHR2E-2178.TheresultsareshowninTable7.Thedataaredisappointing.

Onlytheexpectedcuprichydroxide.

cuprousoxide(cuprite) andmagnetite wereidentified.

X-raydiffraction issensitive onlytocompounds presentinamountsgreaterthanabout2percentofthetotal,butwehadhopedthatothercrystalline compounds, particularly sulfurcompounds, couldbeidentiQed inthisway.Elementmaps(Figures23through29)areausefulwaytoidentifythelocations anddistribution ofparticular elementsinamatrix.Elementmappingdoesnotdetermine concentrations ofelements.

Figures23through29showthatallfourmappedelements, sulfur,chlorine, manganese andironarepresentinalldeposits.

However,themapsdonotrevealanyconsistent patternsinelementdistributions inthedeposits.

Ontheotherhand,themapsareespecially interesting becausetheyseemtoconfirmthedifferences shownbytheICAPandSEM/EDSanalyses.

Foracample,Figures23,24and25areelemental mapsofthreepitsinRHRlE-217B-3B.

Figure23showsabinodalvoidinthemiddleofthepit,withalmostnoneofthefourmappedelementspresentinthisarea.Figure24showsbothsulfurandchlorine'oncentrated inthemiddleofthepit,withmanganese andironinanouterring.Figure25showsmanganese, ironandsomechlorineinthemiddleofthepit,withsulfuraroundtheoutside.Page22 Thomo,sM.Laronge,inc.MicriloialAn1Table8summarizes allofthemicrobiological analysescoQectedduringthisinvestigation.

On-siteculturetestsforlivesulfatereducingbacteria(SRB)andacid-producing bacteria(APB)areshownintherighttwocolumnsofthisTable.Thesebacteriaarecommonlyinvolvedinmicrobiologically influenced corrosion (MIC).Laboratory microscopic countsfortotalbacteria(alltypes)andfortotalSRBareshowninthelefttwocolumns.ToputthedatainTable8intoperspective, considerthefollowing guidelines thatarecommonlyappliedtobothonce-through andopenrecirculating coolingwatersystem.Withatotalbacterial countbelow10~to103cellspermlorpergram,asystemisconsidered tobeundergoodmicrobiological control.Atthistotalcountlevel,anaerobic bacteriashouldalwaysbelessthan10~perml.Between103and104totalcellsperml,acoolingwatersystemisconsidered tobebiologically active.Above104to10~cellspermlthereiscauseforconcernaboutbiological foulingandcorrosion problemsandabove106cellsperml,immediate actionisusuallyconsidered necessary topreventdamagetothesystem.Onthisbasis,the8.5x109cellspermltotalcountmeasuredintheESWBsupplywatertoRCIClE-228B(line1inTable8)isextraordinarily high.Totalmicroscopic countsincludebothliveanddeadbacteria, butevenifasfewas10percentofthesebacteriawerealiveinthesystem,thecountswouldbewellabovethedangerpoint.ItisalsoveryunusualtofindtotalSRBlevels,aliveanddead,above106permlinawatersample.Theon-siteculturetestsforliveSRBandAPBinthiswatersampleagreewellwiththetotalmicroscopic SRBcountandindicatethatasexpected, mostoftheanaerobic bacteriadiedorbecameinactiveduringshipmenttothelaboratory.

tItisclearthattheESWBsupplywaterishighlycontaminated withbothaerobicandanaerobic bacteria.

WehavenowateranalysesPage23

>tgI,,e),k ThomasM.Loronge,Inc.fromtheESWAsystem,butsincethesesystemscirculate fromacommonsource,wecanassumethatESWAisalsocontaminated.

Thisisnotsurprising, sincethespraypondreceivesonlyoccasional algaecide treatment asneeded;noregularchlorination ormicrobial controlprogramisused.ThedepositsampletakenfromtheRCIClE-2288pumproomunitcooler(line2inTable8)producedthehigheston-sitelivebacterial depositcountsfoundduringthisstudy,greaterthan107cellspergramofdeposit.Thiscoolerhadbeenopenforseveraldaysbeforeourinspection.

ThefactthathighviableSRBandAPBcountswereobservedevenafterthisexposuretoairindicates thatactivitymusthavebeenveryhighwhenthesystemwasclosed.On-sitetestresultsfromthethreeRHRlubeoQcoolersandtheDXcondenser areallonetothreeordersofmagnitude lowerthanthet1E-228BRCICroomcooler.Note,however,thatliveSRBandAPBcountsfromRHRlE-217A,theRHRcoolerinthebestcondition, areonetotwoordersofmagnitude

~hfhrthanfrom2E-217C,thefailedcoolerintheworstcondition.

Thisdifference maynotbereallysigniQcant becausethesamplefrom2E-217Cwastakenafterthecoilhadbeendryandexposedtoairforseveraldays,whiletheotherRHRlubeoilcoolersamplesweretakenwhilethecoilswerestillwet.However,thetotalmicroscopic countsshowthesametrend.Asexplained above,totalmicroscopic stainingtechniques asusedinthisworkcountbothliveanddeadbacteriaandthusprovideanindication

.ofwhatthepopulations mighthavebeenlikewhilethesystemwasonline.Thesedataarepresented graphically inFigure3.Thenumbersdonotexactlyparallelthecultureresults,butthisistobeexpectedsincevariablenumbersofanaerobic bacteriawilldiedepending uponconditions towhichtheyareexposed.Thetotalcountdataforthefourdepositsamplesshownin--*."Figure3areapproximately thesame,withintheprecision ofthistest.However,theSRBlevelsinthedepositsfromRHR2E-217CandRCICPage24 0IIf1 ThomasM.Laionge,Inc.1E-228B,asever'ely corrodedcupronickel cooler,arebothtwoorderstofmagnitude lowerthanlE-217A.ThisisasigniQcant'difference anditindicates thatmicrobiological activityalonecannotexplainthedifferences inpittinganddepositformation foundamongboththeRHRlubeoQcoolersandtheRCICpumproomunitcoolers.SectionsofcoilsfromRHRlubeoilcoolers1E-217Band2E-217Cwerecarefully examinedunderastereomicroscope fordirectevidenceofMIConthesecoppertubes.Indications ofMICareclearlypresent,butnopitscouldbefoundinthesetubesthatcouldbeentirelyandunequivocally attributed toMIC.DiinfAnR1Manganese, andprobablyalsodeposited iron,appeartobeproviding'corrosion protection intheRHRlubeoilcoolersratherthanincreasing corrosion.

Sulfurlevels,asdetermined byICAPanalysis, correlate withobserveddepthofpitting,butlocationspecificSEM/EDSanalysesforsulfurandchloridedonotcorrelate aswell.Elementmapsshowbothelements, alongwithmanganese andiron,presentinalldeposits, butinsomecasesnexttothemetalsurfaceandinothercasesinthedeposititselforevenoutsidethepit.Microbiological counts,usuallyassociated withthepresenceofsulfurcompounds incorrosion productdeposits, donotcorrelate wellwitheithersulfurlevelsorobservedfrequency anddepthofpittingintheRHRlubeoilcoolers,althoughalldepositstestedshowedhighlevelsofanaerobic andtotalmicrobiological activity.

Allofthesedata,alongwiththeobserveddifferences inpitmorphology, frequency anddepth,indicatethattwodifferent mechanisms arecontrolling thepittingcorrosion processintheRHRlubeoilcoolersandtheRCICpumproomunitcoolers.Thesemechanisms.

are.conventional under-deposit pittingattackandMIC.Itisprobablethatmanypitsweremicrobiologically initiated, butthenadvancedbyconventional mechanisms.

Page25 Thomo,sM.Laronge,Inc.MICandconventional under-deposit corrosion andsometimebedistinguished bydifferences inthemorphology (shapeandsize)ofthepits.Usingmildsteelasanexamplefordiscussion, MICtendstoproducecircular, dish-shaped pitswithroundededgesanQoftenwithsmallerpitswithinthemainpit.Conventional under-deposit corrosion usuallyproducespitswithirregular shapes,sharpedgesandstraightorundercutsides.Oncopper,thesedifferences areobscuredbythefactthatthebacteriaresponsible forMICoftendieorbecomeinactiveduetothetoxiceffectsofthecopperionsgenerated bycorrosion.

Thedepositsremain,however,andcorrosion continues byconventional mechanisms sothatthepitmorphology becomesobscured.

SeetheRootCauseFailureAnalysissectionofthisreport,beginning onPage.35,forfurtherdiscussion ofthissubject.Thefollowing sectionofthisreportdiscusses ESWwaterchemistry andESWandRHRpumpoperations.

Thisinformation isneededtohelpexplainwhythiscorrosion isoccurring andwhydepositcompositions andratesofdeposition andpittingattackaredifferent amongthedifferent RHRandRCICcoolers.Page26 s-p4l ThomasM.Loronge,Inc.EWSYTEMHEMITRYANDPERATIQN~ESWhAvailable ESWchemistry parameters for1989and1990areplottedinFigures4and5.Conductivity andcalciumlevels(Figure4)showacleardownwardtrendduringthisoneandone-halfyearperiod.Turbidity fluctuated widelyduringthisperiod,whilethepHremainedinthe8to9range(Figure5).Noexplanation forthesetrendsisreadilyavailable.

Figure6showstemperature andLangelier Stability Index(LSI)calculations fortheESW,asprovidedbyPAL.ItisclearfromFigure6thattheLSIwilloftenbeabove+0.5,andoccasionally above+1.0,creatingadefinitepossibility forcalciumcarbonate scaleformation.

Underborderline scalingconditions, suchasthese,smalltemperature eorconcentration changesinthewatercancreatethedrivingforceneededtocausecalciumcarbonate toprecipitate inaheatexchanger.

Table9presentsananalysisoftheESWBwatersupplytoRCICpumproomunitcoolerlE-228B,takenduringoursitevisitonJune9,1990.LSIvaluesforthissample,asshowninTable9,rangefrom+0.4at80'Fto+0.7at110'F,makingthissamplemarginally non-scaling.

TheanalysisinTable9showstheESWasanalyzedtobeagenerally goodqualitywater.Parameters ofparticular interestareironat0.74ppm,manganese at0.75ppmandsulfateat53.6ppm.Theselevelsofironandmanganese aremorethansufficient toaccountforthedepositsoftheseelementsfoundintheRHRlubeoilcoolersandtheRCICpumproomunitcoolers.Withroughly54ppmsulfatepresentinthewater,itisreasonable toexpectsomesulfatecompounds tobeadsorbedoroccludedincorrosion productdeposits.

ThisprovidesafoodsourceforactiveSRBandindicates thatatleastsomeofthesulfurreportedintheRHRandRCICcoolerdepositsmaythepresentassulfate(seeTable5).Page27

'll'J4trkWt ThomasM.Laronge,Inc.Recommendations forwatertreatment attheSusquehanna plantarebeyondthescopeofthisreport.ThedataclearlyindicatethattheESWisatleastoccasionally scalinginnature,andthemicrobiological datadiscussed inaprevioussectionshowthatthesystemishighlycontaminated withbacteria.

EWnRHRPumrnThenatureoftheflowpatternsthroughtheRHRlubeoilcoolersandtheRCICpumproomunitcoolerscanhaveamajorimpactupondepositformation andsubsequent corrosion intheseunits.Toinvestigate thisproblem,westudiedtheoperation oftheESWsystempumpsandtheRHRpumpsinsomedetail.Weappreciate thecooperation offeredbyPP&Lpersonnel inobtaining theoperating datanecessary forthisstudy.NotaQthedata-werereadQyavailable, andthefirstinformation providedtousturnedouttobeincorrect.

