Atomte Energy of Canada Limited STEAM GENERATOR TUBE ...lory. Of Has S4 tetss tew* BO fee fslhinr to...

Atomte Energy of Canada Limited

STEAM GENERATOR TUBE FAILURES:

A WORLD SURVEY OF WATER-COOLED

NUCLEAR POWER REACTORS TO THE END OF 1971

by

P D STEVENS-GUtlU

liver NwcUor laboratories

Chalk «<*•?, Ontario

April 1973

AfCl.4449

firt&n in sad smusd slsaaa

wt umuBy so tetgfe thci wcertera afescark tbeir

i B c n l i i &a» within s f*w hssara or area

in n f f i i caen^ As s» «ftffi$>to, ths> tabs sh*ei

« so ttw H.B Reirfaacai-2 piaia were

ta a radtsuoa ftad of 1.5 to 2 R/fe af te

ct&aiSvd in tb> wstet JSSSL Tb# K$cJro

wei* ra*tfc> in 67 d*y» by 2S& nmm w&© *&«wt»d 345

a often mw»'asEry tffl ragac?

fe!(2a to totersbSc tea-sis. This has beaa Oases

*J KWO (O£rs$J&stat esd K.E. Gtesa-I ssd Qa

rtrmi t ®

Tfee (B4«^sy ©f rassrtor operators wbo taw

tube fi jkifss toour psqicafe: «My eursesl

tiapertion to feteri tcei|siji»ni detects aud

ptaga tee tvpm. Sotna (tnas Use

cfes-micai eootrol to &s8p svoid ecsmsisssai.

contrai af the Kccadajy sysaeo

m thai af !&» primcry, *s

of tubes an? se&i&Oy tt t^f&sd. Ti is

of tfc» Bffroas&sjip sysSsss ars oftoo

by tivisikags of eooHag srstasr fmcaas feited

mism. In

lev is eteasaa

FAILURF RATES

Tafetos 4 Us 6 laA jiil wttefcooled

in fifivio? to t i » ea4 of 1ST 1

in ihta 5o

. andto

firota Ite USSE End

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j5sEf 1000

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STEAM GENERATOR TUSE FAILURES.A WORLD SURVEY OF WATER-COOLEDNUCLEAR POWER REACTORS TO THE

ENDOF1971

P.D.

Chrik Rkver Nude* LaboratoriesChafk Rkm, Ontario

April 1973

AECL-4449

STEAM GENERATOR TUBE FAILURESA WORLD SURVEY OF WATER-COOLEDNUCLEAR rOWER REACTORS TO THE

END OF 1971

P.O. Stain—-CwlB*

ABSTRACT

Strain generator* err eritk*l compoiaraU in wai*r-cooled nucitar paver reactor*. Thry•w rutnenW* to iMermi tasks which mult m radtovrtrre contamination spreading fromprimary to wrotMiBry coolant cytttvM. A world aunty tbowi th«l 19 of 34 naclon h*dnptrierm* «*_m frnrrMor tub* faaum to *Jw end of 1971. Various forrvi' of rorrotioo•vrv th» meat frvqnrns rau» of tatfut*. A mail »urv*>- to rcarlor op«nton thows

use of eddy current tab* HiapsrtiOR and the a» of exploat** p^ogi » ttwfleam genersicr repair methoS The world mean tin** bttwwn m i n

gencntor faihim from defective tubts m 0 6 yean at the end of 1971

Chalk River Nuclear Labonrtorie*Chalk River. Ontario

April 1973

AECL4449

RupiiiMi dca tubet dan* lea ftmrataun da vapawr -Enquftta mondial* air KM raaetaun du pulatanc* rafroMia

par aw, Juiqu'a la tin dv 1971

f.D.

Lr» famntaurs dc repeur aoat dtt a rapomiU ctttiqom dam ias raaeteen dtpfil»iiiwira nfroMb par aau. Ik peur«t ftn rttcqtm i ar daa ftiUaa ia*an)» aj»J foot aaaacrla coadaadnatkNi radioaeUvc dtpuls hi qn*i«i9« prteiair* iaaan'aa rjatiiiii aftoaaaiw di

U w •equate imnnBalt a moBt»6 qua Itt raaetawn atr 34 oat an i> d» atofaalam da yapeur Jaaau'i la fte dt !fl?l. Drntan fonaaada <

• ptaaart da oaa ruptafaa. Vn quaatioeaal«t Mnoyii par b poato a nr a ritaM qua I'on a dt phii an pH» racoon i rtaapaeUoa daa tasaaa par

at a ranctol de boudtoai ncptoatfi ccnuw aaMwot prwfwcaa da rffwaUoade vapaur. La moywiM mondiaia dr l^totenaoa d» rtaapi aotra I n

tabes dam tes (ennateun dr vapetir ittritnaH OS an a la fla da 1971.

L'Emrfia Akmaqac du Canada. LtanHatLaboraloem Nml ia im d» Ctmtk

Chalk Rtv«r. OntarioAvrN 1973

AECL-4449

TABLE OF CONTENTS

1. INTRODUCTION j

2. SURVEY OF STEAM GENERATOR FAILURES 1

3. SURVEY OF LEAK LOCATION, INSPECTION AND REPAIR METHODS 2

4. FAILURE RATES 3

5. PROBABILITY OF DETECTING DEFECTIVE TUBES BY ED. * CURRENT INSPECTION 3

«. SUMMARY 4

ACKNOWLEDGEMENT 4

REFERENCES h

TABLES

1. Reacton with Steam Generator Tube Defects 8

2. CMMM of Steam Generator Patens 14

1 Leak Location. iMoectkNi aatf Repair of Sloan Generator (SG)T»bw 1b

4. Reactor* with No Reported Steass Generator Tube Defects to Jan. 1.1972 19

5. Steam Generator Defects to Jan. 1.1972 30

& Reactor* with AiMmatoiMStaaa Generator Defoet* to Jaa. 1,1972 31

FIGURES

1. Typictl Nudcar Steam Generator *

2. Probabiity of ObMrrteg One or Mon Tube Defects m a Saople n. Defect *Rate for Sample SiwN

STEAM GENERATOR TUBE FAILURES:A WORLD SURVEY OF WATER-COOLEDNUCLEAR POWER REACTORS TO THE

END OF 1971

1 INTRODUCTION

In March 1971 the 100th nuclear power reactor inihe world entered operation I I). By the end of 1971,887 realtor years, of experience had been accu-mulated <4). This survey eiominw steam generatoroperating experience in water-cooled reactors. Itsfindings confirm those of an International AtomicEn*rgy Agency report (II which states that in lightwiur rescton, ""major problems were largely on theconventional side, reflecting inadequate engineeringand design effort, insufficient quality control andlimited understanding of materials behaviour".

