Evaluation and Categorization of

Secondary System Layup and Cleanup

Practices for PWR Plants

NP-2656
Research Project S113-1

Topical Report, December 1982

Prepared by

WESTINGHOUSE ELECTRIC CORPORATION

Nuclear Technology Division
Avenue A and West Street
East Pittsburgh, Pennsylvania 15112

Principal Investigator
W. F. Cleary

Prepared for

Steam Generator Owners Group

and

Electric Power Research Institute

3412 Hillview Avenue
Palo Alto, California 94304

EPRI Project Manager

C. S. Welty, Jr. Nuclear
Power Division
 ORDERING INFORMATION
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requested by EPRI member utilities and affiliates, contributing nonmembers, U.S. utility
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Copyright © 1982 Electric Power Research Institute, Inc. All rights reserved.

NOTICE
This report was prepared by the organization(s) named below as an account of work sponsored by the Electric
Power Research Institute, Inc. (EPRI) and the Steam Generator Owners Group. Neither EPRI, members of EPRI,
the Steam Generator Owners Group, the organization(s) named below, nor any person acting on behalf of any
of them: (a) makes any warrar.1ty, express or implied, with respect to the use of any information,
apparatus, method, or process disclosed in this report or that such use may not infringe privately owned
rights: or
(b) assumes any liabilities with respect to the use of, or for damages resulting from the use of, any
information, apparatus, method, or process disclosed in this report.
Prepared by
Westinghouse Electric Corporation
East Pittsburgh, Pennsylvania
 EPRI PERSPECTIVE

PROJECT DESCRIPTION
RPS113-l is sponsored by the Steam Generator Owners Group to evaluate secondary
system layup and post-shutdown cleanup practices as they are applied in operating
PWR nuclear power plants. Specifically, the project consisted of reviewing avail
able literature and conducting site visits at 14 operating power plants to
determine current industry layup and cleanup practices and to evaluate the impact of
such practices on steam generator corrosion damage.

PROJECT OBJECTIVE
The widespread occurrence of corrosion damage on the secondary side of PWR steam
generators is known to be qualitatively related to the buildup of corrosion-product
deposits on support structure surfaces. A major portion of the corrosion-product
deposits is transported to the steam generator via the condensate-feedwater train.
The shutdown period, where large portions of the steam, feed, and condensate
systems are open and exposed to moisture-saturated air, can contribute to the
release of corrosion-film hnildup dYring povmr operation and can also result 1n the
generabon of a nonadherent corrosion-product film during the period of exposure.
These corrosion products then become available for transport to the steam
generators during the subsequent startup and period of operation. The objective of
the work described in this report is to determine the most effective methods of
minimizing
the corrosion products transported to the steam generator as a result of the
shutdown-startup cycle.

PROJECT RESULTS
This topical report describes the methodology used to develop information on layup
and post-shutdown cleanup practices now in use or proposed for use by utilities with
operating PWR power plants. Additionally, the results of detailed studies conducted
at 14 representative power plants in the United States, Europe, and Japan are dis
cussed. These results show that only about 30% of the plants attempt routine layup
of secondary systems during plant outages; however, some 60% of the plants do
attempt system cleanup prior to and during startup in order to minimize corrosion
product transport to the steam generators. From available data it is not possible
to quantify the effectiveness of placing secondary systems in layup versus not
placing them in layup. However, it is clear that proper system cleanup practices
can achieve a significant reduction in the corrosion-product loading to steam gener
ators attributable to the shutdown-startup cycle.

i ii
This report will be of specific interest to all plant operating and chemistry
personnel, designers, and architect-engineers and of general interest to vendors
and owners of PWRs.

C. S. Welty, Jr., Project

Manager Steam Generator Project
Office Nuclear Power Division

vii
 ABSTRACT

The EPRI Program Sll3-l, "Evaluation of Secondary System Layup and Cleanup
Prac tices" was established to study ways to minimize the transport of corrosion
pro ducts into the secondary side PWR steam generators that occurs during plant
startups following extended outages. As part of the EPRI Program, Task 200 ob
jective was to identify and categorize the layup and cleanup practices now in
use or proposed by utilities for PWR plants. The task study consisted of gath
ering information by conducting site visits to fourteen representative PWR
plants in the USA, Europe and Japan, by conducting a search of the open liter
ature, reviews of related EPRI Programs, and by evaluating the practices in
terms of their potential effectiveness. The results show that about 30% of the
plants attempt routine layup of secondary systems during outages and about 60%
perform some form of system cleanup during the return to power following extend
ed outages. The results also reiterate the importance of including most of the
major secondary systems in the layup and/or cleanup processes and the priority
of cleanup compared to layup in minimizing the transport of corrosion products
 CONTENTS

Section Page

1 INTRODUCTION 1-1
Statement of Problem 1-1
Technical Background 1-2
Objectives 1-3

2 METHODOLOGY 2-1
General 2-1
Literature Search 2-1
Field Survey Methodology 2-3
Plant Categorization 2-5
Mail Survey 2-5
Plant Selection 2-5
Field Survey Data Form 2-14