Wehavereviewedthisproblemseveraltimes,andthefollowing discussion isbaseduponthelatestinformation whichPP&Lassuresusisreliable.

tmrinOurstudyisbaseduponthefollowing PP&Linformation:

TheESWiscirculated fromalargespraypondthroughvariousequipment andbacktothepond.Makeupwatertotheponds,mostlyfromthemaincondenser coolingtowerblowdown, withadditional makeupfromtheSusquehanna Riverasneeded.TheESWsystemisdividedintotwoloops,labeQedAandB.Twopumps,labeQedESWAandC,drivewaterthroughtheAloopandpumpsBandDdrivetheBloop.ThesepumpstakewaterfromacommonsuctionpointinthePage28 ThomasM.Laronge,Inc.spraypond.Waterreturnstothepondthroughtwoseparateheaders.~Thefollowing coolersthatwehaveexaminedareconnected inparallelacrosstheESWAloop:RHRlubeoilcoolers1E-217AandD,and2E-217AandD.RCICpumproomunitcoolerlE-228A.ESWGRDXsystemcondenser 2E-297A.~Thefollowing coolersthatwehaveexaminedareconnected in.parallelacrosstheESWBloop:0RHRlubeoilcoolerslE-217BandC,and2E-217BandC.RCICpumproomunitcoolerlE-228B.~AtanytimetheESWisflowing,oneorbothoftheESWAandBloopsmayberunningandeitherorbothoftheESWpumpsontheactiveloop(s)maybeinuse.Watercirculates throughalloftheequipment.

oneachloopwheneverthatloopisrunning.BThEWSrPnThevolume.ofwaterinthespraypondisestimated byPALat26milliongallons.Weunderstand thatmakeup'from thecoolingtowerblowdown" runsatfrom300to1000gpm,withanadditional 200gpmavailable fromtheriverasneeded.Page29 (4

ThomasM.Laronge,Inc.Wedidnotpersonally inspectthespraypond.Weunderstand fromPP&Lpersonnel andfromwatertreatment vendorreportsthatthepondwaterqualityvariesseasonally inturbidity anddissolved andsuspended solids.Duringthesummermonths,algaegrowsinthepond;thisiscontrolled byoccasional treatment withalgaecide andchlorinearoundtheedgesandacrossthesurfaceofthepond.Itisclearthatthespraypondisasourceofmicrobiological contamination andpossiblyalsosuspended solidsintheESWwaterandcoolers.Chlorinehas,inthepast,beenaddedtotheESWpumpsuctionpoint,butthishasnotbeendoneinrecentmonths.CEWRHRmRunTimPP&LprovidedmonthlyruntimedatainhoursfromAugust1986throughMay1990forboththeESWandtheRHRpumps.Thesedataarerecordedfordiscussion inTable10.Incalculating the"AssumedTotal"runtimesshowninTable10,weusedthefollowing guidelines:

~Weunderstand thatpriortoJune1989,theentirecoolingloadforthedieselgenerators wascarriedbyESWloopAandforthatreason,bothpumps,ESW-AandESW-C,ranwhenevertheAloopwasinoperation.

ToarriveatatotalrunfortheAloopduringthisperiod,wesimplyusedthehigherofthetwohourlynumberseachmonthforpumpsESW-AandESW-C.Duringthissametimeperiod,theloadontheESWBloopwaslighterandusuallyonlyonepumpwasinoperation.

Tocalculate thetotalmonthlyrunhoursfortheBloop,wetherefore usedthesumoftherecordedhoursfortheESW-BandESW-Dpumps.Page30 ThomosM.Loronge,Inc.FromJune1989forward,thepipingwasrearranged sothatthedieselgenerator coolingloadwassharedbetweentheESW-AandBloops.Duringthisperiod,ithasbeennormalpracticetooperateonlyonepumpatatimeineachloop.We,therefore summedthedataforeachmonth,asabove,tocalculate assumedtotalrunhoursforeachloop.Theassumedtotalmonthlyruntimesshowagooddealofscatterthatobscuresanysignificant trends.Tosmooththedata,wecalculated annualruntimehoursasapercentoftheavailable hours(8,760hoursinayear).ThesedataareshowninFigures7Aand7B,representing theESW-AandBloops,respectively.

TheseFiguresalsoincludethepercentruntimesfortheRHRpumpsfromTable10,simplycalculated bysummingthemonthlydata.tThehigherruntimesshownforbothESWloopsin1989comparedtootheryearsmaybeacalculation errorresulting

&omthefactthatbothpumpsprobablydidruntogetheroneachlooppartofthetimeafterJune1989.Thisquestiondoesnotsignificantly affectthedataforourpurposes.

ItcanbeseenfromFigures7Aand7BthattheESWAloopranforroughly35percentofthetimefrom1987throughMay1990andtheESWBloopranforabout25percentofthetime,ontheaverage.TheexactQguresarenotimportant.

Conversely, thedatasay.thattheAloopwasstagnantfor65percentofthetimeandtheBloopfor75percent'ofthetime.Itfollowsthatthecoolersconnected toeachloop,aslistedunderSystemOperations above,werealsostagnantfortheseperiodsoftime.Weassumethatthecoolerswerenotallowedtodrainandremainedfullwhilestagnant.

Page31 I

Thomo,sM.Loronge,Inc.Theexistence oflongperiodsofstagnation intheESWwatersystemisanimportant factorinunderstanding thepittingfailuresthatoccurredinthecopperRHRlubeoilcoolingcoilsandthe90:10cupronickel RCICpumproomunitcoolers.Thepresenceofstagnant, contaminated waterinthesecoolersforextendedtimeperiodsrepresents theworstpossiblecondition forcorrosion protection ofcopperandcopperalloys,particularly withnospecificcorrosion inhibitors forcopperinthewater.Thisproblemisdiscussed indetailinthefollowing RootCauseFailureAnalysissectionofthisreport.TheRHRpumppercentruntimedatainFigures7Aand7BareameasureofthetimethatheatwasappliedtotheRHRlubeoilcooling.coils.Wehavenoinformation onthetimesthatheatwasappliedintheRCICpumproomunitcoolers.HeatwasappliedtotheRHRlubeoilcoolersforasmallfractionofthetotaltime,butagain,moreinloopAthaninloopB(seeFigures7Aand7B).Giventhe8'Ftemperature riseacrossthesecoolers,asdiscussed above,andtheshortRHRpumpruntimes,itseemsunlikelythattemperature differences acrossthecoolercoilscouldbeasignificant factorinthedeposition andcorrosion process.Nevertheless, thedatashowthattheRHRpumpswiththe"best"lubeoilcoolers,namelylA,2Aand1D,ranperhapstwiceasmuchasthosepumpswiththe"worst"coils,namely1B,1Cand2C.D.RHRLuillinWrFlwVlociFlowvelocityisanimportant factoraffecting thenatureanddegreeofbothdeposition andcorrosion thatcanoccurintubularequipment.

TheinitialdatasuppliedbyPALshowedveryhighflowvelocities intheRHRlubeoilcoolers.Thisseemedinconsistent inviewoftheloosedepositsfoundinsomecoolersandthefactthatnoerosionorerosion/corrosion wasfoundinanyofthecoolertubesorelbowsthatweexamined.

This,wasconfirmed byDr.Willertz's inspections ofthesetubes.Page32 ThomosM.LoroncIe, Inc.PALcooperated fullywithusinresolving this.issueandwasabletosupplynewflowvelocitydatathatseemtobereasonable andthatPPM.assuresusaretheirbestestimates.

ThesedataareshowninTable11andFiguresSAandSB,fortheAandBloopsrespectively.

PP&LprovidedvelocitydatafortheAloopforallthreetimeperiodsshowninTablellandfortheBloopfortheperiodfromJune1989throughJune1990.Bloopdatawerenotavailable forJune1986throughJune1989.AtPP@L'ssuggestion, wecalculated flowvelocities fortheBloopduringthisperiodat20percentabovethecorresponding Aloopvelocities.

Thelowerflowvelocities intheAloopfromJune1989through1990maycorrespond tomorefrequentuseofonepumpratherthantwoduringthisperiod(seeabove).Thereisnosimpleexplanation forthehigherflowvelocities intheBloop,especially duringtheJune1989to1990periodforwhichharddataareavaQable.

Thesehighervelocities goalongwithshorteroperating periodsfortheBloop,asexplained inthepreviousdiscussion.

Typicalcriticalwatervelocities, abovewhicherosionanderosion/corrosion damagecanbeexpectedinheatexchanger tubing,havebeenreportedintheliterature:

Materi1Copperalloy¹122Admiralty Brassalloy¹4430090:10Cupronickel alloy¹70600ri1WrV1i6fps10tollfps12to15fpsRfrnThevelocities inTable11andFiguresSAandSBareabovetheguidelines forcopperasquotedabove.Velocities inthe0.5inchdiameterRCICpumproomunitcoolersarelowerthanintheRHRtube'oflcoolersatabout2to3'feetpersecond.Exceptforsomeminordirectional natureinthedepositsinoneRHRlubeoilcoolerPage33

ThomasM.Laronge,Inc.(RHRlE-217B,seeTable1),wehavefoundnoevidencethatvelocityaffectedthenatureofthecorrosion intheRHRandRCICcoolers.However,waterflowvelocityalmostcertainly influenced thetype,amountandphysicalformofthedepositsinthesecoolers.Page34 IJ' Thomo,sM.Laronge,Inl-.RTAEFAILREANALYIBrieflystated,theRHRlubeoilcoolersandtheRCICpumproomunitcoolersfailedbyacombination ofmicrobiologically inducedcorrosion andchemicalpittingcorrosion mechanisms.

Periodsofstandingincontactwithstagnant, microbiologically activewaterallowedinitialdepositstoformonthetubesurfaces.

Underneath thesedeposits, anaerobic conditions allowedsulfate-reducing bacteriatoproducesulfidesfromsulfateionsinthewater.Themicrobiologically-generated sulfidesinitially attackedthemetalsurfaces.

Thebaremetalexposedinthiswaytendedtoinhibitfurthermicrobiological growthunderthedeposits.

However,oxygenconcentration cellsnowexistedbetweenthemoistdepositsnexttothemetalandthebulkwater.Thebaremetalbecameanodicrelativetothemetalawayfromthedepositsandpittingcorrosion began'.Chlorideionsfromthewaterconcentrated inthepitthroughcomplexionformation withcopperionsproducedthroughcorrosion.

Ironandmanganese inthewatersupplyalsoconcentrated inandnearthegrowingtubercles andpits.Irondepositstendedtoreducethepittingcorrosion ratebyinhibiting diffusion ofwaterthroughthedeposits.

Manganese alsoservedinthisrole,butinsomecasesalsoincreased thecorrosion ratebycatalyzing theelectrontransferreactions withinthepitsandnexttothemetalsurface.Thispittingcorrosion eventually producedthethrough-wall failureofRHRlubeoilcooler2E-217Candtheincipient failuresofRHRlE-217BandRCICpumproomunitcoolerlE-228A.Thereasonsforthelessseverepittinganddeposition observedinotherRHRandRCICcoolersarerelatedtodifferences indepositcompositions andoperating conditions amongthesecoolers:Page35 ThomosM.Laronge,Inc.Thefollowing paragraphs ofthissectionexaminethispittingcorrosion failurescenarioinmoredetail.PiIniCopperand90:10cupronickel arechosenforheatexchanger servicebecauseoftheirgoodmechanical andheattransferproperties andbecauseoftheiroutstanding resistance tocorrosion inclean,flowingwater.Thesemetalsaresostableinwaterthatheatexchanger tubesthathavebeencorrodedunderdepositscanbesafelyreturnedtoserviceaftercleaning(4).

However,itiswellknownthatcopperalloysareattackedbysulfides.

Muchworkhasbeendonetounderstand andtodocumentthepittingcorrosion ofcopperand90:10cupronickel thatcanoccurinsulflde-contaminated water(45@.Mostofthisworkhasbeendoneinmarineenvironments.

Ionicconcentrations are,ofcourse,quitedifferent inafreshwaterenvironment suchastheESWspraypond.Sulfideshouldnormallynotexistinthissystem.Thedifference isthattheESWspraypondisbiologically veryactiveandprobablycontainslargenumbersofsulfatereducingbacteria(SRB).Thisassumption isbasedupontheknownlackofbiocidaltreatment inthepond,probableanaerobic conditions nearthebottomofthepondandtheestablished highlevelsofSRBintheESW-BsupplytoRCICcooler1E-228B.WaterintheRHRlubeoilcoolersandtheRCICpumproomunitcoolershasbeenstagnantfrom65to75percentofthetime(Table10andFigures7Aand7B).Duringthesestagnantperiods,suspended solids,biological matterandsolublematerials fromthewater,particularly iron,manganese andcalciumsalts,tendedtoprecipitate onthetubesurfaces.

SomeofthesesolidsmusthavebeenmovedeverytimetheESWwatercirculated, butovertime,adherentdepositsaccumulated.

tSulfldicmetabolic productsfromSRBinthesedepositsactedinthesamewayassulfldesincontaminated seawater;theyattackedthePage36 ThomasM.Laronge,Inc.metalsurfaces.

Thesebacteriatheneitherdiedorbecameinactive.

