[en] A reasonable understanding of PWR steam generator corrosion mechanisms such as denting and wastage has been developed, and adequate chemistry control programs defined to obviate the magnitude and effects of these modes of attack. However, relatively unique corrosion attack modes have been encountered at several plants notwithstanding the presence of a reasonable to very good chemistry control program when considered in light of the Steam Generator Owners Group chemistry guidelines. The uniqueness of attack also suggests that parameters not routinely measured or monitored may be playing a significant role. In the authors opinions, the only reasonable method of routinely identifying corrosion accelerating species present in crevices, sludge piles, and deposits in PWR steam generators is by performing detailed chemical return studies during power transients, shutdowns, and long term layups. Although it would be preferable to obtain samples from regions of attack, such samples generally are not available for obvious reasons

[en] The following conclusions are drawn from the study of the effects of dissolved oxygen on corrosion denting: 1) Following the ingress of fresh-water contamination into a PWR boiler, an acidic chloride solution can be formed in the crevice between tube and tube support plate when an oxidant such as dissolved oxygen or copper ions is present in the boiler water. 2) In the absence of copper, very high levels of dissolved oxygen and neutral chloride are necessary to initiate corrosion. 3) When copper is present in the feed system, sufficient copper ions to initiate corrosion within the crevice are released when the chloride concentration is 0.8 mg/kg and probably also at lower chloride values. Corrosion initiation however may require prior exposure of the copper to dissolved oxygen and can be suppressed by pretreatment with hydrazine. 4) The effect of dissolved oxygen on corrosion already occurring was not explored; neither was the effect of dissolved oxygen on corrosion by acid-forming contamination such as sea-water. In both cases, corrosion rates are likely to be enhanced by the presence of dissolved oxygen

[en] The involvement and relationship of carbon steel corrosion products in the tube denting phenomenon promoted an intensive research effort to: 1) understand, reproduce, and arrest the denting process, and 2) evaluate alternative tube support materials to provide additional corrosion resistance. The paper summarizes a corrosion testing program for the verification of type 405 stainless steel under acid or all volatile treatment conditions

[en] The control of corrosion on the secondary side of pressurized water reactor (PWR) steam generators is the object of considerable research and engineering effort. In the fall of 1975, field data from some operating steam generators indicated that the diameters of the heat transfer tubing were reduced at some tube-tube support plate intersections. This reduction was subsequently termed denting and was shown to be due to the production of magnetite from accelerated corrosion of carbon steel in the annular crevices that exist at steam generator tube-tube support plate intersections. Although each task and subtask of this project has its own specific objectives, the overall purpose of this work was to establish threshold concentrations at which denting occurs and examine relationships between corrosion rates and contaminant concentrations

[en] Steam generator damage in pressurized water reactors is a continuing problem which results from a combination of factors including mechanical design, thermal hydraulics, materials selection, fabrication techniques, water chemistry, and system design and operation. A wide variety of steam generator damage mechanisms has been identified in operating PWRs including intergranular attack, thinning, stress corrosion cracking, erosion, denting, fatigue cracking, pitting, and fretting. Model boilers operated in parallel to the steam generators, i.e., surrogate boilers, may provide a useful tool in the study of these damage mechanisms, their causative factors, and the effects of corrosion actions. To evaluate the applicability of surrogate boilers to such studies, Steam Generator Owners Group I project S111-2 was established. Evaluation of numerous surrogate boiler design alternates led to identification of several possible acceptable approaches. The appropriate surrogate feedwater was identified as plant feedwater. Capability to operate with a tube-side temperature similar to the hot-leg temperature was considered necessary as was the ability to provide mechanical, thermal, and chemical corrosion acceleration. Practical and economically feasible surrogate boiler designs were developed in response to these design requirements