Steam generators are critical components in^ster-cooied nuclear plants. They are vulnerable tointernal leaks due to their Urge thin heat transfersurfaces. Leaks breech containment envelopes,carrying radioactive material frcm primary tosecondarv systems. Leaks also cause economicpenalties in heavv water reactors. As an example,holes as small as 0 1 mm diameter can leaL over l t hat 4.8 MN'm1 (700 pal pressure difference. Manynew plants have steam generators with a heat transferarea of more than 1 hectare, comprising over 75T ofthe total primary system pressure- retaining boundan

The economic penally <>f a reactor shutdown forsteam generator repairs is at least $500 and may be ashigh as $1000 per hour per 100 MW(e|. The ad<!i?dpenalty of heavy water leaks in a hezv> water n .iritsmay be significant but is probably less than lh? lots!•ost of the shutdown.

Steam generators as part of a larger dssa uf hesiexchangers are components of the nuclear swamsupply system that have demonstrated marginalreliability. In a review of seven nuclear planu in theUSA, Hagen concludes that leaks in heal transfersystems were a major cause of operational deviationsand unplanned shutdowns |3). An earlier survey byNelms and Segaser (21 of reactor heat exchangersoperated by the US Atomic Energy Commission,showed that '.ube vibration was a major problem

experienced by 9 of 17 reactor* in ope-rxiioa Thesurvey shows that corrosion hes os«lafe»^i vfSjreu«3sas Lhe major cause af tub* fajtasea.

2. SURVEY OF STEAM GENESATOR FUU'MES

Table 1 summthz»i a surrey »»f resru» <j?ss»r3t»**>and published literature of d f sm fpt3»7*tor tsisrfailures. A failure may be eiUvrv e l«>*£tng uiiw ia o »that is defective due to damaf? by conusttsaor other mechanises. D*fertM- tuts?* *widentified in situ by eddy curwrsl tnspn-lsoa Fo'ertreaders included in this jurrpy err Utken from srecent IAEA list 14). Expe«iia?ntsi BIHS fti«(d»w«reactors are excluded ss ihei:' dmifn andmay differ sijjiiflciintly from current png-itrr1 is a diagram of a typicas steam getspecial terms which occur in Table 1.

Thnw cstegswtsft of fsShirss ar? «fc>ntirj«i m1, futures prv i la reactor operalKW.. Vacs* pntx toJanuary 1. 197 2 End ajbgeKjUPnl fBthirri. >"osjuiSlKlagfiiiurn prto' to Janaarv 1. 1972. of thy .14 p*m«reactom in the world with tteirn gpffrsuiri, 19 ihave i

crarkinj oisi«»el lubes in Ti.rspvr 1 *od 2 ESMJ in <mrgewralcv of tfe? N rejirUs r«a;lte4 tn reiob«r^ prtarto operation S t n » conasaon .-rsrfeunj »sf lyps 304

us-pi lutes >nfor rorr-pSp'-r6 ye«r» a?

lion of one S«B) |Pt5*TBlof tr<nsaiei- thai bsHawamand 75s? of eii t u b i *pre d»<«ni»»

KWO

of

of B N M U

eunlresulted in *n uti».f«?pU!W> "ntjh faiJuru reU' U histeen announced ttai i l» ttesrs grs^raton tn bratfereactors will probab> !a

- 1 -

i to '" • *'•• l e t

Figure 1 — Typical Nuclear Steam Generator.

Ths- HB Robinson-2 reactor experienced massivelube sheet cladding failure damaging two rows oflubes in 2 of its 3 sU-*m generators. The cause is acommon mode failure whk-h affected 72 other steamgenerators both in operation and under construction.

Table 2 lists the r*uw of failure and the percen-tage of reported failures due to each cauje. Variousiypes of corrosion are responsible for 45^ of allfailun-v Corrosion may also be the cause of failure of•H-.TIP of the 13" where ths- reasons for failure are notghen Due to the complexity of corrogior and thelar* if information, no attempt was mad^ to oil>divide corrosion failures by mechanism. Vibrationresulting in fretting wear caused 2 (6.5'; I fa-turei.

both In CANDl' heavy water reactors. Tube ifeeelcladding failure caused 29^ of all f«Jrur«L Then?aresn fpiwrmUin « m fabricated at on« pUot of theWemtttgbauae Etw-lrtc Corp Mechanical damagr- try

2 rvxclott*.

IB mmmmy ev«*i a a i^le tubs? failure proves to b»>da« to tlw l o s of operating revenue, the

ef ppp*sr» sisd tfw rsdatmn doap recesved by theteam

3 SUftVCY Of LEAK LOCATION, INSPECTION•Vr-D REPAIR METHODS

Tabs* 3 mimtaMfizei a survey of operator responseu> lube ftiiur* The sr.furmstion was obUined by ali&ersUiJT Kan-ri and a mali sarvry of power utilities.

Tbe tafete ihows th»t Inks are usually dstected byin the teeondary sydeni detected by

bolter feed o ; shtam samples for 0 end ya«rf tritiarrL Once detected, leaks are usuaify

located by vtsitl otaervation after floodir^ andthe tecondary ode. Thus appears to be a

mrti-sod evee for tow leal: rates. Otbmmrthodi usit^ ultrasonic leak detectors have elsebeen nwd. parUcji*.ry in conjunction with * bungtnsfrtpd in the Asking tube to measure the p m *location of the le>k.