Popeetal(7)explained thatlittleisknownaboutMICoricopperalloysinfreshwaterbecauseoftheknowntoxicityofcopperionstobacteria.

Schiffrin etal+)showedthataerobicorganisms, e.g.,Pseudomonas, canalsoinducepittingcorrosion ofcopperalloysbyformingdeposits.thatleadtooxygenconcentration cellsandeventualdestruction oftheprotective oxidelayersonthemetal.Oncebaremetalhadbeenexposedbymicrobiologically inducedsulfideattack,standardunder-deposit oxygenconcentration cell,corrosion becamethedrivingforce.Manyauthorshavedocumented pittingcorrosion oncopper.During+)described severalcasesofpittingoncopperbeneathironoxidedeposits.

Thephotographs inDuring'sbooklooksimilarinsomerespectstothoseinthisreport.TheAWWA('@explainspittingoncopperwaterpipingingreatdetail,withdiagramsandelectrochemical mechanisms.

Quotingfromthiswork,"Pitting(oncopper)ischaracterized bythepresenceoftubercles, whicharerandomlydistributed.

Theinsideofthetube(contains) blue-green basiccoppercarbonate (Malachite).

Underthislayerisabrownlayerofcuprite(cuprousoxide,Cu20),whichisfriableandeasilyspalledfromtheunderlying coppermetal.Typically, manypitsataHstagesofdevelopment areseen,butonly,afewhaveactuallypenetrated thewallthickness."

Thisdescription seemstomatchquitewellthetheconditions inthefailedRHRlubeoil'ooler, 2E-217C.LymanandCohen(>0) comparedthechemicalcompositions ofmanywatersuppliesassociated withpittingfailuresincoppertubes.ThepH,chlorideandsulfatelevelsintheESW,aslistedinTable9,fallintoLyman.and Cohens'ange ofmaximumsusceptibility topitting.However,theauthorsalsopointoutthatmanysuccessful applications ofcopperpipingexistinwaterswithsimilarcompositions.

Chloridedoestendtoconcentrate atanodicsitesbecauseofcomplexionPage37 ThomasM.Laronge,Inc.formation withnewlyreleasedcopperions.ThiscanfurtherreducethepHattheanodicsiteandincreasethecorrosion rate.EfffulfrIrnSulfidesandsulfatesmaycontinuetoinfluence thecorrosion mechanism duringthesecond,orconcentration cellphaseofpitgrowth.TheAWWAmanual(@describes pitmorphology incopperpipes.Intheabsenceofsulfides, theAWWAclaimsthatmostpitsareirregular inshape,straightedgedandnarrow.WithsulQdespresent(fromthewater,notfromMIC),pitstendtobewiderandshallower innature.Themechanism described hereisverysimilartochloride-

.enhanced pittingcorrosion ofmildsteel.Bothtypesofpittingdescribed bytheAWWAareclearlyevidentintheRHRlubeoilcoolertubes.See,forexample,Photographs 19,~~~~~~~~23,27,30,31,33and34.IntheESWsystem,SRBobviously continuetoexistinthedeposits, althoughnotindirectcontactwiththemetalsurface.Itisentirelypossibleforsulfidesgenerated bySRBmetabolism tocontinuetodiffusewiththewaterandaffectpitmorphology asdiscussed bytheAWWA.ThefactthatSEM/EDSanalysesandtheelementmapsinthisreportshowedsulfurpresentatspecificbut'different locations invariouspitsanddepositsmaybetheresultofthiseffect.SeeTable6andFigures23through29.IronfoundintheRHRlubeoilcoolerandRCICpumproomunitcoolerdepositscomesmostlyfromthemakeupwatertothespraypond,withadditional contributions fromironaccumulated inthepondandfrompossiblecorrosion ofESWtransferlines.Solubleironinthewatermaybeprecipitated intheESWsystembychemicaloxidation orbytheactionofironoxidizing bacteria.

Thesebacteriaareoftenfoundtocoexistwithotherbacteriainbiologically activewatersystems.TheXRDdata(Table7)showthatironindepositswaspresenttentirelyasmagnetite.

Thisisexpectedinlowoxygenlocations, i.e.,insideandunderneath tubercles.

Depending uponotherPage38 ThomasM.Laronge,Inc.$1characteristics ofthespeciQcdeposits, magnetite mayprovidesome,barrierlayercorrosion protection, oritmayserveonlytoincreasethesizeandnumberofthetubercles andtherefore theintensity ofpitting.Thepresenceofmanganese, atthelevelsfoundintheSusquehanna

deposits, canbothaggravate andreduce'ittingcorrosion.

Manganese isamultivalent metal.Itcanexistinseveraloxidation statesandcantherefore actasanelectrontransferagenttoencourage electrochemical oxidation-reduction reactions.

This,ineffect,increases thecorr'osion rateandparticularly pittingcorrosion undermanganese-containing deposits(>>).

Atthesametime,however,tightlyadherentlayersofmanganese oxidescanprotectmetalsurfacesfromcontactwithwater.Manganese oxidesareoftensuggested asproductsofbiological metabolism inmanganese-containing waters.Bothofthesemechanisms wereinvolved'in theRHRlubeoiltcoolerpittingcorrosion.

process.TheRHR2E-217Ccoolershowedlittlemanganese inthedeposits, butthedepositswerecrystalline, scalingandnon-adherent innature.Eventhesmallamountofmanganese foundinthisdeposit(Table5)canincreasecorrosivity byaidingoxidation-reduction reactions involving electrontransfer, asexplained above.TheRHRlE-217Adepositcontained muchmoremanganese, butasexplained intheinspection sectionabove,thesedepositswerelessscalingandmoreadherentinnature.Pittingattackwascorrespondingly lesssevere.Thevariations inmanganese contentofthedepositsmaybepartofthereasonforthedifferences incondition ofthevariousRHRlubeoilcoolers.Theworstcoolers(2Cand1B)areontheESWBloop,whilethecoolersinthebestcondition (lA,2Aand1D)areontheAloop.TheESWAandBloopsmustbeconsidered asonesystem,sothesedifferences arehardtoexplain.PriortoJune1989,theAloopranmorefrequently andcarriedmorewaterthantheBloopandatabouta20percentlowervelocity.

Possiblymoremanganese could-havedeposited intheAloopundertheseconditions.

TheveryhighPage39 ThomasM.Laronge,Inl-.levelsofmanganese inthelE-217Aand2E-217Belbowsremainunexplained.

nfRHR1rRIlrurnikelItisinteresting tocomparethecondition oftheRHRlubeoilcoolers(typeKcopper)withtheRCICpumproomunitcoolers(90:10cupronickel).

Thediscussion inthisreporthascenteredontheRHRcoolersbecauseofthefailurethatoccurredin2E-217Candthenearthrough-wall pitsfoundinotherRHRcoolers.However,theRCICcoolerswerenotfarbehind.Wemeasureda90percentthrough-wall pitin1E-228Aanda60percentthrough-wall pitinlE-228B(Table4).TheflowvelocityintheRCICcoolerswasreportedbyPALasabout2to3feetpersecond.WaterflowsinboththeRHRandRCICcoolerswhenevertheESWpumpsarerunning.RCIC1E-228Aisconnected totheAloopandlE-228BtotheBloop.RCIC1E-228BandtheESWBinletwaterlinetothiscoolershowedthehighestlevelsofmicrobiological activityofallthecoolerstested.Themanganese levelinthedepositfromRCIC1E-228Bwasverylow,similartoRHR2E-217C.Itisclearthatthepittingcorrosion problemisjustasseriousintheRCICroomcoolersasintheRHRlubeoilcoolers.Thisisimportant becausetheRHRcoolersaretheonlycoppercoilsintheESWsystem;allothercoolersare90:10cupronickel orotheralloys.Cupronickel andcopperarebothknownfortheirexcellent resistance tocorrosion inclean,flowingwateratneutralandalkalinepH.However,cupronickel ismoresusceptible thancoppertobothgeneralbiofouling andMIC(>2).Thisbehaviorhasbeenobservedanddocumented, butnot.explained verywell.Copper(and304stainless steel)formpassive,protective Almsthatprovidecorrosion resistance.

90:10cupronickel alsoformspassivesurfacefilms,andobtainsadditional corrosion Page40 ThomasM.Loronge,Inc.resistance fromtheelectrochemical nobilityofthealloyedsurface.Inthepresenceofacorrosive agentsuchashydrogensulfidefrombiological metabolism, andintheabsenceofoxygenneededtorepairpassivefQms,itispossiblethatfilmsonthesinglecomponent coppersurface.mightbemoreresistant toattackthanthoseonthetwocomponent 90:1'0cupronickel surface.0Page41 ThomosM.Larongt,Inc.ENDIPage42 pi'p,tErr4' ThomasM.Laronge,Inc.BIBLIRAPHYy1.ClaudeD.Tapley,"ProcessIndustries Corrosion."

NationalAssociation ofCorrosion Engineers, 1975.Texas,2.R.JamesLandrum,"Fundamentals ofDesigning forCorrosion Control:ACorrosion AidfortheDesigner."

Texas,NationalAssociation ofCorrosion Engineers, 1989.3.K.I.JohnsonandD.A.Neitzel,"Improving theReliability ofOpenCycleWaterSystem:Applications ofBiofouling Surveillance andControlTechniques toSedimentandCorrosion FoulingatNuclearPowerPlants."Washington, DivisionofSafetyReviewandOversite, OfficeofNuclearReactorRegulation, U.S.NuclearRegulatory Commission, 1987.~'rthurH.Tuthill,"Successful useofCarbonSteel,CopperBaseAlloysandStainless SteelinServiceWaterSystemsinOtherIndustries."

Presented attheEPRIServiceWaterSystemReliability Improvement Seminar,Charlotte, NorthCarolina, October1988.5.H.A.Videla,M.F.L.deMele,andG.Brankevich, "Assessment ofCorrosion andMicrofouling ofSeveralMetalsinPolluted8*1."81LNNN448.1,4ty1888.6.D.FSchiffrin andS.R.deSanchez,'TheEffectsofPollutants andBacterial Microfouling ontheCorrosion ofCopperBaseAlloysinSeawater."

Quernin,41,No.1,January1985.7.D.H.Pope,D.Tuques,P.C.Wayner,Jr.andA.H.Johannes, "Microbiologically Influenced Corrosion:

AStateoftheArtReview."MTIPublication No.13,Materials Technology Institute oftheChemicalProcessIndustries, Inc.,secondedition,1990.Page43 c~MH ThomasM.Laronge,Inc.8.EvertD.D.During,rrinA111nfIllurHiriV12NewYork,ElsevierPress,1988.9.AWWAResearchFoundation, nrn1rrinfWrDirinmpp.337-365.Denver,AWWAPress,1985.10.W.StuartLymanandArthurCohen,"ServiceExperience WithCopperPlumbingPipe."Mri1PrinnPrfrmnV~111,No.2,pp.43-53,February1972.ll.VictorJ.Linnenbom andJeffreyJ.Forshee,"ServiceWaterSystemExperience atBeaverValleyPowerStation."

Presented attheServiceWaterSystemReliability Improvement Seminar,Charlotte, NorthCarolina, October1988.12.DavidS.Hibbard,"CopperAlloyTubeApplications inPowerPlanteCondensers."

PwrEninrin,August1981.Page44 P)jc0 ThomasM.Laronge,inc.LIFTABLETABLE1TABLE2TABLE3TABLE4TABLE5TABLE6TABLE7TABLE8TABLE9eTABLE10TABLE11TABLE12RESULTSOFVISUALINSPECTIONS OFSPECIMENS RESULTSOFPHYSICALMMBUREMENTS ONAS-RECEIVEDSPECIMENS RESULTSOFDEPOSITWEIGHTDENSITYMEASUREMENTS RESULTSOFPITDEPTHSURVEYSCHEMICALANALYSESOFDEPOSITSSUMMIARYOFSEM-EDSANALYTICAL RESULTSRESULTSOFDEBYE-SCHERRER X-RAYDIFFRACTION ANALYSISOFDEPOSITSAMPLESUSINGCOPPERK-ALPHARADIATION RESULTSOFMICROBIOLOGICAL ANALYSESRESULTSOFTHEANALYSISOFESWBWATERSUPPLYTORCIC1E-228BPUMPROOMUNITCOOLERESWANDRHRPUMPRUNTIMES,HOURSRHRLUBEOILCOOLERFLOWVELOCITIES COMPARISONS OFOBSERVATIONS ANDPHYSICALMEASUREMENTS Page45 C(I TABLRESULTSOFVISUALINSPThomosM.LoIonge,Inc.NSOFSPECIMENS ItemNumberDescritionRCIC1&228APumproomunitcooler.RCIClE-228BPumroomunitcooler.RHRlE-217ALubeoQcooler.RHRlE-217ALubeoQcooler,90degree90DegreeBendsbends.~RHRlE-217BLueocooer,3rowSection3Bfromtop,2ndcoQfromcenter.RHRlE-217CLubeocooler.PhotoNo.1,14,15.16, 40,41,4311,48,491313,37,38,39

,20,21,2, 23,42,44,45 7,28,29,30, 31,46,47VisualInsectionsofInteriorSurfacesUormthinbrowndepositsplustubercles, alsosomemse/tandepositsonsurfaces.