3 SECONDARY SYSTEM LAYUP PRACTICES 3-1

General 3-1
Purpose of Layup 3-1
Secondary System Layup Practice 3-2
Layup Practice 3-2
Suitability of the Layup Mode 3-16
Corrosion Prevention 3-17
Summary of Layup Practices 3-19

4 SECONDARY SYSTEM CLEANUP PRACTICES 4-1

General 4-1
Cleanup Practices 4-2
Background 4-3
Prestartup Cleanup 4-4
Startup Cleanup 4-12
Cleanup During Normal Operations 4-14
Summary of Cleanup Practices 4-16

1
 CONTENTS (CONT.)

Section

5 SECONDARY SYSTEM CORROSION PRODUCT DISTRIBUTION 5-1

AND TRANSPORT
General 5-1
Corrosion Product Formation 5-2
Corrosion Product Distribution 5-4
Corrosion During Outages 5-13
Corrosion Product Transport 5-15
Summary 5-19

6 TECHNICAL RESULTS AND CONCLUSIONS 6-2

General 6-2
Summary of Results 6-3
Layup Practices 6-5
Cleanup Practices 6-7
Corrosion Product Distribution and Transport 6-6
Conclusions 6-6

APPENDIX A SUMMARY OF LITERATURE SEARCH A-1

APPENDIX B SECONDARY SYSTEM DESIGN INFORMATION B-1
APPENDIX C MAKEUP WATER SYSTEMS C-1
APPENDIX D PLANT SECONDARY SYSTEM LAYUP INFORMATION D-1
APPENDIX E CONDENSER WATER SIDE AND COOLING SYSTEM
SHUTDOWN PRACTICES E-1
APPENDIX F SECONDARY SYSTEM CLEANUP EQUIPMENT AND
METHODS F-1
APPENDIX G CORRELATION OF OPERATING PLANT IRON AND
COPPER TRANSPORT DATA G-1
APPENDIX H FEEDWATER CORROSION PRODUCT VARIATION
WITH OPERATING PLANT MODES H-1
APPENDIX I MAIL SURVEY FORM I-1
APPENDIX J FIELD SURVEY DATA FORM J-1
 ILLUSTRATIONS

Figure
Page

3-1 Flow Diagram- Main Steam System 3-12

(Two Steam Generator Plant}

3-2 Flow Diagram - Main Steam System 3-13

(Three Steam Generator Plant)

3-3 Flow Diagram - Feedwater Condensate System 3-14

(Two Steam Generator Plant}

3-4 Flow Diagram - Feedwater Condensate System 3-15

(Three Steam Generator Plant}

4-1 Schematic of Feedwater Train Prestartup Cleanup Paths

4-6

5-1 Normalized Yearly Iron (FE} Transport

5-16

ix
 TABLES

Table

2-1 Keywords and Descriptors 2-2

2-2 Literature Sources 2-4

2-3 Plant Categorization Criteria 2-6

2-4 List of Plants With Operation Prior to 1977 2-8

2-5 Summary of Mail Survey Results 2-9

2-6 Plant Sites Visited Under Field Survey Phase of Program 2-12

3-1 Secondary System Layup Modes 3-3

3-2 Summary of Secondary System Layup Practices 3-4

3-3 Estimated Secondary System Volumes 3-10

3-4 Categorization of Prescribed Layup Modes 3-22

4-1 Summary of Prestartup Secondary System Cleanup Practices 4-7

4-2 Feedwater Iron Concentrations Following Startup 4-15

5-1 Estimates of the Quantity of Secondary System Corrosion 5-3

Products

5-2 PWR Steam Generator Sludge Lancing Data 5-5

xi
 TABLES (CONT.)

Table

5-3 Normalized Sludge Lance Data 5-6

5-4 Relative Internal Surface Areas for Major Secondary 5-9

System Regions

5-5 Secondary System Corrosion Product Relative Distribution 5-12

5-6 Iron and Copper Feedwater Transport Associated with 5-18

Steady and Transient Operations

5-7 Secondary System Corrosion Product Transport 5-20

xii
 SUMMARY

PURPOSE AND SCOPE

Secondary system corrosion products of iron and copper (where copper alloys
are used) are transported into the steam generators in significant quantities
via the feedwater. These corrosion products, in the form of sludge, contri
bute to conditions conducive to steam generator tube corrosion and have been
associated with the tube denting phenomenon. In addition, the corrosion pro
ducts may possibly contribute to the loss of steam generator and/or turbine
performance by tube or turbine blade fouling. Since blowdown does not prevent
the accumulation of corrosion products on the steam generator tube sheet and
because feedwater iron and copper concentrations have been observed to be in
excess of normal values by as much as two orders of magnitude during plant
startups following extended shutdowns, methods of limiting the production of
corrosion products during extended outages and/or limiting their transport
into the steam generator during startup were considered worthy of investiga-
tion. Accord ingl.Y, tire Electric Power Research Instltute (EPRI) Steam
Gener ator Project Office identified Task S113-1, "Evaluation of Secondary
System Layup and Cleanup Practices", for the purpose of investigating
methods for improving secondary system corrosion product control.