After locating the leek (or leaks) the m c t o toperator fans a diienusc Is this merely an iaMxitxievent or the s u n of a tube failure epidemic? One wayto resotrr Ais dBeroma is by Inspecting other tubti inih<> steam fraemtixt. Scanning the intenul surface ofthe tubes with an eddy current probe ts the preferredinspection method for locating defective tubes. Thetechnique is capable of detecting wall thinning, cracksand holes with good sensitivity in materials with tlow magnetic permeability such as type 304 itainlesssteel and Incortel-600. In the early le»k cues a fewsurrounding tubes were eddy current scanned. Thepresent tendency is to inspect 100% of the tubes in asuspect steam generator. As this work exposesoperators to high radiation fields, remote eddycurrent inspection has been used In Beznau-1 endIndian Point-1. In the future, increasing attention willbe given to remote and automatic tube Inspection.

The preferred repair m#thod is ' •> block both endsof the tube in the tube sheet w(t»» _,^ciaJ plugs whichare explosively welded to the tube This method h*sbeen adopted by at least three mcjor etetni generatormanufacturers: Westinghous? Electric Corp,, Sieiwnsand Babcock & Wilcox Tb« latter have pufalishwireports on the development and uae of explosiveplugs (54. 55)

- 2 -

Radiation fW-ls In and around (team generator*ara tauafly so high that workers abaorb tfaetar mrd-mum aiiowabte dose within a few hours or evenmtoutos In tome oaes. As an example, the tube sbeet

repairs to the KB Robinson-2 plant weretn • radiation f!#id of 1.5 to 2 fi/h after

was Insulted in th* water box. The rcpainwrrs made in 67 dry* by 256 mea wfeo abaorbsd 345man

P*ccwUmtn»t!on is often nccawtry torsdUtion ftsidt to toierabfe ks?ei£. This h » be«i donsat KWO (ObrigfceiBi) and R.E. Ginna-1 sad tissN-re»et«. In the latter caaas, the who!* psins*jrycircuit was dectmtaininated (56).

The minority of reictcw operators who hmc hadbibs ftiluws favour periodic eddy current tubeInspection to detect incipient defects and explosfrrswelding piugs for repair. Some stress the importanceof precise chsmiea) control to help evold eocnakm,CbsmtcsU control of the secondary systma appears tobe a important aa that of the primary, at the outsidesurfaces of tubes arse uajslly attacked. T8» ebrsnieaJconditions of the secondary cyitera art often ehsagedby it>les**fe ot cooilns ostw frore failed coftdenaerlubes, in gen*r*l, condenan tube faiSuras easy be n

to oreraii ptsat re4ial)4!!ty M eistube fsilurss. Soro* data cotlactsd by tf»

that con^nser tube foiiispe raksc may bethan those for sleain gSEerzlsars, m>t«itf5-

Us tow e^rapâUire and prsfflsmw coaditioas.

4. FAILURE RATES

Tststes < to 6 IK-1 E!I wster-coaied reactor steasagmmsUirs is (BBKS to the end of 1S71. Table 4 listsreectora wbere DO <taa gBtwrator faihirw («T» baterepotted, infcamtiton in this Ubia la beUev«d to beaccurate, hctevver, sora? utilities ire rrioctaai toreport failures, and infonnaUoa trsm Uts USSR aoc!East Gtsmisry ii sither gpane or noa-existarsl. Open-Un{ time ohce-n in th# Ubie« ie defined ea Um« duriafehteh sbe nssctcr grrwntSe* eSectricity; down Urn* fe.iot irveludrd

have «xpe«1eficed faiittraishown in Ta»« S Ortaw reactcn wiC:fatSures Hf rxehtded tsd ltated ia Tafcte 6. M m tbsebetweur, ffiiSiam (MTBF) per 1000 tubes tsr pmexetm fffnentat are c*Scuts!td by dM<Sng Vmproduct of eithef Uib>yean or eisaHi fc««rsto7-yi?i»sby toii! tube faihuva. (Tbe Shipplagpcrt resclw is

twice as its ete*cs grneretosa were related. It is

es Shljspin©cirt-! rad 1) TotaSs ftxaaTable 4 ssw 'nduded for «3«?uUitta§U fc f

Tabte 6 Itets nsctoraDwtaiis of tbow failure* B « pvsr. in Taate 1 and o e

born Tahte 5 as iVy would sStiors tiaeuadyly. (The N-.IKIOC b (tated us both

Table 4 and 6 aa its ctaczs fgaenisre o«r» Pfftabftd.)SOGM of the GBomaUec «w ileted M "epfeteaite"biitBM, Le, usapectedt-y high faQu;, rat#s ^ ^ te

U» Ufa of tbe ptBt.

it csn be 9MS tfest the dtz& teas 6s beê. To sfee^J of 1971, 34 reactors with ^srsstoaSaly 300.000tabs* In 141 jtaaic feoenioss bad tea-aaskteds*i«rty ^ years of roaetor opewtloo. Of Si» 127

In operettas at ths cad of 1971, «GEeiw, 27 s-ialssiMB slerf mi 4S Sa^sarf

of U» remfisinf Ages gesoratoes wusTbe Un^sacy- b toirsrd* [nccesJ a tie

tabs eaaterSal in re*rtcfs broyît oc ti;»1971. SxespUoa* e e S CANDU rescttsrs.

4 sad RAfP 1 witij Mcest, a«5 KKS

( U »

afte?