Greenandreddepositsbeneathtubercles.

Pitsmostlyhemispherical, somejaggedandirreular.Noundercuttin

.Noeneralcorrosion.

DeosftsandfttfnsfmQartolE-228A.Uniformthindeosits,notubercles, veslhtfttin.Apparently brasselbows.Blackpowderydeposit,somearemetal.Novisiblecorrosion underdeposits, exceptpittingoncoppertube(PhotoNo.39).Mosysmoorownaceposft,someagreendeposits.

Largebrowntubercles, 0.25inchdiameterandheight.Under-deposit pitsmostlyhemispherical, noodd-shapedored-edepfts.Largeamountosmoothbrown/black deposit,rightgreencrystalsaroundtubercles andpits.Sparkling silver/red crystalsinbottomsoflargeshallowhemispherical pits(SEMPhotoNos.46and47.RHR2E-217A Lueocooer.6Uormrown,sto1E-217B,utmucsmaertubercles.

Nosignificant visiblelocalized orgeneral'orrosion.

RHR2E-217B LubeoQcooler.9RHR2E-217B LubeoQcooler,90degree90DeeBendsbends.10-RHR2E-217C LubeoQcooler.RHR2E-217D LubeoQcooler.8,9,10,12, 32,33,3412,35,362,17,18,19 4,5,24,25,26,27 Scattered blackandgreendeposits, appeartoollowowpattern.Nosignificant tuberculatfon.

Hemispherical pitswereQlledwitheenandblackdeposits.

Apparently copperelbows.Smoothtan/black deposits.

Novisiblelocalized oreneralcorrosion.

Heavygrey/green scalydeposit,nosmoothrown/black layerasinothercoQs.Largetubercles coveringgreenandreddeposits.

Manyjaggedandhemispherical pits,MostseverepfttfnofallRHRlubeoQcoocoQsexamined.

Uormbrowndeposit,manysmalltubercles withgreenedges,greendepositbelowtubezeles.

Shallow,Mundpits,lessseverethanothercoolers.Page46

'I'8aii TABLE2RESULTSOFPHYSICALMEASUREMENTS ONAS-RECEIVED SPECIMENS SpecimenRCIClE-228AHorizontal SplitRCIClE-228AVerticalSplitRCIClE-228BHorizontal SplitRCIClE-228BVerticalSplitRHRlE-217A90DeBendsRHR1E-217B-3B RHR1E-217CRHR2E-217ARHR2E-217B-2 2ndRowFromToRHR2E-217B-2ndRowFromBottomRHR2E-217B-2 2ndRowFromTopsA,B,C,DRHR2E-217B90DreeBendsRHR2E-217CRHR2E-217DOverall,Length,Inches20.319.622.52.3to2.516.010.014.0VariesDepending onSecimenConsidered SecimenConsidered VariesDepending onSecfmenConsidered 1.9to2.116.515.5OutsideDiameter, Inches0.6370.6350.6370.6370.9800.8730.8900.8550.875VariesDepenon0.8750.8250.90to1.00.8500.895InsideDiameter, Inches0.5290.5310.5280.5140.7600.7410.7650.7500.7430.7430.7130.75to0.850.7180.755MeasuredWallThfckness, Inches0.0550.0520.0600.0600.0980.0710.0710.058to0.0700.0650.0650.0560.0750.0750.070TypicalMinimumWallThickness

+/-Tolerance, Inches0.049+0.0040.049+0.0040.049+0.0040.049+0.004Uncertain 0.065+0.00450.065+0.00450.065+0.00450.065+0.0045.0.065+0.00450.065+0.00450.065g0.00450.065+0.00450.065+0.0045Page47 TABLE3RESULTSOFDEPOSITWEIGHTDENSITYMEASUREMENTS~

SecimenRCIClE-228A,Horizontal SlitRCIClE-228A,VerticalSlitRCIC1E-228B,Horizontal SlitRCIClE-228B,VerticalSlitRHRlE-217A,90DereeBendsRHRlE-217B-3B, 3rdRowFromTop,2ndRinFromtheInsideRHRlE-217CRHR2E-217ARHR2E-217B-2, 2ndRowFromToRHR2E-217B-5, 2ndRowFromBottomRHR2E-217B,90DereeBendsRHR2E-217CRHR2E-217Dm/ft210.677.137.727.7715.4031.7324.075.2513.216.8617.2337.9027.25DeositWeihtDensim/mm20.110.080.080.080.160.340.260.060.140.070.18~0.410.29'Calculated according toASTMStandardD3483-83MethodAPage48 I

ThomosM.Loronge,Inc.TABLE4RESULTSOFPITDEPMSURVEYSSecimenRCIClE-228A,Horizontal SlitRCIClE-228A,VerticalSlitRCIClE-228B,Horizontal SlitEstimated DensityofPitting,Pits/Square Inch5to50Estimated MaximumPitDepth,Inches0.0500.0170.017alculated PercentThrough-WallUsingMaximumPitDepth,Percent913328RCIC1E-228B,VerticalSlitRHRlE-217A,90DereeBends2to50.036Essentiall FreeofLocalorGeneralAttack60RHRlE-217B-3B, 3rdRowFromTop,2ndRinFromtheInsideRHR1E-217C:5to5025to3000.0250.01318RHR2E-217ARHR2E-217B-5, 2ndRowFromBottomRHR2E-217B-2, 2ndRowFromToRHR2E-217B,90DereeBendsRHR2E-217CRHR2E-217D4to500.0070.025Essentiall FreeofLocalorGeneralAttack1to2000.0280.015Essentiall FreeofLocalorGeneralAttack3837Page49 ThomosM.Lo,ronge, inc.TABLE5CIIEMICAL ANALYSESOFDEPOSITSDatainWUeightPercentAllTestsRunbvICAPExcet"ParameterRHR1ERHR2ERCIC1EES%V"2'17A217BRHR1ERHRlERHR1ERHR2ERHR2E2MBGRDXElbowElbow217A217C217B-3B217C217CHor.solit 2E-297AFeCuMnZnICaiIPAlIBaIglIiYia~T'IVCrMoSi02SO4"lCO""'.~U10.1922,802663.140.200,95NDADND.'4DYiD0.21<0.010.14NDYiDQTD5.009.5323.373.944290.270.970.49(0.63(0.47IO.o4~0.'2~I0.14)<0.01)0.15IYiDf'i2.9570.30?.070.79'.200.060.001.090.460.290.270.040.08<0.01<0.013.640.303.207.~Dl49.54l4.98,.'.83l1.40i2.08l3.93I0.39!0.23lO.22',0.18!0.26i0.05l<0.01l0.02,II~DiYiDi4D',I'.02'1.470.670.170.684.954.720220,030.040.030.050,010.01<0.01NDADND0.9657,901.220.250.774.484.480.210.040.070.040.26<0.01<0.01<0.01NDYiDXDIl0.86!80.30l0.89ii0.30iO.8Oii2.81'!0.00>0.41f0.04i0.10I0.08il10.00i<0.01'0.01i1<0.0'1,1.07'i8.40I!6.80ill~l3.36I4O.8O72.59l0.020.34'.110.27i0.08031i0,120.69l0.635.84i0.000.38,'.86 0.04l0.020,12I0.100.09i0.630.13l0.091.24I<0.01<0,01l<0.01<0.01,<0.01ND').80NDi0.63XD,0.10LOI(@:i'105C850CiNDYiDND<YiDiiIII9.40NDii,'ADND14.90'.10iuDIiiiDYiD11.?0i38.2012.50""SCombustion toSO2SO4Estimatefromtotalsulfurdetermination CO3Yieutralization Page50 1~II ThomasM.Laronge,Inc.TABLE6SUMMARYOFSEM-EDSANALYTICAL RESULTSPage1of2Fig.illumbersEDSMAPSPhotosRHRPumLocationEDSWt.%'Aormal,Atom%iiletIntensitv I923I10!23IIII1EilE-2178-38 Waterside pitbaseIIIIIIlI-2178-~8!Depositinsidewaterside pitIIClMnFeCUI16.42I83.58I6.750.65I0.91I91.69II2d.O4i73.96I11.45I0.710.98i86.8537.15100.4127812.173.05177,99112444i1B-217B-3BtDeposit insidewaterside pitIIIIIIIIIIISMnFeCU6.12II1,43I1.37I91.08I1.4785.59I4.891878011.3916.121.55I5.1524IIIII1E-2178-38!

Waterside pitbaseIIIiIIII13.35)MnFeCu82.67'2.17!II1.SOi23.26I2'71II1.81I72.72'.30.106.034.93133.72131IIIIIlt14.IIIII45IlE-2178-38 IDepositinsidewaterside pitIIIIIIIIIIIIIII1E-2178-38 iWaterside pitbaseIIIIIIISClMnFeCuSClMnFeCli3.57i15.93II1.07IZ91I76.52I0.00I0,24I0,99I'72896.48!6.05I24.47I1.06I2.84!65.58',O.OOI0.43I1.142.58I9585I10,1256.673.409.08144.820.000.893.878.83211.9215I76II46I1E-217CAdjacenttowaterside pitII/IFeCli1.07I1.21I,98.93'98.79,'.75 196.9116I2611E-217CIInsidewaterside pitbaseIIFeCu0.93I99.07I1.05I98.95I2.77167,81Page51 f<Zp ThOmaSM.Lo,rOnge, InC.TABLE6SUMMARYOFSEM-EDSANALYTICAL RESULTSPage2of2Fig.NumbersEDSMAPSPhotosRHRPumEDSWt.%Normal,Atom%NetIntensitv i17IIII18II(I(I20-(1i1r2727I(IIIIiI48I11E228A(1I'1E-228AiIIIII(1E-228B((Il(1E-228BIIllII((Horizontal splitI(Depositinsidewaterside pit(IIII'Horizontal splitI(Waterside pitbaseIiIIII(Vertical splitI,Adjacent towaterside pit(rI(Vertical split,'Insidewaterside pitbaseIIIlClFeCUAlSiSKFeCQClMnFeNiiCUSClMnFeCuI0.11(3.79(96.09(10.2143.485.972.078.2130.050,35(1.475.71((87.77'85(0,25I0.79(15.73t4.88(75.50(429(95.51I1358(55.57(6.68(1.90(5.28i16.98'.61I6.39i5.01I86.32'.34(0.42,0.87(16.93,'.oo,'1.44 i0.36'l285184.9518.40109.6613.558.9123.3655.191.335.897'7<71245196,886.140.70'72543.519.02119.1121I,29('1E-228B iI,Vertical split(Adjacent towaterside pitrIIIrIIIIIClMnFeNiCu8.87',1.01i3.21i6.72',80.19l14.70r1.08'D.DI6.73'4.12i35.503.86121017.48176.60(III,1E-228BII(Vertical split'Insidewaterside pitbasel1FeCu5.35(94.65(I6.o4t93.96(17.22173.17'"Elementmapscoverpitareaforeachspecimen.