Sl13-1 was to be directed towards ascertaining the current utility practices

and problems regarding layup and cleanup, and based upon these findings and
related information, developing recommendations for secondary system layup
during extended outages, and cleanup guidelines applicable to return to power
operations following extended outages. The intent of these guidelines would
be to minimize the quantity of iron and copper corrosion products transported
into the steam generators. The investigation described in this report ful
fills the first of these objectives by presenting the evaluation of the layup
and cleanup practices in the operating PWR plants, and by providing a review
of the related information in the open literature and EPRI programs.

The investigation consisted of a detailed field survey of fourteen representa

tive PWR plants including ten domestic, three European and one Japanese
plant. The field survey included a preliminary mail survey of twenty nine
plants from which the four·teen were selected for site visits. The site visits
were con ducted by a survey team, consisting of a chemist and a systems
engineer, whose
function was to interview site operational personnel and review and gather
plant information relevant to the study. A literature search involving the
review of over 2300 abstracts from science and engineering computerized in
dices and hundreds of technical papers was also conducted. Only thirty-two of
the papers proved to be useful in the study. Included in the review of the
published information were the results to date of the PWR secondary water
chemistry studies conducted by the NWT Corporation under the EPRI programs
RP404-l and RP704-1. These studies provided the most complete quantitative
information available on iron and copper transport.

RESULTS AND CONCLUSIONS

The functions of layup and cleanup are to minimize iron and copper corrosion
product transport into the steam generators, primarily following extended out
ages, for the overall purpose of reducing the steam generator sludge burden.
Layup fulfills this function by minimizing the corrosion of carbon steel in
ternal surfaces in the secondary equipment during extended shutdowns. Cleanup
achieves its function by removing corrosion products from the secondary sys
tems before they can be transported into the steam generators, regardless of
their source or when they are formed.

The benefit of a special layup treatment is directly dependent on the degree

to which atmospheric corrosion of carbon steel is likely to be reduced by the
treatment, which in turn is dependent on the portion of the total secondary
systems internal surface area subjected to the treatment. The benefits which
accrue to cleanup processes/procedures are directly dependent on the degree of
system flushing by secondary steam and/or water which can be subsequently ef
fectively purified before becoming part of the steam generator feedwater.
This, in turn, is subject to secondary system features which promote suitable
flushing and filtration at appropriate times during startup operations. Be
cause the objective of cleanup is to eliminate from the secondary systems all
iron and copper corrosion products that are transportable, without regard to
when they were formed, cleanup provides a broader range of benefits than lay
up, and therefore, is potentially capable of a greater reduction in the steam
generator sludge burden. However, both treatments can serve complementary or
supplementary functions.

The secondary system prescribed layup treatments which have had varying appli
cation in PWR plants are forced air drying, dehumidified air drying, wet layup

S-2
of reducing the transport of corrosion products into the steam generator by
proportionately larger amounts.

An estimated 700 to 1500 pounds of iron oxide and 100 to 300 pounds of copper
oxide (where copper alloys are used) are transported by the feedwater each
year during steady plant high power operation, with the actual amount being
dependent on the plant size and installed cleanup features. An additional
amount, ranging from 10 to 80 percent of the steady high power operation
val ue, may be transported during startup operations associated with short
dura tion shutdowns. The amount of transported iron corrosion products
attribut
able to extended shutdowns of six months has been estimated to be twenty per
cent or less of the total corrosion product burden for any one year.

A simplified generic corrosion product distribution model has been formuulated

which assumes that the corrosion product release and transport is approximate
ly porportional to the relative internal surface areas of the major secondary
systems and equipment, including heat transfer surfaces. This model, which
compares favorably with available inplant data, provides a useful tool for
assessing the potential corrosioR prodtlet release from the major secorrdary
regions and the degree to which layup or cleanup practices can be expected to
reduce corrosion product transport into the steam generator. Estimates of the
relative corrosion product release during startup and normal operation deter
mined by using the model show that: 38 percent of the iron and 19 percent of
the copper (where used) corrosion products are released from the high
pressure drains; 18 percent of the iron and 10 percent of the copper are
released from the low pressure steam and related systems and equipment which
are drained via the low pressure drains to the condenser; 28 percent of the
iron and 53 per cent of the copper are released from the condenser; and 16
percent of the iron and 18 percent of the copper are relased in the
condensate-feedwater train. Applying the model to carbon steel corrosion
product release from systems
which are left untreated during extended shutdowns indicate that: the high
and low pressure steam path systems, equipment and drains potentially contri
bute 56 percent, the condenser contributes 28 percent, and the condensate
feedwater train contributes 13 percent to 16 percent of the corrosion product
release attributable to extended outages. These estimates are subject to ad
justment for those plants having carbon steel feedwater heater tubes.