Ofla jôani the orstafl fsihije rslei K

is opefi«OR 19Only

hs!7« EHiremMialeid mam f&mvitfe no foSs* fa&a^g. As sH t&rteaf gisEkms

tabs (a

to? tn of 20 'fe?

of aactesof the

fe-ss tetes la

thk6S.< y«,rs el

vt t i i esly 17 3 ywws fear tf a l l s ret . Tbits «.%>* f#8*T*tt-;

ônaaec* ef rs%?t«s «%*•"£ iw-"

tfeae.

or

se

Bt EDDY

i&e o n

la Us&it t«

detecting one or more defects in a tube inspection. Asthe probability of tube failure kt tow. • ajwdaistatistical analysts i* IWUI mmry. F%ur* 2 attorn ananalysis bawd on a guide lo ampt* lisas of lowprobability events (57) The cvtrrm as* applicable to"sampling with repiareawflt". Le. wieettag tferwrtmd and KibaFqtient tubes at random fron alltubes In the r«wrtor Prortded U*e staple da* b notmore than about 2€F? of the witole. ties* rawionbe used with little error for Use practical caat whewlutes arc Mtnpted vtthout ntpiacamaeL Aaaim?tubes are icanned sniaully aad Use? die detect rate t»appro* traatlsiy equei to th* actual faftiti* rate. Figkie2 fchows the probability of obacrtiB([ one or raoe*lub? defects m a aunpto ptotie<j a^bwt Uw tfffactrale pr* year 11 shows thai If &t defect ral«c ar» »low « 10 * lo 10 * pm yew (MTBF 50OO Utl*ra 10 to100 yccrs) Itwn a v«ry Lwfp numb** of Uibe* (>10.000) imiM ix i?aztnMt p»» y*« for aprtjbebiUsv ci su«*«. SfKM* ngctan « t wrurvml hm t*»Js itae^ *™ ptou&d ID Ftpis? 2Imlur? »tcs lik*a frora TtfcA* 4 II mm im wem thaiih* fK«*Mif«i!tv o< »i«-t;r)4 one or more de&rta by

t«T)ty>4J 4iT?iS>ilRS B H>. « i e s . g fKKX' 1VCSTQ for titt

rail

W 3 M •••OOI

Figw* 2 - Prob4b*)!t> of Obamtng One or ManT-jbe Drferi* to a Saiaplr *&. Defect R*t* for SampleStee N.

While this sutistical m«thod offers a pstde toiunpi« lize and the probability of det*ctiag dafwrU.it does not, of course, provide any tttort cuta iolocatini defecti. If the failure rate ia Mfh (Iff1 lo10'4 per year) the reactor operator k farced to seenup to lOfTr of the tubes to Identify defect* for repair.

* SUMMARY

6.1 Thb winery * o w i conciwtrrefy Uiat xteamgenerator lube failure* ere est»nsiv», frequent endcostly.

6 2 19 of 34 reactors in operslksn si the end of197! htv<? «pefienc«d tube fiiKiret At least 2reactor* feme had epidemic faitaree resisting la tubenpiacentest ta one caae and poarfWe steam generatorrtptmrvmml is thp otlicr.

6.3 Varioui tvp*5 of corrosion were the mostfrKpwn! cmsara of tube failure. Other causes includedvibration, mamifaftiiring feaSta, cad demage fromik-tw-it Although tome raaettm with aUlalee siecitubes experieaced the higfaest failure rales, op*f»tii*

to stii! too tknitod to cortehid* thai eitheror Monel it

ft. 4 There is a tefMivibcy towards psftod^ceddy cvrrmt tab* litayttlnaM to deioctdefects. Inrreaaiag attention ia being patf toinspection and rap«if one to itign nwltatiao fW<it essteam (vnercton, De»mUvn4?>«lkn IHHperformed in only % ractert to redtt«*fields. Ttu> preferrvd trpafe ts*titod to lo •weld piup into bolh fsvds of the &ematubes.

6.5 The world meas ttrw bet*»efi sS«*tO ;failures u 0.6 yem*, eich»dSn| opidcmk taiiurst

ACKN OW LEOG EM©IT

T>i* cutltor tfeaaka th* many raactor opcralon afiover tb? wortd vho irunte- tills Rjnrey poaalbtc. It iabc wK) th*i iht? coofwntkHi will continue with theolutn*iif aizfrcxifc* of insproriag atenn fenerntor

- 4 -

REFERENCES

1. D. Ch*w, tl aJ., "Operating Experience withNuclear Pewv; Statiora la Member States UnUlEnd 1970", IAEA-137 International AtomicEtwrgy Agwsey, Vtaus*. 1971.

1 HA. Neta*. *t aL. Harvey of Nocfew ReactorSytfra Prtaary Circuit Haot h c h i i y i i " ,ORNL-4S99, Apr. 1969.

3. E.W. Hafts, "Reactor A*aflab*8*y a*d State*R*ltabUity for Gonttenoui Sarrice", N«c&w

r, Vet 12 No. 6 p. 49S, Sept-Oet. lt7L

4. "Power and ftecaereh Raaeiocs laStates", 1972 Edition, lutmtstikmti AtasfeEnergy Afeacy, V Jeans, 1972.

5. "Dtrsctory of Nuctoer Raectce* - Powsr Re-actcn", Vohiaw* IV, Vll, IX, IutermUona!Atomic Eoergy Ajrtvcy, Vtgtsa.

6. DJL Hsyter. "KID Operation Dwriag tl»Y«v (Apr. 90, 1SS9 te Apr. 30, 1S70)",7&CNA-61S. C«s*dton NurimrAeasai C o ^ i t x a , 197a

7. a

8. A.

"Stefits erf the Docgtss fotettaper 71-CNA-333. C«n*c2*n

Afiiasal Cocfgrtcoe, 1971.

el , "Eter B^rteb aae&nlTr--tTiiii fete DUB.

p. 581

S. W.

1972.

Besses, e*- *L, ""Ojsftfe^ ^faagtemai. Re-

3304me fWR Obrtghrtn Nesfcar PowoV e a N b ^ trf tl» Awerteae P o w Coe-Vot SS, Apil»7i.

10. Uc&afKi K«ra-p. 407.

l i . NudPoese* Wwi. VoL 13, Na 44. Nov. 2, 1972,

11 P. Jte*K. "A R«rtow of Stxwe-Comrtia QacktneEKptrtooee in Water Csoted Raac£on", P»p« 6,Bnttih Naeias? Eaafgy Scswty Cssf««a» onEffects of K»rSiTOoso«tts oe HCJHW ftoptstim to

Lomfca, 1»?1.

3S. A M. Aogetai, "Operatiag ExpwteK» iaNuetasi Poww RaaU", Proe. 4th Jet. C^f.Pacesftd 'Jaw Atotatr Esm& % p. 1W,

11972.

