State-of-the-art review of OPG steam generator tubing degradation mechanisms

Steam generator (SG) degradation has been a major cause of pressurized water reactor (PWR) incapability world-wide and has limited the useful life of SGs at some utilities. The vast majority of the degradation has been the result of SCC of the thin walled nickel alloy SG tubes and has been most prevalent in mill annealed (MA) Alloy 600. Fortunately, Ontario Power Generation (OPG) SG tubes are manufactured from alloys that have much better resistance to this form of localized corrosion than Alloy 600MA and as a consequence have not encountered SCC to date. Other forms of degradation nevertheless have been experienced; some units at Pickering - B in particular have had many Alloy 400 SG tubes removed from service due to severe underdeposit corrosion (UDC) and costly modifications have been made to Darlington SGs to prevent leaks as a result of SG tube fretting-wear at tube supports. Degradation other than UDC and fretting-wear which could pose a threat to the future reliable operation of OPG's nuclear fleet has also been observed. Important activities in effectively managing SG degradation include determining the mode of degradation and arriving at an understanding of the contributing factors. This is done by a combination of non-destructive examination (NDE) of SG tubing in-situ, SG tube removals for metallurgical examination and research and development. SG tube metallurgical examinations provide information that can be used in the timely development of a strategy dealing with the degradation in the short to intermediate timeframe. Determining the main causative factors at a mechanistic level helps to improve the predictive capability and increases the probability of dealing with the problem in the most cost-effective way. OPG has used this approach together with in-situ NDE inspections during planned outages of its nuclear reactors to minimize the possibility of unscheduled outages and provide the best possible fitness-for-service assessments. Many metallurgical examinations have been done and research projects completed. The result is a bewildering and often confusing body of information that exists in many different reports, memoranda and technical notes. As a consequence was a need to bring this information together into a single state-of-the-art report of SG degradation in OPG SGs for future reference. (author)