The overall conclusions indicated by the results of the evaluation summarized

above are:
Those cleanup and/or layup methods which do not involve the major steam
path regions of the secondary systems are inefficient in mini
mizing corrosion product transport to the steam generators because the
corrosion products are internally generated on the surfaces of all the
secondary equipment and, therefore, those systems with the largest
surface areas can be expected to release approximately proportional
amounts of corrosion products to the secondary fluids for eventual
transport to the steam generators.

Full flow condensate polishers, in conjunction with system features

which 1) permit return of the high pressure drains to the condenser up
to 50 percent power and 2) provide feedwater recirculation paths for
prestartup cleanup, provide the most effective cleanup of the second
ary systems likely to be attained during the return to power operation
following extended outages. These combinations involve all the sec
ondary systems in a flushing process, with subsequent filtering of
suspended corrosion products and removal of soluble impurities from
the system fluids before they can be introduced into the feedwater
going to the steam generators.

The most feasible layup treatments for secondary systems during ex

tended shutdowns are dehumidified air drying, forced air drying and
nitrogen blanketing or purging. Wet layup is applicable only to the
feedwater train and heater shell and special layup treatment for the
condenser shells is not considered practical. The dry layup and/or
nitrogen layup treatments are adaptable to all secondary system re
gions and are flexible in regard to initiation of the layup, subse
quent interruption for maintenance, ease f control, and ease of ter
mination. Since steam path regions contain a major part of the carbon
steel surface area, layup treatments suitable to these regions have
the highest potential for limiting the formation of iron corrosion
products during extended shutdown.

The benefits which accrue to the use of special secondary system layup
treatments in reducing corrosion product formation during extends
shutdowns are apt to be limited to about 10 percent of the total re
lease for a normal year for outages under two months duration, and to
about 20 percent for outages under six months duration. For this rea-

S-3
and nitrogen blanketing or purging. Of the plants surveyed, approximately 70
percent of the secondary system equipment which are potential candidates for
layup are not routinely placed in a prescribed layup mode. Thus, the second
ary systems in most plants are left in the "as-is" mode during extended shut
downs, while in the remaining plants one or more systems (but not all) will
receive a prescribed layup treatment on a routine basis, but not at all
times. All four prescribed layup treatments, if properly implemented and
maintained, have the potential for reducing carbon steel corrosion within the
secondary systems to very low values during extended shutdowns.

Invariably, inherent practical difficulties are encountered in both establish

ing, and subsequently controlling, prescribed layup treatments. The most sig
nificant of these difficulties is that the secondary systems are not designed
to facilitate the implementation, maintenance and control of prescribed layup
treatments. Implementation is difficult and time consuming; plant resources
(e.g. demineralized water) are not always adequate; and conflicts with
equip ment inspection and maintenance schedules are inevitable.
System and, possi
bly, other BOP modifications are required to offset these difficulties. At
those plants where lay!lp po1ici€ls are establislled they are usually motivated
by either specific equipment problems or the urgent concerns of the equipment
suppliers.

Considering the four prescribed layup treatments, the comparative choices in

order of preference are dehumidified air drying, forced air drying, nitrogen
blanketing and wet layup. The factors influencing the order of preferance
include corrosion prevention capability, suitability of application to
second ary systems, relative ease of implementation and control, the burden
imposed
on available resources and the degree of system changes and new equipment ad
ditions. Wet layup is only considered applicable to the condensate-feedwater
train and the feedwater heater shells. The consensus of survey respondents is
that the wet layup of the condenser shell is not practical.

Secondary system cleanup may be conveniently defined as either prestartup

cleanup or startup cleanup. Both of these cleanup modes consist of establish
ing system alignments and conditions, and the utilization of specific plant
features which make possible the removal of suspended and dissolved solids
from the secondary system fluids. Prestartup cleanup precedes significant
power operation and involves flushing of the hotwell and condensate feedwater
train. The startup cleanup is accomplished during the power ramps from low
power ( Io percent) to approximately 50 percent power and involves steam
and/or water flushing of the steam path equipment, heater shells, drains and
condenser.

There are four currently employed prestartup cleanup practices identified by

the field survey. These are recirculation of hotwell and feedwater train
water through a full flow condensate polisher; recirculation of condensate
through a filter loop; blowdown (bleed and feed) of the hotwell and conden
sate-feedwater system water; and drain and refill of the condensate-feedwater
systems. Over one half the plants surveyed have full flow condensate polish
ers and the capability of recirculation cleanup of the feedwater. One plant
replaced the time consuming fill and drain method with a condensate filter
loop for removing suspended solids from the condensate. Two plants blowdown
the hotwell and feedwater train until dissolved and suspended solids concen
trations are below acceptable values, utilizing large quantities of demineral
ized water. Approximately one third of the plants do not have a prescribed
prestartup or startup secondary system cleanup policy.