14. Nwcteata Wsei, Vol. 13, No. S8. A«e. 17.

mz16. NueJeer Newt 14(8) p. 87. Ite . 1»7L

16. IL Ksttm. et >d.. "Startup and Operattag Es-pemae« wtifc the Fint Two Swte Nuciw? PowsrStatk>» B«iiau wsd Kwfateterg", Pros. 4th Itt.Cocf. Pwec&S U«M Ataesk Ewec 2 p. 117,United Nfttkffis, 1S7L

17. Nuctecr HemtetUs trota Swit^riaad, 14, p. 3,

i a Nectar NewdeUcr frota Swiâtsnd, 17, p. 2.AotiUBB 1971.

19. Nasser titrmbeLtsi tJocs 28, p. 2,

2a "A Taeteieal Report on StMB Geawmtor TubeS!se?t Cfeddlaj", W<îj^Sioae EteOtte Carp.WN&T-10Z, Ksdi 1972, LKwtaft 58247-€9,1972.

21. "OpsaSfeg Htsfesry of U£. Ni Saa» Powe? Be-aetesft, IMS", DMôa cf Resets?aBdTBcfeasde©. USAEC,

22.Uftil Co.,

23.

Pa.", es UEAEC Dffle sis DL£S.

Vmm Espasiwses", VoL FWR-1, -tei

24. "Dsaafca Nacta? Power S'atScm, (Uait I) AoasalRaât of Ststise Opsslioo for U» year 1989

Co. Chfcagss, a f; tOClCK4, J«a. 1970.

aL. Ûai5«d State UUSty Es-Uîi Wtta? Re-

oa SBUO t

Eaecton, Ch&o, 1S70.

R.A Cee,

Petet Sta&ioa VHt Ho. h FtBare

Yogis) itestet S00OM1. VSASC,

27. W.K. Kjator, "Examination erf Inccoel-600Tubefrom N-Reactor Sletni Generator 6A",DUN-SA149, Dougiae United Nuclear Inc.. Nov.1970.

28. W K. Kratzer, "304 Stainlens Steel Stnun Gene-riuw Tube Experiem-e at N-Reactor". DUN-SA-178 Douglas United Nuclear Inc., Sept. 1971.

29 "Nuclear Power Experience". Vol. PWR 2. Jul.

1972.

3a K.W. Araish, Rochester Gas and Electric Corp, toUSAEC-DRL, Docket 50244-96. Apr. 1972.

31. Nucleonics Week, Vol. 13, No. 14, Apr 6, 1972.

32. E Utley, Carolina Power and Light Co., toUSAEC-DRL, Docket 50261-64, Jun. 1971.

33. "H.B. Robinson Unit No. 2, Operating Repor*No. 2 March 20, 1971 -September 30. 1971(Carolina Power & Light Co., Raleigh, N.C.)",Docket 50261-79, USAEC, Nov. 1971.

34. AC. Thies, Duke Power Company to USAECDRL Docket 50269. Apr. 4. 1972.

35. "Nuclear Electricity Generation". Tahiti inAtomwirtschsfL

3S. O. Deubieira el al.. ""Operating 0.%peneiice fromDemonstration Nuclear Powe? Stations in theFederal Republic of G*rmam and Progress ofNew PlanU Under C-otBHtoiUon". Pror. 4th Int.Conf. Peaceful Vtet AUsma- Eastfy 2 p 59.I' tiled Nation*. 1971

37. A M. Angeitnt. "Operattttg E^p^nwtr* in iulu&nNuriear Powsr Sutsoas' Pv«sr 4tr. fwi. CottfPeaceful 0 M S Alomtr Efl'.'rfv 1 p 165 L nitodNations, 1971

3H. i. Cerver*. et al F.iprriww^ He la* '. *«lr*k»sEleclncas EjpsnoUs" Pf<* 4Oi !nt (ful l!ses AtoniM- T.nrrp, 1 p ',Nations, 1971

39. "Yankee Nurlesr Puwer '-tstitwi.Report No 132 Dw 19**! <V«n*#* Memx F.lwiric Company. Weslbom Man ; " ian 197 1

40. "Indian Point Station il nit No is ^pimtaBrjusJOperations RVporu (Coasolwiats-d £4tw>n Co irfNPW York)", on I SAE< |),« ln>i. *,\jmn

II "Powpr Rear tors 1972 IrnVx". Surlpai ^ ng)ne^fing Int Apr 1972

42. "San Onofre Nuclear Generating Station Unlt-I,Operations Report for the Month of Dec. 71(Southern California Edison Company, Row-mead, Calif.)". USAEC Docket 50206-159, Dec.1971.

43. "Haddam Neck Bant. Operations Report No.71-12, D»c. 71 (Connecticut Yankee AtomicPower Company, Haddam)", USAEC Docket50213-131, Jan. 1972.

44. "H.B. Robinson Unit No. 2, Routine OperatingReport No. 1, September 20, 1970-Mwh 20.1972 (Carolina Poorer and Light Co., Raleigh,N O " , USAEC Docket 50261-60, Jan. 1971.

45. "H.B Robinson Unit 2. Routine OperatingReport No. 3, Get 1. 1971-Mar. 31. 1972(Carolina Power and Light Co.. Raleigh, N.C.)".USAEC Docket 50261 93. May 1972.

46. "Robert Ginna Station, Unit No. 1, SemiannualReports (Rochester Gas and Efectrte Corp.N.Y.I" USAEC Doek*U 50244.

47. "Point Beach Nudesr Plant Unit* 1 & 2, Opera-tions Report No. 3. JuL 7l-D«c. 71 (WisconsinElectric Power Co., Milwaukee)". Docket50266-62, Jan. 1972.

48. "Sena Nuclear Power Plant Annual Report for1969. (Sociel* d'Enerfia Nueieaire Frenco-Belgedes Ardennes, Chooz4s-Giv*t (France))", USAECT1D-25704. Sept. 1970.