Page52 I),+%1~~f TABLE7RESULTSOFDEBYE-SCHERRER X-RAYDIFFRACTION ANALYSISOF.DEPOSITSAMPLESUSINGCOPPERK-ALPHARADIATION DepositSampleFromRHRlE-217B-3B LineNo.10"d"Measured5.373.722.942.682,532.47.272.142.081.74"d""'ables 5.383.732.972.692.532.472.132.101.71.CompoundCuOH2CuOH)2Fe304CuOH)2Fe304Cu20uOH2Cu20Fe304Fe304LineNo.5.405.382.7DepositSampleFromRHRlE-217C"d"Measured"d""'ables CompoundCu(OH)2Fe32.472.141.731.512.472.131.711.51Cu20Cu20Fe304Cu20LineNo.1.461.48DepositSampleFromRHR2E-217B,90DereeBend"d"Measured"d""'ables Fe304Compound2.952.532.432.151.952,952.512.472.131.95Fe304Fe304Cu20Cu20Fe304LineNo.1.491.48"d""'ables "d"MeasuredDepositSampleFromRHR2E-217CFe304Compound105.403.733.002.69.472.131.731.511.290.985.383.732,972.69.472.131.711.511.290,98Cu(OH)2CuOH)2Fe304CuOH2Cu20Fe304Cu20Cu20Cu20"'d"inangstroms Page53 ThomasM.Lo,ronge, inc.TABLE8RESULTSOFMICROBIOLOGICAL ANALYSESSamleTotalCountTveUnitsbvFITCTotalSRBbvIFALiveSRBLiveAPBbyOn-SitebyOn-SiteCultureCulture1E228BRCICroomcooler1E228BRCICroomcooler7Aoilcooler2E217BRHRoilcooler2E217CRHRoilcoolerIWater',Cells/mttlIIIIIIIIIDepositlCells/gm lIIIIIIIDepositJCells/gm

~)I'IIIIIIDepositICells/gm iIIIIIII,IIDepositlCells/gm lI'III3SE+09IIIII3.8E+07l'1.8E+08IIlIIIIII1~9E+07IIII6.1E+06iIIII1.9E+05ItI8.2E+06iIIIIIIIlI<9.8E+04iIIII>1.0E+07iIIII>1.0E+07II>'1.0E+06

'II>'1.0E+04 IIIII>1.0E+04lIII>1.0E+07>1.0E+07>1.0E+05>1.0E+03>1.0E+042E297ADXCondenser I1IIIDeposit',Cells/gm

',4.5E+07'1.2E+06 I>1.0E+05,'>1.0E+04 IIPage54 ThomasM.Laronge,Inc.TABLE9RESULTSOFTHEANALYSISOFESWBXVATERSUPPLYTORCIC1E-2288PUMPROOMUNITCOOLERSamleTakenJune9,1990Parameter pI-ITotalalkal.Conductivity AsMethodIi1ipHIpHI<CaCO3iTitrationi

'umhos,'eter iIIPPM7.7183.0587.00AluminumBariumCalciumCopperIronMagnesium Manganese Potassium SilicaSodiumZinci1iAlII,Ba',CaCO3i1Cui'FeiCaCO3iI,Mn'I1~Si02gT~ZntiICAPICAPICAPiICAPiICAPiICAPiICAPICAPICAPICAPi(0.10(0.10150.000.040.7455.600.755.754.7518.800.28ChlorideFluorideYlitrate]nitrite SulfateCl"FISO4ICICICIC33.300.1510.~~53.60LSIat80FLSIa<<OOFLSIat110F-:0.4+0.6-:0.70Page55 0

TABLEESWANDIilll<PUMI'IIML'S,IIOUI(SPage1of2LoopAIuopl3AssumedAssumedMoutltESW-AESW-C'l'otalFSW-I3l>W-I)Totall<lIi<Pumps1A113IC1D2A213=-2C20Aug46Sep-S6Oct-S6Nov-86'ec-86Jan-S7I'el)47-Mar47Apr-S7May47Jun-87Jul47Aug-87Sep-87Oct-87Nov47Dec47Jan-88I'eb48Mar-88Apr-SSMay-88Jun-88'407448l62213487289355173166190l503525692323377l36)53580264254S4074474311622l14767893461721651901503735552383377136S967416445-lS407.4484311622134872893551731661901503735692383377136596802644548042344760105SS5231320S189106108435553384156416284118257-174436217191'I641012210183415221185086113929574245214961269571423846110110811845358739917852125146398021'1105401003006204447204145l721221003111001091211425099242203017706982181329216102122l3-231304214300124113'05'21022904175005080137415400030'.03370221100032'211136000000144027640245372265210Note:RHRpumpdataforApril,1987includeJanuarythroughApril,1987.Page56

~+a%

TABL"ESWANDRlIRPUMP10IML'S,IIOIJI(SPage2of2I.oop13AssumedAssumedMontbLS'W-AESW-C'I'otalI'.SW-}3le-DTotalICI<Ill<Pumps1D2A'282C2DJul-88Aug-88Sep-88Oct-88Nov-88Dec-88Jan-89Feb-89Mar89Apr89May-89Jun-89Jul-89Aug-89Sep-89Oct89No~-89Dec89Jan-90Feb-90Mar-90Apr-90iVfay-90l08134635847O'Ilool68162506607360907651143210731412871100108133745737,.4010016816250760739942592123212467391511315632108l347458474110016816250760775913213553267855617483465259l27l3256967836334314126137166~D29881l044344051745741315146531001757243114789835040161012743551534352426226811134335471724014425533512112053567952921084367188ll51261329201210155211242387213241781593133l85261727151514137172208901100334315156'125650341120201000001001423101100007540001383105'l91512434729685521080083262178600008426170.1010008lo0009703Page57

ThomasM.Laronge,Inc.TABLE11RHRLUBEOILCOOLERFLOWVELOCITIES RHRPum4Jun-86toAr-87FeetpersecondAr-87toJun-89Jun-89toJun-90ESWLoopAI8.08.01D9.08.0Q22A9.08.07.32D10.5eiESWLoopB~,'B9.69.51C10.8922B10.88.02C12.6""8loopdataforJune1986throughJune1989calculated as20'Pohigherthancorresponding Aloopdata.8loopdataforJune1989throughJune1990areactualmeasurements.

Page58 Pa ThomosM.Lcxronge, Inc.TABLE12COMPARISONS OFOBSERVATIONS ANDPHYSICALMEASUREMENTS Pagelof2CoolersESWLooARHR1E-217ARHR1E-217D2E-217ARHR2E-217DRCIC1E-228Ahoriz.splitRCIC1E-228Avert.splitESWGRDX2E-297APitDensityPits/s.in.Verylow,notmeasured.

Nottested.LWreportedlittletonopitting.Verylow.notmeasured.

5to50Notmeasured.

DeepestPitInchesIIIIIIIIIlNotmeasured)lIINotmeasured)IIIIIII1IINotmeasuredIIIlIlIIII0.015IIIIIIIII0.050IIIIIIIIIIIII0.017IIIIIIIIIIIIIIl.iotmeasuredIIIDep.Wt.Dens.mn/s.ft.NotmeasuredNotmeasured27,~D10.677.13NotmeasuredvisualheavyObservations IIIIl)Uniformthindeposit.'veryslightpitting.)iNottested.LWreported'lightgeneraloxidation IIw/greencoloration.

lIIUniformbrowndeposit,I,nosignificant tubercu-IIlationorpittin~.IIUniformbrowndeposit,Imanysmalltubercles.

',shallow roundpits.IIlUniformthinbrown,'deposit withtubercles,

~hemispherical and,'irregular pits,I,Uniformthinbrown,'deposit withtubercles, Ihemispherical and',irregular pits.II,HeavyscaleRslime.no,'visible pitting.Page59 ThomosM.Lo,ronge, Inc.TABLE12COMPARISONS OFOBSERVATIONS ANDPHYSICALMEASUREMENTS Page'2of2Coolers<<~ESNVLBRHR1E-2178)<<<<IIRHR-1E-217C RHR2E-2178-2 iRHR2E-2178-5 IRHR2E-217CRCIC1E-2288horiz.split'E-2288splitPitDensityPits/s.in.5to5025to3004to50lto2002to50.017',7.72,0.036/.77DeepestPitDep.WVt.Dens.

Inches'm/s.ft.II<<<<0.025)31.73<<I<<I<<<<<<0.013)24.07<<II<<0.0~><<13.21<<j<<I<<<<0.007'.86I<<0.028<<37.90Observations

<<<<I<<<<Smoothbrown/black and,'flakygreendeposits,

<<largetubercles and,hemisperical pits.<<1<<Heavybrown/black deposit,largetubercles

<<andhemispherical pits.<<'Scattered black/green

<<,deposit, nosignificant

'tubercles.

hemispherical

<<pits.<<<<<<Scattered black/careen

,deposit.nosignificant

'tubercles.

hemispherical "pits.!'Failedtube.Heawscaly,deposit.

manyjagged8r.,'hemispherical pits.<<,Uniformthinbrowndepositwithtuhercles.

Ihemispherical and'irregular pits.;Uniformthinbrowndepositwithtubercles.

I-hemispherical and'irregular pits.

i'I>lt Thomo,sM.Laronge,lnl-.LITFFIREFIGURE1FIGURE2FIGURE3FIGURE4FIGURE5FIGURE6FIGURE7AFIGURE7BFIGURE8AFIGURE8B'IGURE9FIGURE10FIGURE11FIGURE12FIGURE13FIGURE14FIGURE15FIGURE16FIGURE17SKETCHOFVERTICAL, HIGHTHRUSTINDUCTION MOTORGEH-3298COMPARISON OFDEPOSITCOMPOSITIONS OFF-SITEMICROBIOLOGICAL ANALYSESESWALKALINITY, CALCIUM8tCONDUCTIVITY'SW TURBIDITY ANDpHESWLANGELIER INDEXDATAPERCENTESWANDRHRPUMPRUNTIMES-ESW LOOPAPERCENTESWANDRHRPUMPRUNTIMES-ESW LOOPBRHRLUBEOILCOOLERFLOWVELOCITIES-ESW LOOPARHRLUBEOILCOOLERFLOWVELOCITIES-ESW LOOPBENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHR1E-217B-3B DEPOSITINSIDEWATERSIDE PITENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHRlE-217B-3B WATERSIDE PITBASEENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHRlE-217B-3B DEPOSITINSIDEWATERSIDE PITENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHR1E-217B-3B WATERSIDE PITBASEENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHR1E-217B-3B DEPOSITINSIDEWATERSIDE PIT'NERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHRlE-217B-3B WATERSIDE PITBASEENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHR1E-217CADJACENTTOWATERSIDE PITENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHRlE-217C'NSIDEWATERSIDE PITBASEENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228AHORIZONTAL SPLITDEPOSITINSIDEWATERSIDE PITPage61

ThomasM.Larongt,Inc.FIGURE18FIGURE19FIGURE20FIGURE21FIGURE22FIGURE23FIGURE24FIGURE25FIGURE26FIGURE27FIGURE28FIGURE29ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIC1E-228AHORIZONTAL SPLITWATERSIDE PITBASEENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228BVERTICALSPLITADJACENTTOWATERSIDE PITENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228VERTICALSPLITINSIDEWATERSIDE PITBASEENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228BVERTICALSPLITADJACENTTOWATERSIDE PITENERGYDISPERSIVE X-HAYSPECTROSCOPY OFRCIClE-228BVERTICALSPLITINSIDEWATERSIDE PITBASEELEMENTMAPS,RHR1E-217B-3B ELEMENTMAPS,RHRlE-217B-3B ELEMENTMAPS,RHR1E-217B-3B ELEMENTMAPS,RHRlE-217CELEMENTMAPS,RCIClE-228A,HORIZONTAL SPLITELEMEKI'APS, RCIC1E-228B,VERTICALSPLIT,TOPSECTIONELEMENTMAPS,RCIClE-228B,VERTICALSPLIT,BOTTOMSECTIONPage62 ThomasM.Laronge,Inc.Figure1SketchofVertical, HighThrustInduction MotorGEH-3298TopCapDCB.A1CEXEXED2CDXXED3tXXXXED4Q3XXED5CEXE3XD6CE3XXEOMotorShaftNutsandLockwashers JournalSleeveandThrustBearingOilLevelCoolingWaterOutletCoolingWaterInletSixrowswithfoureach,co-planarcoolingcoilsStatorFramePage63 t$iI~4 FIGURE2COMPARISON OFDEPOSITCOMPOSITIONS 03000(QCPAz0K400)I-QKeec;0-1A1C1BRHRLUBEOILCOOLERS2C[IIIFegQMn~ca~sJPage64 14'~

FIGURE3OFF-SITEMICROBIOLOGICAL ANALYSESIE+09-1E+08=~1E+07-GKUJ0V)1E+06=UJ1E+05=v3>cgpXjw./)a~1E+04-1E217A2E217C1E228BHEATEXCHANGER DEPOSlTS2E297AQQTOTALBACTERIAIISULFATEREDUCERSPage65 I