The startup cleanup practice is restricted to those plants which have full
flow condensate polishers and are, therefore, capable of treating the conden
sate from the low pressure steam path equipment, extraction system, low pres
sure heater shells and drains, the condenser shell and hotwell. One third of
the plants surveyed have the capability of returning the high pressure drain
water back to the condenser at up to 50 percent power. This latter capability
permits the condensate polisher to also treat the condensate from the high
pressure steam path equipment, MSR's, heater shells and drains during the
startup cleanup. The combination of condensate polisher, high pressure drain
return and the prestartup feedwater recirculation loop features make it possi
ble to subject all the major secondary systems to the cleanup process. A full
flow condensate filter could conceivably serve the same function as the con
densate polisher.

The effectiveness of the four prestartup cleanup practices in reducing corro

sion product transport into the steam generators is judged to be less than 20
percent because the secondary system regions involved represent less than 20
percent of the surfaces subject to corrosion product formation; i.e., the hot
well and condensate-feedwater systems. Startup cleanup, by contrast, involves
regions which contain 40 to 80 percent of the secondary system surface areas
subject to corrosion product formation and, therefore, is potentially capable

S-4
 son, particularly where adequate cleanup is available, the usefulness
of layup is dependent on the specific plant circumstances.

The results and conclusions of this evaluation of the layup and cleanup prac
tices summarized above and presented in the report confirm concepts either
already known and/or intuitively understood. However, in the course of gath
ering, correlating and presenting the pertinent information on layup and
cleanup, the function of each method of secondary system corrosion product
control an the relationship between them has been highlighted in a manner not
evident in the available literature. It is hoped that this may contribute to
a better tanding of the many interrelated factors involved in these re-
spective processes. It is also hoped that the "relative surface area - corro
sion product release" model, although approximate, may be useful to utility
personnel in making estimates appropriate to the corrosion product control of
their specific plants.
 Section 1

INTRODUCTION

STATEMENT OF THE PROBLEM

Secondary system corrosion products are the principal constituents of the

sludge inventory in PWR steam generators. It is well established that the
sludge consists primarily of the corrosion products of the iron and copper
alloys utilized in the secondary system turbine cycle equipment and that the
sludge enters the steam generators via the feedwater. In addition, in recent
years the possible influence of tube sheet sludge accumulations on PWR steam
generator secondary side corrosion has been a concern to the operators of nu
clear power plants. Also laboratory testing has demonstrated that copper com
pounds from the secondary system accelerate the acid chloride corrosion pro
cess which results in denting of the Inconel tubing at the carbon steel tube
support plate intersections. Steam generator tube cracking and thinning have
also been observed to occur within the t11be sh9@t sl dge piles.

The concentrations of iron and copper corrosion products in the feedwater en

tering the steam generators have been observed to increase by several orders
of magnitude during startup. Unless these concentrations are reduced prior to
and during startup, significant quantities of corrosion products are trans
ported into the steam generators, leading to increased sludge inventories and
the potential for the onset of secondary side corrosion. In addition, con
siderable time may be required to bring steam generator suspended solid con
centrations within allowable limits, unduly extending the time to reach power
operation. In this regard it should be noted that steam generator blowdown
systems do not prevent the deposition of sludge on the tube sheet, and do not
efficiently reduce the concentrations of iron and copper corrosion products in
the steam generator water. For these reasons, methods for limiting the
gener ation of corrosion products during extended outages and/or limiting
their transport into the steam generator during startup was considered to be a
worthwhile subject for investigation.

1-1
Being aware of the problem, the Electric Power Research Institute (EPRI)
iden tified Sll3-l ''Evaluation of Secondary System Layup and Cleanup
Practices". This task was to be directed towards ascertaining the current
utility prac tices and problems associated with layup and cleanup, and then,
based upon these findings and related information, to develop recommendations
for second ary system layup procedures applicable during extended outages, and
cleanup concepts and procedures applicable prior to or during startup. The
overall intent would be to develop methods or concepts for minimizing the of
iron and copper corrosion products into the steam generators. Sll3-l is divi
ded into several subtasks addressing each of the foregoing areas of study,
identified as follows:

Task 200 - Evaluation and Categorization of Layup and

Cleanup Practices
Task 400 - Layup Process Evaluation and Development
Task 500 - Cleanup Process Evaluation and Development

This topical report addresses Task 200 - Evaluation and Categorization of Lay
up and Cleanup Practices.

TECHNICAL BACKGROUND

Experience throughout the power utility industry has varied considerably with
regard to layup and cleanup practices for the secondary systems. Some utili
ties have employed cleanup methods of questionable effectiveness because of
system limitations. Others, because of layup difficulties, rely on cleanup
systems to clean up the condensate feedwater train. Many, because of systems
limitation and maintenance requirements during outages, are prevented from
providing corrosion free environments in the secondary system during layup
periods, or from conducting a cleanup prior to admitting water into the steam
generators. Layup methods and cleanup concepts have been developed for fossil
plant preboiler systems, particularly where supercritical boilers are instal
led. These concepts have been applied to some PWR plant secondary systems.
However, very limited information is available on these practices and systems
in nuclear ants.