49. ""Sena Nudear Powtr Plant. Rerxart for D«remb?r1970 (Societe d'Erxwgia Nucte«ire Fr*nro-B«tgrde« Ardennes, ChccKE-te-firvpl (Fwnceli", USAECT1D-25806.

50. "Sen* Nuclear Power PUn'L Report for Janusry1971 (Soctet* d'Enerfta Nudealre FnuKo-Belfedes Ardennes, Chooz !e-Giwt (France))", USAECT! l> 25HO7.

51 EK Utley (Carolina Pciier and Light Co) toI'SAEC DRL Docket 50261-98, Jur» 1972.

52. Nucleonics Week Vol. 13, No. 45. Nor. 9, 1972.

53. "Nuclear Power Experience". Vol. PWR-2, Nov1972.

54 M Ploger, "Erfahrungpn beim Dichtschweinsenvon Dampferzeuger-Rohren niit dem Explosion-sverfahren". Reaklortagunf, p 594, Hamburg.197Z

™* o —

55. W.R Johnson, el i l . "Explosive Welding Plugsinlo H**i Exchartftr Tubes", Ariencan NuclesrSociety, Wtliiamrtjurt, V«.. Sept 1970.

56. W.D. Bsiraartt el a) . "Chemical Decontaminationof Large Nucipar Steam Generators: A CeseHis tory" . DoujU* United Nuclear Inc.,DUNSA-62, 196a

57. R.G. Janriii, "A Guide to Ssnple Size* for TestingFvenU of Low Probability". Atomic Ener|y ofCatuida Limited, AECL-3903. May 1971.

58. Nuclear Powervember 1972.

Expetitnee Vol. PWH-2, No-

59. Nuclear Engineering intemaUonfil. Voi. 17, Na198, p. 903. November. 1972.

oO. "Operating History of L'.S. Nuck>ar Power Reac-UH\ 1971". United SUtss Aisaaic Energy Coen-missaon. WA.SH-1203-71. 1972.

61. "Pslbades Plant Final Safety Anaiyias Report.Aroemiffienl 9. Voi 1 (Consumer Power Com-p»tsy, Jackion Mkh.)". USAEC Docket502S&-H, NOT. 1. 1968.

S2. M. D«y»S, "PerfonntSK* cf the Tuapar AtomicPower Station", Free. 4th Int. Conf. P*»eefu!Usss of Atomkr Sntrfy, 2 p. 4S. United Ngtiom.1971.

TABLE I REACTORS WITH STEAM GENEHATOS TUBE DGFSCTS

Ihmnut. Type

CANADA

tfi)PMWB'311.

CntusWy

Apt SI

N(M M

PtfWR

KM)

FRANCE

Ardrnmn

ICHOOZI

237

GERMANV FED H

IBS

STEAM GENERATOR (IK3|

Ne./RMK-tM. SUM. rein

hbesxtHottioaud. I! thrS Md

3088 wSM. &7T si'8 04 W i n ' 277*C11167 (Kl. &30°ri

B iiata «>Sk 10I3S tubd. CT m'«.l MN'n1. JM'C

Ventral. I loiK w i*i3*07 tKtaoU 7 U<H<«'. 110 C

T * * . Sow

Mutwttl

1 1 1 mm 0(>

i 00

23 nun OD(1.8 is |

4

\ c*fma At I unslnK-

l*u«ui El*ctriqur& 4v

fhsrlrrxM NA

V»rtac.il t1670 luJwi

, iUlSJ EM.

sul»

n ; mm

bm ti

i

i

18l*«

.S

mm OOIH.I

Skt«<

f ,

4r «HI

in

/ »

3 of

To J*n.Na ! :14

k i i

f ntuing *t ktfiii <h» to rraa

FRUMf U UUr4 UlfW (rod top 7on pnlMU l«(. F»Uur» |taa u> Oih* i

from cor« ^ yv«r ihutdownfw

112 F*Uun In refloo of rallkd bwut7 Ink radius. Ballnwt to bs

1011

Dirt-J 1372 Fuiami vlliUa M « » of bibs f&srtNo 1 SO. 11 tMfci M&* latcustMittu HUrk rnM neon-No. 2 BG. 2J twin <<vy lidi Bra I n M n n of »tl*rt from

«. 3ot» SC i t u ; to

KWL

2M

1.300 k^m. I»0 n' S. StartTOJKL 1872

About 12Duriaf 1C72Btuki. UAd

tato akast. Mas; u t a .

kotfe SG'i

• I

: M

% I 1

1 * f ,

k &

[gl

i•5

I1

'

U II

' 5

if !ill* I ** S 3

» 3= !

I !C tS 801 I —

£ 3

I!I!

iill

•

• I s 1£f IIi is IMl!

11.

if

I!3?

5fc8

- 1 0 -

m M I OBtnUTOB (SO)

Uua

. 44

OgnoQag Caa4MnnTukaSiM.Cfctcrtel

To .tea 1973lMe>!u«Miis til 4 80 "i

Craw of D»f«rt. Rssuriu Raft

for Cattin* as< (tnmTout SO antafs of 1 vi ymn

BSD IBS)U-O6B Is *r*H

S"C

IS 9 sua ODItrfttn I

To i»i 1*T2TobJ 323 Is "A". M m" • " . 1 an "C"

R C M M B far [tiHir» HEM (tews

PIKIVHC ntanuH)1

24

Ifte

ITS

le ffiB N i t t

II9SS p*I. MS'

•tteach AWBroa

Bll. 270'C

"Fl

ItraOD

KMtt. Dtoal

2S.4i»mOOIt H)S

41 IB a9 4 SG'i

33 deferti,

17 w

Paitunn AM IO commkm HIMExert

K M kaown.

FatianitiM l a i necieklitf lo i t SG'iiy I » IM driereuitos Is SO N« 14

D a 13

KM)

Sea Oisatra-I

I' usbu EI

J379 » '

16 9 rasa OOt&tQ ts |

S Otnri-3041TS8 tatm

Prtoi to OperationSmog cjFKjataKi rasriitag M^accol tube

•3»"I M S tttfen enckad tontfUi la SO "IS" b "4A">&C'i <rail in " i A " ntuMat ft repiiten tBeiMdaf laai •-—1% at tEtaM its In resoiindw toic«S tout mtukla(.ramteAw tnxk»i. frtavf tot>|> acoiaUnilaatMl ByToJaa I»7S NOT TO. 8 »f 10 ratvk^ r*w 2 »*f lassay feiSujw Uoul DG'i vttk IneoaaMOO Itthcr. No

tutn hKti la Inccra! tukrf SO'i.