800FlGUR4ESWALKALINITY, CALCIUM8CONDUCTIVITY 8000OOEOOZ700600500400300200100CalciumConductivity Alkalinity 700600.500400300200100OOJELl-OClz0Q198919900r-a--i---,-rarTat-7at-w~t-rww.rvwr002/0604/1105/2607/1108/0909/0611/0301/0303/0805/1506/0206/11MONTHLYDATA,1989TOPRESENTPage66

,r 1098765.432.1.FIGURESN/TURBIDITY ANDpHpHTurbidity 090031989I9900'1ttrT'f1il7TlII7TIII1TII02/0604/1105/2607/1108/0909/0611/0301/0303/0805/1506/0206/1IMONTHLYDATA,1989TOPRESENTPage67 FIGU6ESWLANGELIER INDEXDATATEMPERATURE 100-804>CLLIC3z3.CCLLl(g2LSI60LUa40CL"I--20LLICL-0LLI0-20-1TII02/0604/1105/2607/1108/0909/0611/0301/0303/0805/1506/0206/11MONTHYDATA,1989TOPRESENT19891990rvtgqrT's;rrwawrT'sa-40Page68 17'4~I4'Itf0'I~l~~1II ThomosM.Laronge,Inc.60FIGURE7APERCENTESWANDRHRPUMPRUNTIMESESWLOOPA50I=4oZ30O20100.198719881989YEAR1990,'m'ESW-AggRHR-1A1RHR-1DRHR-2A~RHR-2DI60UJ50I-4030z.'OCCLLI100FIGURE7BPERCENTESWANDRHRPUMPRUNTIMESESWLOOPB19871988YEAR19891990'ESW-BggRHR-1BmRHR-1CII~FQRHR-2B~RHR-2CPage69 e)Ii'n~gh'IC4~E%

,ThomasM.Laronge,Inl-.Oz00t4121086420FIGUREBARHRLUBEOILCOOLERFLOWVELOCITIES ESWLOOPAJun-86toApr-87Apr-87toJun-89Jun.89toJun-90TIMEINTERVALS, 1986-1990 eimRHR-1AggRHR-1DmRHR-2AggRHR-2DbO000t4t21086420FIGUREBBRHRLUBEOILCOOLERFLOWVELOCITIES ESWLOOPBJun.86toApr-87Apr-87toJun-89Jun.89toJun-90TIMEINTERVALS, 1986-1990 ImRHR-1B+RHR-1CmRHR-2BggRHR-2CPage70 Jfl4P0 ThomasM.Laronge,Inc.FIGURE9ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHR1E-2178-3B DEPOSITINSIDEWATERSIDE PITIq4~>~0'~'i~aJ~Il~lCALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementClWeightPercent16.4283.58Normalized AtomicPercent26.0473.96NetIntensit37.15100.41Page71 ThomosM.Laronge,Inc.FIGURE10ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHRlE-217B-3B WATERSIDE PITBASE'cCXCALCULATED.

RESULTSFROMSTANDARDLESS ANALYSISElementClMnWeightPercent6.750.650.9191.69Normalized AtomicPercent11.450.710.9886-.85NetIntensit22.812.173.05177.99Page72 ThomasM.Lo,range, Inc.FIGURE11ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHRlE-217B-3B DEPOSITINSIDEWATERSIDE PITCALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementSMnFeWeightPercent6.121.431.3791.08Normalized AtomicPercent11.391.551.4785.59NetIntensit16.125.154.89187.80Page73 QCW' ThomasM.Laronge,Inc.FIGURE12ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHRlE-217B-3B WATERSIDE PITBASE~/PAJQJ+a r~CALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementSMnFeWeightPercent13;352.171.8082.67Normalized AtomicPercent23.262.211.8172.72NetIntensit30.106.034.93133.72Page74 4~tflI~I'f'P Thomo,sM.Lo,ronge, Inc.FIGURE13ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHR1E-217B-3B DEPOSITINSIDEWATERSIDE PITj+l(lpVl~~Q)0/'ALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementSClMnFeWeightPercent3.5715.931.072.9176.52Normalized AtomicPercent6.0524.471.062.8465,58NetIntensit10.1256.673.409.08144.82Page75 l

ThomosM.Laronge,Inc.FIGURE14ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHR1E-217B-3B WATERSIDE PITBASEYCAYMYCOV~CALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementSClMnFeWeightPercent0.000.240.992.2896.48Normalized AtomicPercent0.000.431.142.5895.85NetIntensit0.000.893.878.83211,.92Page76

)h0 Thomo,sM.Laronge,Inc.FIGURE15ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRHRlE-217CADJACENTTOWATERSIDE PITCALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementFeWeightPercent1.0798.93Normalized AtomicPercent1.2198.79NetIntensit3.75196.91Page77 ThomasM.Laronge,Inc.FIGURE16ENERGYDISPERSIVE X-HAYSPECTROSCOPY OFRHRlE-217CINSIDEWATERSIDE PITBASE)~fVthlpshC,~h'l~~>'qg>vy j(f<tvsYhg~~UOJOlUY/h'~<0~4 LP~'A,~g4pg~

~CALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementFeWeightPercent0.9399.07Normalized AtomicPercent1.0598.95NetIntensit2.77167'.81Page78 Thomo,sM.Lo,ronge, Inc.FIGURE17ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIC1E-228AHORIZONTAL SPLITDEPOSITINSIDEWATERSIDE PIT'lehCCAChhCCa1'ChCIJm4lLJUOJU*CALCULATED RESULTSFROMSTANDABDLESS ANALYSISElementClFeWeightPercent0.113.7996.09Normalized AtomicPercent0.204.2995.51NetIntensit0.3612.85184.95Page79 J'

ThomasM.Laronge,Inc.FIGURE18ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228AHORIZONTAL SPLITWATERSIDE PITBASE'leVA4tVU4hVQ~+~CALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementSiSFeWeightPercent10.2143.485.972.078.2130.05Normalized AtomicPercent13.5855.576.681.905.2816.98NetIntensit18.40109.6613.558.9123.365519"=Page80

~~3n=~~~,y'\l~'IVl+P Thomo,sM.Lo,range, Inc.FIGURE19ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228BVERTICALSPLITADJACENTTOWATERSIDE PITV5VUCCACOLJC5C~~~~~J('~YM//~)'ilpga(gC'~Pi.y~'~~,vgpssE5X4IUl~s,Žig<eCALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementCIMnFeNiWeightPercent0.351.475,714.7087.77Normalized AtomicPercent0.611.676.395.0186.32NetIntensit1.335.8922.5712.45196.88Page81 tl~Vl Thomo,sM.Larongt,inc.FIGURE20ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228BVERTICALSPLITINSIDEWATERSIDE PITBASEVbCEIUCALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementSClMnFeNiCuWeightPercent2.850.250.7915.734.8875.50Normalized AtomicPercent5.340.420.8716.935.0071.44NetIntensit6.140.702.2543.519.02119.11Page82 ThomosM.Loronge,inc.FIGURE21ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228BVERTICALSPLITADJACENTTOWATERSIDE PITbCCVCApA~>>iyi=>ii+(<i)J, hChC4t4(~<i,rgCALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementClMnFeNiWeightPercent8.871.013.216.7280.19Normalized AtomicPercent14.701.083.376.7374.12NetIntensit35.503.8612.1017.48176.600Page83 Thomo,shh.Lo,ronge, Inc.FIGURE22ENERGYDISPERSIVE X-RAYSPECTROSCOPY OFRCIClE-228BVERTICALSPLITINSIDEWATERSIDE PITBASEDVViCALCULATED RESULTSFROMSTANDARDLESS ANALYSISElementFeWeightPercent5.3594.65Normalized AtomicPercent6.0493.96NetIntensit17.22173.17Page84 I~'FIGURE23ELEMENTMAPS,RHR1E-2178-38 I.EGENDSMnPage85CIFe J~~I~gggmgg~i(g~igggg I;pygmygj"ggpj+igg%IHN~I~gg)gpg~i+iGQNcjmggjjggggigJJggI%I%IIGURE24~EI.EMENTMAPS,,RHR 1E-2178-38 I.EGENDSPage86CIle

I~IGURE25ELEMENTMAPS,RHRlE-2178-38 LEGENDSMnPage87C1Fe

FIGURE26ELEMENTMAPS,RHR1E-217CLEGENDSMn,Page88C1Ie

FIGURF27ELEMENTMAPS,RCIC.1E-228A; HORIZONTAI SPLITLEGEND.SMnPage89C1Fe.

FIGURE28EI.EMENTMAPS,RCIClE-2288,VERTICAISPLIT,TOPSECTIONLF.GENDSMn.CIFePage90 0

~S'liiiiQSSRR,fan%

F498Riiiii55iRR f..&lkNQ,~~yplQRi55RRSRQ l%%biiQRMWf:~MFIGURE29EI.FMENTMAPS,RCIClE-228B,VERTICAISPLIT,BOTTOMSECTION.LEGENDCIMn.Page91Ie ThornM.j.aronge, Inc.Photograph Desination10121314'5Approximate Magnification AsPrinted,Diameters 0.30.30.40.40.40.40.60.30.30.30.30.30.31.91.9LISI'FPHOTOGRAPHS SecimenDesinationandDescritionofPhotoahsRCIClE-228A,As-Received.

RHR2E-217C,As-Received.

RHR1B-3B(lE-217B-3B),

As-Received.

"3B"Signifies theThirdRingFromtheTopandtheSecondRowinFromtheInsideDiameter.

RHR2E-217D,As-Received.

RHR2E-217D,As-Received.

RHR2E-217A,As-Received.

RHRlE-217C,As-Received.

RHR2E-217B,As-Received.

RHR2E-217B,As-Received.

RHR2E-217B,As-Received.

RCIC1E-228B,As-Received.

RHR2E-217B,As-Received.

RHR-lE-217A,As-Received.

RCIClE-228A,InteriorViewofSectionofVerticalSlitTube.RCIClE-228A,InteriorViewofSectionofVertical.

SplitTube,asSeeninPhotorahNo.14,AfterSandBlastin.Page92 ThomasM.Laronge,Inc.LISTOFPHOTOGRAPHS (Continued)

Photograph Desination161718192021.2223242526272829Approximate MagniAcationAsPrinted,Diameters 4.72.32.32.42.02.01.02.42.44.32.12.3SecimenDesinationandDescritionofPhotorahsRCIClE-228A,CloseUpViewofInteriorSectionofVerticalSplitTube,asSeeninPhotorahNo.15,AfterSandBlastin.RHR2E-217C,CloseUViewofInteriorSurfaces.

RHR2E-217C,CloseUViewofInteriorSurfaces.

RHR2E-217C,CloseUpViewofTypicalInteriorSurfaces, AfterSandBlastin.RHR1E-217B-3B, ViewofInteriorSurfaces, AfterSectionin

.RHRlE-217B-3B, CloseUpViewofInteriorSurfaces,-as SeeninPhotorahNo.20,AfterSectionin Note:DamaedWallisEvident.RHRlE-217B-3B, ViewofInteriorSurfacesofaSmallSectionofPie,AfterSectionin

.RHR1E-271B-3B, ViewofInteriorSurfacesofaSmallSectionofPie,asSeeninPhotorahNo.22,AfterSandBlastin.RHR2E-217D,ViewofInteriorSurfaces, AfterSectionin

.RHR2E-217D,CloseUpViewofInteriorSurfaces, asSeeninPhotorahNo.24,AfterSectionin

.RHR2E-217D,ViewofInteriorSurfacesofaSmallSectionofPipe,AfterSectionin

.RHR2E-217D,CloseUpViewofTypicalInteriorSurfacesofSecimen2D,AfterSandBlastin.RHRlE-217C,ViewofInteriorSurfacesofaSmallSectionofPie.RHRlE-217C,ViewofInteriorSurfacesofaSectionofPie.Page93

~'

ThomasM.Loronge,Inc.LISI'FPHOTOGRAPHS (Continued)

Photograph Desination30333436;374041Approximate Magnification AsPrinted,Diameters 1.63.81.61.64.71.21.61.21.61.611.012.5SecimenDesinationandDescritionofPhotoahsRHR1E-217C,ViewofInteriorSurfacesofaSectionofPipe,AfterSandBlastin.RHRlE-271C,CloseUpViewofTypicalInteriorSurfacesof1C,AfterSandBlastin.RHR2E-217B,ViewofInteriorSurfacesofaSmallSection.RHR2E-217B,ViewofInteriorSurfaces, asPicturedinPhotograph No.32,AfterSandBlastin.RHR2E-217B,CloseUpViewofInteriorSurfaces, asPicturedinPhotoahNo.33,AfterSandBlastin.RHR2E-217B,ViewofInteriorSurfacesofTwo90DegreeBends,AfterSectionin

.RHR2E-217B,ViewofInteriorSurfacesofOne90DegreeBend,asSeenintheToofPhotorahNo.35,AfterSandBlastin.RHR1E-217A,ViewofInteriorSurfacesofTwo90DegreeBends,AfterSectionin

.RHRlE-217A,ViewofInteriorSurfacesofOne90DegreeBend,asSeenintheBottomofPhotorahNo.37.RHRlE-217A,ViewofInteriorSurfacesofOne90DegreeBend,asSeeninPhotorahNo.38,AfterSandBlastin.RCIClE-228A,ViewofIrregular CraterBeforeRemovalofOverlying Material.