In 1975, EPRI initiated studies of PWR secondary water chemi to be conduc-

ted by Nuclear Water and Waste Technology Inc. These studies undertook to
 Section 2

METHODOLOGY

GENERAL

The major work effort in determining layup and cleanup practices consists of
summarizing industry experience to date regarding layup practices, determining
means for controlling layup conditions, and investigating cleanup concepts and
the effectiveness of these concepts in removing iron and copper corrosion pro
ducts from the feedwater. This work effort centered primarily on a field sur
vey of representative operating PWR plants, supplemented by a search of the
open literature for information related to secondary side corrosion product
formation, distribution and transport, not only in nuclear plants but also
fossil plants as well. The methods for conducting the literature search and
the survey of operating PWR plants is described in this section.

The literature search consisted of a review of the output of the available

computerized indices, as described below, and a manual review of International
Water Conference and American Power Conference Proceedings and the technical
magazines ''Power" and "Combustion". In addition, miscellaneous published
papers drawn from referenced bibliographies of articles from the above sources
were also reviewed. In these reviews, not only information directly bearing
on layup and cleanup was sought, but also ancilliary information which addres
sed interfacing areas. These interfacing areas included:

- Transient or cyclic operation of the steam plant.

- Corrosion product formation in the steam cycle.
- Corrosion product transport in the steam cycle.
- Corrosion rate data for secondary systems.
- Use of corrosion inhibitors.
-Methods of secondary side oxygen removal.

2-1
The computerized search was initiated by formulating keywords and
descriptions as shown in Table 2-1. These key words were employed in
searching the follow ing three indices

- The Energy Information Data Base (EDB)

- Nuclear Science Abstracts (NSA)
- The Engineering Index (Compendex)

From each of these three indices, a printout was obtained which supplied
title, author, and an abstract. A total of 2,313 abstracts were
visually scanned and some 57 of promising content were obtained in hard
copy form.
These were then reduced and either included in the bibliography or rejected if
not pertinent.

TABLE 2-1

KEYWORD AND DESCRIPTORS

Keywords and Descriptors used in search of Computerized Indices:

Processes on Components giving Results

Cleanup Steam Generators Corrosion

Purification Feedwater Heaters Transport
Layup Condensers Sludge
Steam Lines
Turbines
Secondary Circuits

Fossil-fuelled and Nuclear.

A11 Languages.

The indices of the International Water Conference and the American Power Con
ference Proceedings were manually scanned for the years 1952-78 as well as
the tables of contents of "Power" and "Combustion" for the years 1974-79 and
determine actual secondary water chemistry variations during various phases of
plant operation, including startup, at a number of operating plants, The
studies revealed that feedwater iron and copper corrosion product content in
creased dramatically during startup. Corrosion products transported into the
steam generators under startup conditions represent a significant fraction of
the total quantity of corrosion products transported during all phases of op
eration. The data provided documented quantitative justification that second
ary layup and cleanup merited more detailed evaluation if iron and copper cor
rosion product transport into the steam generators is to be minimized.

OBJECTIVES

The prime objective of Task 200 was to evaluate the secondary system layup and
cleanup practices now in use, or proposed for use by utilities owning and op
erating PWR plants. A secondary objective, not specifically identified in the
task, is to summarize pertinent secondary system information from the plants
surveyed which is relevant to layup and cleanup or other programs of interest
to the utility industry.

In accomplishing these objectives, two distinct steps were identified. One

was to conduct a literature search to ascertain the available published infor
mation on secondary system layup, cleanup and related subjects, The second,
and the major step, was to conduct a detailed field survey of selected PWR
nuclear plants, both domestic and foreign. To insure that the survey would
include representative choices, the plant selection was based on a careful
review of the pertinent characteristics of domestic and foreign PWR plants
where the operating experience was sufficient to provide meaningful data. The
field survey was detailed, in that it probed not only the layup and cleanup
practices, but also collected as much of the supporting plant data as avail
able. The goal was to accumulate information which would possibly indicate
the basis for the individual practices, where practical layup and/or cleanup
improvements might be realized, and any evidence of secondary system corrosion
product distribution and transport, particularly that which could be attri
buted to extended outages.

The information obtained and evaluated in completing Task 200, and reported in
subsequent sections of this report, is intended to form the bases for recom
mendations for layup and cleanup procedures and/or systems to be developed
under Tasks 400 and 500 of the overall program.

1-3
1973-79 respectively. A significant source of pertinent information was pub
lished papers identified by miscellaneous references revealed during the
course of the study.