To " M 1972 Rmtsaasfw feiitin acx nailaMa I SO4 (Mug^<3 Is "B" No. B <!ru i|MNi 4&0 ran durtag isasLsiDuring I&72: 18 taMon rmsld hsvt cenmi lb«» fattviz

STEAM GENERATOR (SO)

CnticatKyOur

. Su>.

July 81

(CraaKttnilYuihxi

Mwwfitc«an<

WnunfhouafElKrtfwCotp

VrrUrai, I' lute m •*»»37»< tuim. » ' ! « . '13 8 MM m; m ' t

I 3000 fM. Mk» r.

l l n a U O

T«*» QMU> O< Dt{<td.

To J M S SI 3 f m t Mutuo cf Incaatt tub* future 12IIMIC a s f W R iBlorjnaiiln crackt m n !>]

[ 1*73 c o M I toy iK t inwd kMaU»4 con- S«Attuu. O H US* ferate*. otkw

S b l u 3 RW1I*4 W% Unw^ n l 21 mas

*jw» Uit» stoct. n^gag 1 l*tiw uvdIMBOTMI I n of 4al*ctti* tukt took

700

Srpt 70

K»

I

EWrtrkr Corp I t * MM <•>'

I J J 1 3 | M »1

To tea I»1I

I rri

fknt CMS oJ nuaanv iB-wrrkv tub*

on SO " A " » "C" Cttsl rovodutoa<w nt'ti iM> of |rfal> pluMton* 2 U n m . S7 <«yv

to ill 3 S G ' L

MB

323)20

51

Paut

4f7

N o . TO

EterUtc Cotp

Vcruul, U tula » <*utoutaU. 1 MN • ' SIS 1

5 •

1 SO'i

47

74

87J

(J4ak>

am rw»

MHOrant laMMMMi f:*«5e

20

Ocosa»lBcteoctli

16H31 inkn1& JMN m'. SI8*C

r>3 m l

(tetena Itan c^m rosiMtaa| of 21

ittW«4 * U l l wpiHT pro-

(MW(.) |

PWB491

Tirriwy r"ulol-S,4

993

Surrey I

789

CrttfeaK;

DM*

Aug. 73

Ao#.

3TILAM GENERATOR (SO)

No.f&Mdw.

Cor© 1 1 l MN:*!« pa

513 (

I MM m

i pa. SM'f

Eub* in t&aST»4 tufen, «7tt4 m1

15 < MN.m 1 . HS'Cs». (»O6"C|

I ivc orw 1-600

tVrct* Ciu» at Dafert.

Tuba n m w l» wld dirtier pl*t* onSflNo 2

Pnor to op«rg|Jcj<i (bidding failure brlvoen tub* L>Wuitf partHion pUt« on bolii uniti

Prior to oprnUon CUddrnf fallurr btivtm lub« iti«#iTub* rows next lo fend cttvtdrr plaUr un S(< No 3pvtlUon pill*

20

I Cte-lPWB

9 « HN m' r76"CI 1423 p«. i-'«"?I

Son» tubf Iftaki

CHWB/iU*» aedmtMl Md coolx) rv«ct«r

nrat-luiLljiJl »*

TABLE 2 CAUSES OF STKAM GENERATOR FAILURES

Ca us

Corrosion

Vibration

Tube sheetcUdciini fusl-a*

Mechanic*!

daroife

Other rMtoasnot given

KWO(ObrtgJ»imlTarepur-!Tampur-2GangiianoMihune-1BeziuulShippirigporl- <Shippingport-2Dresden-1Yankee (Ro««)N- ReactorHaddain NeckH.B. Robinson 2Indian Point-!

NPDDoiiglts Point

Beznau 2H.8. RobinsciviIndian Point-2Indian Point'sTurkey Point-3Turkey Poini-4Surrey-1Point Beach-2

ArtieniwsOconee-1

Point Belch-1NovcreoroRKh-1San Ono^re-1

KWL (Ungen)

H

8 5

6.5

13

31 1OCPJ

- 1 4 -

i!

!h

'illsues-° I 4 1- I B S

Iii"8

S 2

3 i 4 S

[1!i iIII

s

s

u I!hi

o •

2 :

ax

I

f

s

^ Jl

2 f6- 6

i|=

I

1 1

8

1

2

! ii

S S I

Pi t . :

Ktcrtor

fnSan

7 2

StiTvtong

Malarial

Uat D H M M HMI lnnpirUnaMethod

uoa erf Sf.1 IUIMK Is lSKmveru.1

t u m p l v f «1dv rurnnt in^MM-tiun ptanordwith prubr thai willLravprw I' bend.

No TuU"

Utta! !>2

mi

Cine (ub«ntnunntton

tUf

12 tnruw(-600TrltlUPi mrssuremenu All tubes e*kf) rurrvni ftu(g»d & t#a)

ortdod b-, C tkO - I S to id tddy cum-nt tnipecHon

woriung *!«•» tvcomnwiuiKL SG opantedfoe •* 18 ntonttu with ttcopday ii<fo chemuiti7 out ofspeclficatlori.

&»

1

4,pf Juo 7 S

A (it 7|

(>» A p. 7]

Z ViauU (oraUoa aT U t ey *f l*f AH*> v<Ui ninvnl

firtrti

5917

UMSJ60B

M«nw>y tool picls l»«kjKl& o n replaced 16

17IB

20

tube* ptuggml tortroit tints fMwtaUoa.

UtbM fiii)o»«< (or atmittsUaa.

13)

DtMltOH

CtMir tute vllft 0 1 S

• s

3

1 *1I

8

id

mM

IHIa

"8

E

S3

1i

i. » s ti i » *

i II I ! 1 !