Overlying MaterialwasRemovedtoPreparethePitforBioloicalExamination.

RCIClE-228A,ViewofIrregular Crater,asSeeninPhotograph No.40,AfterRemovalofOverlying Material.

ThisPitwasBiologically ExaminedtoDetermine theExtentofBacterial Contamination.

Page94

Thomo,sM.Lo,ronge, Inc.LISTOFPHOTOGRAPHS (Continued)

Photograph Desiation424445464748Approximate Magnification AsPrinted,Diameters 151515151535015015SecimenDesinationandDescritionofPhotorahsRHR1E-217B-3B, SEMPhotograph ofTypicalPit.ElementMappingandEDSWerePerformed onthisPit.RCIClE-228A,Horizontally SplitSection,SEMViewofTypicalPitasSeenontheInteriorSurfacesof1E-228A.ElementMappingandEDSWerePerformed onthisPit.RHRlE-217B-3B, SEMPhotograph ofTypicalPit.ElementMappingandEDSWerePerformed onthisPit.RHRlE-217B-3B, SEMPhotograph ofTypicalPit.ElementMappingandEDSWerePerformed onthisPit.RHRlE-217C,SEMPhotograph ofPitContaining Crystalline Deosits.ElementMainandEDSwerePerformed onthisPit.RHRlE-217C,CloseUpSEMPhotograph ofCrystalline

Deposits, asSeeninPhotoahNo.46.RCIClE-228B,TopHalfofVertically SplitTube,SEMViewofSmallPit.ElementMainandEDSWerePerformed onthisPit.RCIClE-228B,BottomHalfofVertically SplitTube,SEMViewofPit.ElementMainandEDSWerePerformed onthisPit.Page95 ThomasM.Laronge,inc.POSTOFFICEBOX338~CALIFON.NEWJERSEY07830~i201]832-5097~FAXt201)832-9775ARTHURJ.FREEDMAN, Ph.D.Executive VicePresident June12,1990Mr.RaymondS.TombaughProspectEngineerPennsylvania PowerandLightCompanyTwoNorthNinthStreetAllentown, PA18101Sub)ect:Preliminary ReportofSomeSusquehanna ESWCoolerInspections

DearMr.Tombaugh:

hisletterconstitutes ourpreliminary reportofourstudyofpittingorrosionintheSusquehanna ESWsystemcoolers.Briefly,wehavedetermined thattherootcauseofthepittingisconventional under-deposit corrosion aggravated bythepresenceofhighlevelsofmanganese inthedepositsnearthecorrosion sites.Microbiologically-influenced corrosion (MIC)isacontributing factorthatmayhaveaggravated theattackinsomecoolers,butMICisnottherootcausaoftheproblem.Detailsfollow.WearrivedatthePP&LAllentown officeatabout11:30AMonFriday,June8,1990.Afterdiscussions withLouWillertzandRayTombaugh, wewenttotheSusquehanna plantforrequiredtraining.

LateFridaynight,weinspected the2E-217CRHRoilcoolercoil.Overthenexttwodays(Saturday andSunday),weinspected thefollowing equipment:

1.1E-217A2.2E-217B3.OE-507D4.OE-533D5.OE-505E1,2D 6.1E-228B7.1E-228A8.2E-297ARHROilCoolerCoilRHROilCoolerCoilDieselGenerator JacketWaterCoolerDieselGovernorCoolerDieselGenerator Intercooler RCICPumpRoomUnitCoolerRCICPumpRoomUnitCoolerESWGRDXSystemCondenser llowingisasummaryofourdataandtheconclusions wehavedrawnfromourrktodate.QualityforIndustry III ThomasM.LaroncIe, Inc.InsectionMethod0doingourwork,weusedthefollowing methods:Visualinspection oftubesanddepositsaswesawtheminplaceorastheyweiepresented tousattheplant.oVideoprobe inspections oftubesinplace.oVisualinspection witha15Xmagnifying lensoftheinteriorsurfaces, ofcoolingcoilsandtubesthathadbeensplitlongitudinally.

oMicroscopic examination ofselectedcoolercoilsinthePP&LHazletonLaboratory.

0Microbiological culturesofdepositsfromcoolingcoils,usingmediaspecificforsulfate-reducing andacid-producing bacteria(SRBandAPB).On-siteInsectionResults2E-217CRHROilCoolerCoilThisandtheotherRHRoilcoolingcoilaretypeKcopper.The2E-217Ccoolerhadbeenremovedfromthesystemforseveraldaysbeforeourinspection, andthespecimens wesawweredry.Theinnersurfaceswerecoveredwithaheavy,densescale.Areasofthisscalewerecoloredgreen,white,andbrown,indicating different metalliccomponents inthescale.Wecarefully cleanedthedepositfromsectionsofthiscoilandexaminedthemetalwitha15Xhandlens.Wefoundnumerousrandompitsovermostofthesurface.Thesepitsvariedgreatlyinsi.ze,depth,andshape.Mostwereirregular inshape,smallandshallow,butsomeweresharp-edged andquitedeep.Wetooksamplesofthedepositfrompittedareasofthiscoilandranbiological culturesforSRBandAPBasexplained above.Theseculturesshowednoresponsein24hours.After48hours,sufficient growthhadoccurredtoindicatethatlowtomoderatelevelsofthesebacteri.a werepresentinthiscoil.2.1E-217ARHROilCoolerCoilThe2E-217CRHRoilcoolercoilcarriesESWwaterfromtheB'loop.Toobtainacomparison withtheAloop,weinspected the1E-217Acoil,usingthesamemethodsdescribed above.Weinspected sectionscutfromthesecondcoillayerfromthetopandthesecondlayerfromthebottom.Thenatureofthedepositinthe1E-217Acoilwasentirelydifferent fromthe2E-217Ccoil.Wefoundnoneofthehard"scale"depositsdescribed in2E-217C.Instead,wefoundaloose,flowableblackdeposit,andbelowthat(nexttothemetal)ahard,firmly-attached blacklayer.SEM/EDAXanalysisofthisdepositatHazletonidentified thisblackdepositasprimarily manganese salts.Page2

4gIIA, ThomasM.Laronge,Inc.,.Wefoundpitsbeneaththeblackdeposit.Allwereverysmall,irregular inshape,andrandomlydistributed.

Nopitswereasdeepasthosefoundin2E-217C.2E-217BRHROilCoolerCoilToprovideasecondinspection ofoilcoolersontheBESWloop,weinspected the2E-217Bcoil.Thiscoilwasfoundtobeintermediate incondition betweenthe1E-217Aand2E-217Ccoils.Nohardscalewaspresent.Wefoundsubstantial blackdepositsthatwerelateridentified bySEM/EDAXasprimarily manganese compounds.

Theblackdepositwasstringyandcoveredpartbutnotallofthesurface.Underthedepositinthiscoilwefoundpittingthatwasmoreprevalent anddeeperthanin1E-217Abutnotasseriousasin2E-217C.Microbiological culturesofthedepositscoveringthesepitsshowedlessactivitythaneitheroftheothertwoRHRoilcoolers.4,OE-507DDieselGenerator JacketWaterCoolerThetubesinthiscoolerarereportedtobe90/10cupronickel.

ETinspection ofthisexchanger hadidentified atleastonetubewithmorethan60Xwallpenetration.

Weidentified thistube-fromthe"map"intheETinspection reportandwereabletovisuallyinspecttheentireinsidesurfaceusingthenewly-acquired fiberscope equipment.

Wewereableto.seemanypittedareasinthistube.Wecouldnotmeasurepitdepth,butsomeappearedtobeverydeep.Asinothercoolers,thepitswererandomlydistributed andirregular inshape.'hesetubeshadbeencleaned,andwewerenotabletocollectsufficient depositformicrobiological analysis.

Tubesshouldbepulledfromthisheatexchanger formoredetailedinspection.

5.OE-533DDieselGovernorCoolerWeexaminedthisverysmallsingletubecoolerbutwerenotabletomakeadetailedinspection.

Thetubehadbeencleanedandnodepositswereavailable.

Wecouldseewhatappearedtobeminorpittinginsidethetube,butnootherobservations werepossible.

6.OE-505E1,2D DieselGenerator Intercooler Inspection ofthiscoolerwasdifficult.

Thetubesweretoosmalltopermitentranceofthefiberscope.

Thetubeends(internal) werecleanandappearedtoshowmanysmallpits.Nofirmconclusion canbedrawn;atubeshouldbepulledfromthisexchanger forinspection whenpossible.

7.1E-228BRCICPumRoomUnitCoolerThiscoolerhadbeenopen'forseveraldaysbeforeourinspection.

Thetubesarecupronickel.

Thetubeshadbeencleaned,butwefoundonetubethatcontained substantial amountsoflooseblackdeposit.Wecouldnotusethefiberscope effectively becauseitfitonlyashortdistanceintothetube.Page3 ThomasM.LaroncIe, Inc.The"depositfromthisdirtytubeshowedthehighestmicrobiological activityofanysampletested.'hissamplewasonetotwoordersofmagnitude moreactivethananyoftheRHRlubeoilcoolers.Weunderstand t'hatthisunitisontheBESWloop.Onetubefromtheoutsidelayerwascutoutforinspection.

Byvisual(15X)examination, thistubewasfoundtocontainnumerousunder-deposit pitsofvaryingdepthandrandomshape.8.ESWBSulWaterLineto1E-228BBydisconnecting theflexiblehosebetweenthe1E-228BRCICPumpRoomUnitCoolerandtheESWBsupplywaterline,wewereabletoinspecttheinteriorofthesupplywaterline.Usingthefiberscope, wewereabletoseeapproximately 18inchesintothislineincluding one90-degree elbow.Thismildsteellinewasheavilycorrodedandcoveredwithauniformlayerofscale.Thisscalewasdarkbrownincolorandvariedbetween1/16"andabout3/16"inthickness.

Nooutstanding tubercles.

werevisible.Thescaleprobablyismostlyironoxides.Weremovedsmallpiecesofscalefromthepipeopening.Theunderlying metalseemedtoberelatively smooth.Noseriouspittingwasseen.However,viewingwasverydifficult, andthisshouldnotbeconsidered acompletestatement of.thecondition ofthispipe.Thispipe,aswesawit,wastypicalofmildsteelpipeexposedtocorrosive waterwithnochemicaltreatment formanyyears.Theheavylayersofcorrosion-produced scaleareprobablyatthispointproviding someprotection againstfurthergeneralcorrosion ofthepipe.However,anyunder-deposit corrosion goingonunderneath thesescalewillbeverydifficult tocontrolwithoutcleaningthepipe.Weranmicrobiological culturesonamixtureofdepositandwaterfromthispipe.Theculturesresponded inlessthan12hours,indicating veryhighlevelsofSRBandAPBatthispoint.Thegrowthratewassimilartotha'tfoundinthesamplefrom1E-228B.Thiswastheonlypieceofmildsteelpipingorequipment thatweinspected duringthisvisit.Webelieve,however,thatthecondition ofthispipeissimilartothatofmostoftheESWpipingexposedtosimilarflowconditions.

9.1E-228ARCICPumRoomUnitCoolerThisunitwasopenedforinspection inourpresence, sothatwewereabletoexaminethedepositimmediately uponexposuretoair.Thisisimportant becauseanaerobic

bacteria, typically theSRBandAPBofconcernatSusquehanna, tendtoformspores(becomeinactive) inthepresenceofoxygen.This'nitwascleanerthan1E-228Bandcontained brownratherthanblackdeposits.

Mostofthedepositsseemedtobeintheformofloose,well-flocculated solidswithclearwater.1E-228B,bycontrast, contained muddywaterandslimy,blackdeposits.