A total of eight sources of literature were used for selecting information and
compiling a bibliography. These are listed in Table 2-2 which indicates that
only thirty-two merited being included in the Bibliography presented in
Appen dix A. The results of the literature search are reported in the
appropriate technical discussions of Sections 3, 4 and 5. Included in
the review of pub lished information were the results to date of the PWR
secondary water chem istry studies conducted by the NWT Corporation under the
EPRI programs RP404-l and RP704-1. The studies provided the most complete
information available on iron and copper transport during startup and the
specific data used in the layup and c,leanup evaluation was obtained from the
series of progress reports listed in Appendix A.

FIELD SURVEY METHODOLOGY

The method employed for conducting the field sur"Y consisted of the follmdng
steps:

• Categorize operating PWR plants according to criteria intended to re

flect a broad spectrum of secondary system corrosion experience.

e Conduct a mail survey to determine those plants in a position to

participate in the field survey and likely to comply with the
criteria.

e Select candidate plants from the results of the mail survey.

e Prepare a detailed field survey data form to be used as a guide for

accumulating field survey information.

e Conduct the field survey by visiting the candidate plants,

interviewing operating and maintenance technical personnel and
reviewing operating data and logs applicable to secondary system
corrosion and layup and cleanup practices.

2-3
 TABLE 2-2
LIST OF LITERATURE SOURCES FOR BIBLIOGRAPHY
No. of refs. No. of articles No. Included
Sources Dates Scanned appraised in Bibliography

1. American Power Confer.Procs. 1952-1978 136 46 17

2. International Water Conf. Pr. 1952-1978 182 6 3
N
3. Energy Infor. Data Base (EDB) 1974-1979 1074 22 0
I
+:> 4. Compendex (Eng.* Index Inc.) 1970-1979 448 28 0
5. Nuclear Science Abstracts 1967-1976 791 7 0
6. Power 1974-1979 420 0 0
7. Combustion 1973-1979 566 5 1
8. Miscellaneous Sources 1935-1978 - 50 11

*Copr.Engineering Index Inc.

 TABLE 2-3 ( ONT.)
8. Units in which the steam generators are operated
using AVT chemistry and phosphate chemistry.
9. Units which have full flow condensate
polishers (FFCP), employ secondary system layup
and/or cleanup procedures and systems, and
steam
tor wet layup systems - in that order.
10. Plants with high and low steam generator sludge
removal history.
N
I the feed train. FFCP reduce the transport
'-J
11.Plants representative of turbine, condenser and
feedwater heater suppliers in that order.
12.Units using deaerators.
13. Units with a history of few and many
secondary equipment failures due to corrosion
e.g., feedwater heater and condenser tube
leaks.
8. Robinson 2 and San Onofre 1 operate their steam
generators on phosphate cheffiistry. All other
plants operate under AVT conditions.
9. All units havinOTSG's have full flow conden-
sate polishers (FFCP); except for these, few
plants operating prior to 1977 have FFCP. Since
that time several plants have installed condensate
polishers.
10. Plants which have copper alloy materials in the
feed train typically have larger quantities of
sludge formed and transported to the steam
genera tors than those which have non copper
alloys in
of sludge formed in the condenser.
11. All units have Domestic supplied turbines.
12. Crystal River is one of the few domestic PWR
plants using inline deaerators.
13. This information was not available prior to
the response to the mail questionnaire.
 TABLE 2-4
LIST OF OPERATING PLANTS > 300 MWe (NET)
WITH OPERATION PRIOR TO 1977

Robinson 2 Maine Yankee

Zion 1 and 2 Millstone 2
Conn Yankee Palisades
Indian Point 2 St. Lucie 1
Indian Point 3 Ft. Calhoun 1
Turkey Point 3 and 4 Calvert Cliffs 1
Cook 1
Prairie Island 1 and 2
Trojan
Salem 1
Ginna
Surry 1 and 2
Point Beach 1 and 2 Arkansas 1
Kewaunee Oconee 1, 2 and 3
San Onofre 1 Rancho Seco
North Anna 1 Crystal River 3
Tihange 1
Ringhals 2
Doel 1 and 2
Takahama 1 and 2
Mihama 1 and 2
Genkai 1
Ikata 1

2-8
 TABLE 2-
SUMMARY OF MAIL SUR EY RESULTS
Sec. Sys. Ora ins
Agree to NSSS Cleanup Sec. Sys. Pumped Coppe I SG Tube Dents. History of SG Wet
Partici- Supp1i er, Sys tern Layup FWD/Back non-e p- Cracks or Condenser AVT Feedwater layup
pate in location or Method Proced. Condensate to Con- per H at Thinning Cooling vs. Heater Mixing
Plant Program (b) Ava i1able Available Polisher denser Exc. at. (High/lo-1 De area tor Water P04 Leaks System

Zion Yes !!. Yes No No FWD Non-C None No Fresh AVT None (c)
(exce t
MSR)

Conn Yankee (a) !!.