I -•« *!1* ii j i l t

* I *TS-

iiii

- I f -

MiDMaaC

"tart

TiaUawiFrfc Hi

U»«Uaa KKfcefti

aarondary wta2. Visual tar alien afUtflootfin| UKI ptnsuruaif

3 SpMMi bun| to fledtociiton (loaf tub* toitfth.

tutan.

-2000 tubnins<; Mo 3

He. TvA»»IU|Mli*d

iaconat F**|

J Hy*w pmwra•Mt for 8* at 6.2UN m' iSOOpd)

• ptup. I kuii13 w»ll

It R/b *l hilv gbevl I Pluf Ik tail tnia oo»1 R, h it nuowiy «usf»rlur> *j» ui tt«ki ..n1 M> »ra uaxt to b)«tro Uslp4u| 3 UibM end Z SwrUonn frms 2 iuta»Eimwi 1 m of prmevcid foi ei«»^ia«iK?a(tetevtm tuba .1 Etpksuveda« to hlfh ftaidL

3360

i 7)

> 72

arllvH> in 1 I

2 V'uuaJ loriuon after lubv duel cludriinjprvaairainf arcondar) uda failure al divider3. U*ki d*l«ct*d by ptnl*rs*«iion montlor In SG 2. Eddy currrnlMowdown Una.

Manual (nndingend v«Mln(.

Explosive

2 rovs oftubct In 2 Hti'i

376

346 nian Krrontcclvad by 2b&man.I.& R h >1 bibadwrt in HC "A"2.0 Rib m 0"

sf Verted 12 m&*s M.

I7BAMona<

1. Vluutf tocalioaafter rutint lubeswkh araVw

Nona 36 In "A"72 in "8"

0.3 R/h {*nr«J30 R/h in SO

tutsoin & H

ntomr)

AU lubm ta SGrfaacked rteuillyfcr

Mwiuntraily Sol jr»

TABLE 4 REACTORS WITH NO RETORTED STEAM GENERATOR TUBE DEFECTS TO JAN 1. 1972

Reactor

Ptek^afrl

fe&ZFR

KH8

AKW-1

Triaa VeresUsM

Kanapp

Urns Cabrera

i3**B*l-2

N-Reactor

RE. Ginna-1

fellsadai

Nos (worotssih- 2

Movovoroaesth- 3

Toftsis

Type

PHWR

PHWR

PHWR

BWR

PWR

PWR

PWR

PHWR

PWR

PWR

LWGR

PWR

PWU

LWGR

PWE

PWR

Power

SOS

508

62

260

70

247

340

126

163

360

800

420

700

6 K 100

365

440

No. Tubs*/Reactor

31200

31200

4276

5787

-

- 6 6 0 0

4 4 %

8130

-2700

6000

22992

7588

17038

-

-

—

E-HS837

No. SG's/Reactor

12

12

2

3

-

4

2

6

1

2

12

2

2

-

8

6

1 7 4

Operating

Ttaw

0.5

0.2

3.3

3.8

-

3.2

0.9

~ 0

2 b

0.1

~1 2

1.6

~0

-

I 17.3

TubeMaterial

Monel

Morael

S. Steel

-

S. Steel

Inccnel

Moncl

Inconel

Inconel

Inconel

Inconel

Inroiiel

—

—

Reference

35

35

35,36

35.36

35. 37

I, 35

35

36.38

35

60

4G

36

4

4

4

TABLE i STEAM GENERATOR DEFECTS TO JAN 1, 1972

R**ctor So Tub*[MKU

NoR*«Ho>

No.SG't/Stsscfor TtBM

trrmr/ MT8F/SO

Tub*

Gsrigtano

Shippingport'2

Indian Point 1

Yankee Row*

Dmdtn '.

Shippingjjort 1

KWO(O&rijfc»4ra|

KWL<Unj>N»

Stn Onofra- 1

Haddom Neck

NPO

Douglcs Point

HOB

93

4i

32

14

4

2

1

1

3670

S224

72O4

6O34

521,4

IKXJl)

1I3H2

15176

2069

15600

5.6

S 3

e i

S.6

HO

4 7

2.1

2.6

3.2

3.M

6.1

3.0

0.2

0 3

0.2

1 5

1 H

• 1 7

0 9

2.2

a i

2 8 . M

12.6

46.8

0.1

0 2

, $ 3

OS

1 0

' 1 1

0 3

0 4

24

7 6

i> 1

24 0

MorwJ

Inranci

S Stwl

S H«««l

S Start

S St«H

Inconel

S Sfcwl

Incoor)

1 nroiwl

lncoiwl

M-jraH

3 i 37

34. 22

40

39

21 J-4

i5 2X

43

43

3S

36

1429 191887 £42 2.30.4 13.0 5.9

Keet-ton with noTube Dvfeu

4)£146887 1173

Tuiits £429 £338874 £116 177.7 43.3 21.0

TABLE 8 REACTORS WITH ANOMALOUS STEAM GENERATOR DEFECTS TO JAN. 1. 1972

Tub* Defect* No. Tuba /Rcector

NT. SG'tl

Ructor

Operattag

Tin*Tub*

MaterielRafamu*

H-Pjmcias

Arst-enawlCHOOZ)

H.8. Robinson. 2

Petei Beach-1

Tar»$ss$r-1

T«ra?K2r 2

TraSad

> 31! 3, epidonk failure

~ 500, epidemic failure

F«w (»y cow debrii

376 by ctackfing fellura

Number not known

Number not vrkUabto

NutnNrr not d»«iilafat»

Numbsr not cveilabJ*

19160

5000

6380

9700

8520

-6Q00

-6600—

I-S0S40

10

2

4

3

2

2

2

£25

- 1 6

i.6

3-0

0 6

1 1

- I t

~1 2

I~9.0

28. SO

35

•a. 49. io

36, 45. 43

35

1

A d d i t i o n o l c o p i « t oi Shit d o c u m e n tmay b« obtained from

Scientific Document Distribution OfficeAtomic Energy of Canada l imited

fiivsr, Ontario. CanadaKOi UO

Price $1 00 p»r copy

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