Page4 ThornosM.Laronge,Inc.contained lessdepositandfarfewerlE-228B.Weunderstand that1E-228A10.2E-297AESWGRDXSstemCondenser Wecouldnotseemorethanafewinchesintothetubesasinstalled.

Onetubewascutfromthe"outside rowforourexamination.

Thistubepitsthanthecorresponding tubefromreceivesESWwaterfromtheAloop.Thisexchanger wasopenedgustbeforeourinspection.

Weunderstand thatthiswasthefirstinspection ofthisunit.Roughly75Xofthetubesheetwascoveredwithathickdepositconsisting ofvariouscolored"scaledeposits" plusloose,slimyblackmaterial.

Mostofthetubeswerepartially orcompletely blockedwiththismaterial.

Thesedepositsmustrestrictflowthroughthiscooler.Thefiberscope wouldnotfitmorethanafewinchesintothetubes.Also,thevoluminous depositmadeviewingthemetalsurfaceimpossible.

Wetookamixedsampleofthedepositformicrobiological cultureanalysis.

Afteroneday,thissampleshowedonlylowlevelactivity.

The2E-297Acoolerwasclosed,withnocleaning, immediately afterourinspection.

Werecommend thatthisequipment becleanedandthoroughly inspected assoonaspossible.

Laborator Examination Heatexchanger tubingremovedfromfiveESWcoolerswasexaminedintheazletonLaboratory ofPP&L.Thisexamination consisted ofvisualexamination thandwithoutamagnifying loupe,visualexamination usinga0.7Xto4.5Xnitronstereomicroscope andSEM/EDSexamination usinganAmray1830SEMfittedwithaPrinceton GammaTechnical EDSAnalyzer.

ThelatterwasoperatedbyMr.T.J.PensockandMr.L.E.Willertz.

.Thesectionsofheatexchanger tubingexaminedwerefromthefollowing exchangers:

~ExchacacVlacalStereomicrosco eSEM/EDS1E-217A2E-217B2E-217C1E-228A1E-228BXXXXXXXXXXXXXInallcasestheRHRpumplubeoilcoolersexaminedwereremovedfromthefifth"pancake" orhorizontal bankoffourloopsnumbering fromthebottom.Fourelbowseachfromunits2B(fabricated) andfrom2C(cast),respectively, werealsovisuallyexamined.

Alltubesweresectioned inahorizontal planesothat"top"and"bottom"couldbedistinguished.

Additionally, asectionoftubingfrom2E-217Bwassectioned top-to-bottom sothatthehorizontal sidescouldbeexaminedintact.TheRCICPumpRoomCoolertubesexaminedwerefromanouterlocationi'nthetubebundles.Thetubesweresplitwithoutnotingthespecificdirection ofstallation.

Page5 tlil~>>

ThomasM.Loronc3e, Inc.Visualinspection clearlyshowedforeignmat'ter,i.e.,scaleanddepositsonalltubewaterside surfaces.

Eachofthetubeshadnearlythesameappearance onthewaterside exceptforthosefrom2E-217C.helattertubewasessentially coveredwithamottledmixtureofgreen,white,andbrowndeposits, rangingfromafewthousandths ofan,inchtobetterthan0.125inchinthickness.

Thematerialappearedtohavebeenlaiddowninlayers.Thissuggestsformation inaseriesofdiscontinuances, discreteeventssuchason-offoperating periods,significant waterchemistry changesfromscalingtonon-scaling, andsoon.Thee..posedsurfacewasdryingoutandevidenced crackingatintervals of0.125inchto0.375inch.Thisresultedinarectangular tosquarepatterned peelingappearance.

Allotherexchanger tubeswerecoveredtovaryingdegreeswithapredominantly browntoblack,"oily"appearing film.Thefilmwasmattedwithsmalltolargepatchesoforange-brown togreen-brown materialwhichhadadullsurfacefinish.Thedeposit/scale laidinadistinctpatternonallexaminedtubes.Specifically, intheRHRpumpslubeoilcoolertubestherewasmoredeposit/scale attheinsidediameterthanattheoutsidediameter.

Additionally, therewasmorematerialatthebottomofthetubesthanatthetopofthetubes.Uponcuttingthesetubes,moredeposit/scale spalledfromtheinsidediametersurfacethanfromtheoutsidediametersurface.Wherethedeposit/scale spalled,ablotchyappearance resultedshowingmetalsurfaceatomepoints.Mostoftheblotchestendedtorangeincolorfromacopperolortoanorange-brown color.Pitswerefoundinalltubespecimens examined.

Mostofthepitswereround,althoughsomeelongated pitsinthedirection offlowwereseen.Nohemispherical pitswithinpitswereseen.Whereasinglepitappearedtobethecomposite oftwoormoreindividual pits,thisappearedtoresultfromhorizontal growingtogetheratthecorrosion boundaries.

Inotherwords,themorphology ofsmallhemispherical pitswithinpitsthatisoftenascribedtothemorphology resulting whenMICoccurswasnotfound.Also,noodorcouldbedetectedonfreshlycutsurfaces.

Notunneling ormajorundercutting wasnoticed.Almostallpitswerecoveredwithdeposit/scale materialintheshapeofatubercleexceptforthepitsof2E-217C.Thelattersimplyhadpitsbeneaththerelatively thickdeposit.Severalspecimens from1E-217A,2E-2178,and2E-217CweremountedforSEMexamination.

Someofthesespecimens werevaporcoatedwithcarbontoreducethetendencyforsurfacechargingintheSEM.TheexactdetailsshouldbeobtainedfromMessrs.Pensockand/orWillertzastheydidthework.Wesimplywitnessed asignificant portion,ofthisonSunday,June10,1990.Whilethesampleswereinthescanningelectronmicroscope, EDSwasusedonmanyareastoobtainsemiquantitative identification ofmaterials presentatexaminedsurfaces.

Basically, theelectronbombardment ofthesurfacesesultsinthegeneration ofx-rayswhoseenergiesareassociated withecificelements.

Theseenergieswerescannedfromabout0toabout10,000ectronvoltsandthequantityofx-raysversustheirrespective energiesPage6 ThomasM.Laronge,In(:.hwereplottedusingcomputergraphics.

Theresulting plotorspectrumgivesanearexactideaofwhichmaterials arepresentandaqualitative tosemi-qualitative ideaofhowmuchofeachmaterialispresent.Alldeposit/scale samplesexaminedhad,atleast,thesamebasicfourelements, namely:1)2)3)4)Copper.Manganese.

Iron.Calcium.Itisbelievedthatthemanganese camefromeitheroftwosources.ThesearetheinfluentESWwaterandcorrosion productsofcarbonsteelorothermanganese-containing materials.

Itisbelievedthattheironcamefromthesametwosourceslistedformanganese.

However,someoftheironfoundcouldhavebeentheresultofiron'II)oxidation by"ironbacteria" toiron(III).ItisbelievedthatthecalciumallcamefromtheESWinfluentwater.Thiscalciumdeposited astherespective solubility productsofcalciumwithcertainanionswereexceeded.

Thesesolubilities arefunctionally dependent upontime,temperature,

pressure, andtheamountandtypeofothermaterials present.Sufficeittosay,thecopperwasdetectedbecauseofthepresenceofcopperinthetubes.Othersourcesofcoppercouldnotbeexpectedtoyielddetectable amountsinthepresenceofcopper-containing materials.

EDSanalysisshowedthepresenceofmanyotherelements.

Bothchlorineandsulfurwerefoundwithinpits.Generally, thesematerials werefoundtogether.

Therewasonepitexaminedinwhichsulfurwasdetectedandchlorinewasnotdetected, butoverall,wheretheseelementswerefound,chlorinelevelswerehighandsulfurlevelswerelow,relativetoeachother.Bothchlorineandsulfur-containing compounds aretypically implicated inmanypittingcorrosion processes ofcopperandcopper-bearing alloys.Themajordifference inimplication isthatchlorineisinvolvedingenericunder-deposit pittingandsulfuristypically involvedinMICpitting.Mic'robiolo icall-Influenced

'Corrosion (MIC)MICreferstoaspecialized formofunder-deposit corrosion inwhichthemetabolic productsofbacteriaplayasignificant roleinthecorrosion process.Typically, SRBandAPBgenerateacidthatmakest'eenvironment underdepositsmorecorrosive tothemetal.ItisoftenassumedthatthepresenceofSRBand/orAPB(orotheranaerobic bacteria) inasystemisproofthatMICisoccurring inthatsystem.Thisisdefinitely notthecase.InorderforMXCtobepositively confirmed inasystem,threeconditions mustexist:a.Theappropriate bacteriamustbepresent.Page7

~,n<

ThomasM.Laronge,1nc.b.Thedepositnexttothemetalsurfacemustshowsignificantly higherlevelsofsulfurthanwouldbeexpectedfromsimpleconcentration ofsystemwaterandsulfur-containing generalsystemdebris.c.Themorphology ofthepitsonthemetalsurfacemustshowpatternsknowntobecharacteristic ofMIC.IntheSusquehanna plant:Significant levelsofSRBandAPBarepresent.Thisisnotatallsurprising sincetheESWwaterisdrawnfromapondthatsupportsaquaticplantgrowthandisknowntohaveanaerobic bottomconditions.

Thispondreceivesnochemicaltreatment otherthanoccasional algacidearoundtheedgesasneeded.b.TheSEM/EDAXdepositanalysispreparedbytheHazletonLaboratory showshighlevelsofcopperandchloride, tobeexpectedinunder-deposit corrosion, butonlymarginally higherlevelsofsulfurinsomecases.c.Themorphology ofMIConmostmetalsconsistsgenerally ofshallow-walled hemispherical pits,oftenwithsmaller"pitswithinpits."InsomecasesofMIC>severallayersofpitswithinpitsmaybeobserved.

Onsomemetals,particularly theaustenitic stainless steels,tunneling underthesurfacemaybeseen.Thesecharacteristic patternsofpitformation anddevelopment werenotenerallyfoundduringourinspections atSusquehanna.

Asarule,thepitsendedtobe'eparate, randomlyorientedandirregular inbothsizeandshape.WebelievethatalthoughMICundoubtedly wasasignificant factorinsomepitsandprobablyaggravated corrosive conditions inothercases,itwasneitherthemajorcausative factornortherate-determining stepinthepittingcorrosion process.Under-DeositPittinCorrosion Whendepositsareallowedtoformonametalsurfaceexposedtocorrosive water,differential concentration cellsarecreatedthatincreasethecorrosivity ofthewaterlayerbeneaththedeposit,relativetothebulkwater.Ineffect,a"battery" isformedinwhichthemetalsurfacebelowthedepositbecomestheanodeoractivesiteatwhichmetaldissolves.

Thisresultsinpittingcorrosion.

Thedegreeofpittingthatoccursinanygivencasedependsuponmanyvariables, including particularly themetalcomposition, thewatercomposition, andoperating variables.

Flowconditions, temperature, andtimearethecriticaloperating variables.

Thepresenceofmanganese, especially atthehighlevelsfoundintheSusquehanna ESWdeposits, canseriously aggravate pittingcorrosion.

Manganese isamultivalent metal.Itcanexistinseveraloxidation statesand,therefore, encourages electrochemical reactions.

This,ineffect,increases corrosion rateandparticularly pittingcorrosion underanganese-containing deposits.

Page8 Thomo,sM.Lo,ronge, Inc.RootCauseSummar'heevidencewehavegatheredfromtheworkdescribed inthisletterleadsusotheconclusion thattherootcauseofthepittingattackobservedoncopperandcupronickel heatexchanger tubesintheSusquehanna ESWsystemisconventional under-deposit corrosion aggravated bythehighlevelsofmanganese inthedeposits.

SRBandAPBareclearlypresentthroughout theESWsystem,andMICmustbeacontributing factorinthepittingcorrosion.

Somepitsmaybeprimarily causedbyMIC.However,thechemicalanalysisandmetalsurfacemorphology onallspecimens thatweexaminedindicateverystronglythatMICisonlyacontributing factorandnottherootcauseoftheproblem.Wemustpointoutthatflowconditions, particularly longperiodsofnoflow,canseriously aggravate pittingcorrosion.

Thismayhelptoexplaintheheavierdepositsandmoreseriouspittinginthe2E-217CRHRoilcoolercoil,comparedtootherpartsofthesystem.Ourcompletereport,tofollow,willincludefulldocumentation anddiscussion ofourfindings, including appropriate references andbackground information.

Pleasecontactuswithanycomments, questions,

requests, and/orinstructions.

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