[en] Tube supports used in the tube bundles of PWR steam generators have consisted of mechanical devices located at intervals along the tube bundle. The presence of tube supports creates regions of restricted flow with altered flow patterns and increased pressure drop. An additional and very important effect is also the possibility of local complete vaporization or dryout occurring in the tube/support flow passage and crevices. The thermal/hydraulic conditions at which dryout occurs are of particular interest because of the possibility of the deposition of dissolved solids with the occurrence of dryout. As long term build-up of solid deposition could have a deleterious effect, knowledge of the conditions at which dryout occurs would possibly provide a means to avoid this build-up. A test program, sponsored by the Steam Generator Project Office of the Electric Power Research Institute, was conducted to determine the thermal/hydraulic conditions at which dryout occurred for selected tube supports. The liquid deficient heat transfer associated with dryout will cause a local tubewall temperature rise, i.e., a tubewall temperature excursion. The onset of this tubewall temperature excursion was measured and assumed to indicate the initiation of dryout. Pressure drops across the supports were also measured and photographic documentation of the flow both above and below the supports was made. Test conditions covered the range of typical PWR steam generator operating conditions

[en] Rapid corrosion of PWR steam generator carbon steel support structures and consequential denting of steam generator tubes led to investigation of alternative support designs and materials. In recent designs of steam generators the carbon steel drilled hole tube support plate has been replaced by one of quatrefoil or trefoil shape to minimize the contact area. These plates are now made of more corrosion resistant chromium steel (approx. 12%Cr) to ensure that they are less vulnerable to attack in the event of adverse boiler water chemistry. This study was initiated to examine the corrosion behavior of a range of chromium steels in the acid chloride environments characteristic of tube/support plate crevices under adverse boiler water conditions. Objectives of the study were to: 1) determine the relative susceptibility of candidate tube support plate steels to acid chloride corrosion; 2) investigate the corrosion product morphology and its relationship to the corrosion mechanism; 3) determine the effect of environment aggressiveness on 12%Cr (A405) steel corrosion rates and mechanisms; and 4) investigate the effect of restraint stress/environment on denting potential of A405. Experimental method and results are discussed

[en] Several types of corrosion have damaged alloy 600 tubing in the secondary side of steam generators. The types of corrosion include wastage, denting, intergranular attack, stress corrosion, erosion-corrosion, etc. The environments which cause attack may originate from leaks of cooling water into the condensate, etc. When the contaminated feedwater is pumped into the generator, the impurities may concentrate first 200 to 400 fold in the bulk water, depending on the blowdown, and then further to saturation and dryness in heated tube support plate crevices. Characterization of local solution chemistries is the first step to predict and correct the type of corrosion that can occur. The pH is of particular importance because it is a major factor governing the rate of corrosion reactions. The pH of a solution at high temperature is not the same as the ambient temperature, since ionic dissociation constants, solubility and solubility products, activity coefficients, etc., all change with temperature. Because the high temperature chemistry of such solutions is not readily characterized experimentally, modeling techniques were developed under EPRI sponsorship to calculate the high temperature chemistry of the relevant solutions. In many cases, the effects of cooling water impurities on steam generator water chemistry with all volatile treatment (AVT), upon concentration by boiling, and in particular the resulting acid or base concentration can be calculated by a simple code, the HITCH code, which is very easy to use. The scope and applicability of the HITCH code are summarized

[en] Various electrochemical techniques are available to continuously monitor corrosion in conditions simulating those on the secondary side of PWR steam generators. This paper reviews those electrochemical techniques which are potentially useful to measure denting in tube-support crevices in situ. Attention is also given to corollary needs for monitoring the water chemistry which leads to corrosive attack. Finally some suggestions are offered for corrosion monitoring in autoclaves, model boilers and operating steam generators

[en] The objectives of the project were to develop operational techniques for promoting contaminant hideout return from tube support crevices and to identify the effect of chemical inhibitor application on corrodent transport. The implementation of routine procedures for promoting the return of sequestered corrodents could retard the progression of denting or other corrosion processes and improve steam generator availability. Tests also quantified the effect of inhibitor application on crevice hideout and hideout return processes, with the intention of developing a better understanding of the inhibition mechanism. By carefully monitoring the hideout and hideout return inventories, the program also has provided the opportunity to study steam generator concentration processes in general