Ind. Pt. 2 (c) !!. No No No (c) Cu I High No Brackish AVT (c) No
Ind. Pt. 3
Beaver Val-
ley 1
(a)
Yes
!!.
!!. Yes No No FWD
.,,_,I .,,.
(exce MSR)
No Tower AVT Infrequent No--
Thermal
Mixing
Turkey Pt. (c) RP 404-1 Yes No No FWD Cond ; High No Sea AVT Infrequent Yes
3& 4 !!. Ti
N
I Cook 1 Yes !!. No No No Back Cu; FWr Low No Fresh AVT None No--
'-0 304SS Thermal
Mixing

'" l
Pairie Is. (a) RP 404-1
!!.
Trojan Yes RP 404-1 No Yes Yes (c) None No Tower AVT 1/year No--Gas
!!. Thermal
Mixing
Salem 1 Yes !!. Yes Yes No (Yes-- FWD; No; Ex None No Brack ish AVT None No
7-79) Not cept M R
Startup

Ginna Yes !!. Yes No Yes FWD Cu I low No Fresh AVT 1/year No--
Thermal
Mixing
Surry 1 & 2 Yes RP 404-1 No No No (Yes-- Back Cu High No Brackish AVT 1/year No--
!!. 12-7g) Thermal
Mixing
(a) Ma11 Questionnaire response not received.
(b) This column identifies 1) if the particular plant is participating in the EPRI econdary Water Chemistry Studies (RP404-1 and RP704-1 Program, 2)
the NSSS supplier, 3) A European or Japanese location. The objective was to i Jude at least two CE plants, two B&W plants, two European plants,
and two Japanese plants.
(c) Mail Questionnaire response was not sufficiently clear for a definitive state t.
 TABLE 2-5 (CONT.)

Sec. Sys. Ora ins

Agree to NSSS Cleanup Sec. Sys. Pumped Copper/ SG Tube Dents. History of SG Wet
Partici- Supplier, System Layup FWD/Back non-Cop- Cracks or Condenser AVT Feedwater layup
pate in Location or Method Proced. Condensate to Con- per Heat Thinning Cooling vs. Heater Mixing
Plant Program (b) Available Available Polisher denser Exc. Mat. (High/low) Deareator Water PO leaks System
Pt. Beach No !i No No No FWD Cu Moderate No Fresh AVT 6 tubes - No
1&2 2 years

Kewaunee {a) !i
No. Anna 1 Yes !i Yes Yes Yes FWD; Cond. 304SS None No Fresh AVT None (c)
Not FWHT Cu
Startup Startup

McGuire 1 Yes w Yes Yes Yes FWD-Op Non-Cu None No Fresh AVT None Yes
McGuire 1 not operating as of 9-79 Back Ex. MSR
Startup
Robinson 2 Yes !i No No No FWD Cond. Cu Moderate No Fresh P04 Infrequent Yes
FWHT Cu Dent
Except 2- Minor Crack
304 ss
N San Onofre 1 (a) !i
I
....... Main Yankee Yes CE Yes No
0 No FWD Cu Low No Brackish AVT 1/month No
Millstone Yes CE Yes No Yes FWD Cu High No Sea AVT 4 in 2 yrs. No--Gas
Palisades No CE No No No (Yes-- FWD; Cu; LPHT High !to Tower AVT Infrequent (c)
1979 Not 304 ss
Startup
St. Lucie 1 {a) CE
Ft. Calhoun No CE Yes No No FWD Cond. 304SS None No Fresh AVT None Yes
lPHT
Cu/304 SS
HPHT 304 SS
Calvert No RP 404-1 Yes Yes Yes Back Cu; FWHT None No Brackish AVT 12 in 4 No
Cliffs CE years
The criteria used for the selection of plants for site visits are listed in
Table 2-3. Considering these criteria, a tentative list of thirty-four
plants was chosen, as shown in Table 2-4, for further consideration by means
of a
mail survey.

The mail survey was intended to provide more complete information in regard to
the selection criteria established by the tentative categorization and to de
termine whether or not the plant personnel were in a position to accommodate
the visit of a field survey team at a time consistent with the program sched
ule. The mail survey form is reproduced in Appendix J.

The mail survey response was remarkably good, with a total of twenty-eight
completed survey forms being received, resulting in an 806 response. Of
these, twenty indicated a willingness to participate in the field survey phase
of the program. Thus, an adequate number of plants were available to meet the
target of twelve to fifteen site visits and to accommodate subsequent contin
gencies. The mail survey results are summarized in Table 2-5.

Plant Selection

From the results of the mail survey and subsequent considerations, fourteen
plants were selected for the field survey site visits, and are listed in Table
2-6. The technical bases underlying these selections are as follows:

Participation in the EPRI secondary water chemistry studies RP404-l and

RP7041 was a consideration because of the data available from these stud
ies on corrosion product transport in secondary systems.

Selection of generating stations which have different NSSS suppliers

and/or are located in foreign countries were considered a reasonable ap
proach to obtain an adequate sampling of the secondary layup and cleanup
practices across the industry, and to represent different plant configur
ations, system material differences, and corrosion effects.

2-5
 TABLE 2-3
PLANT CATEGORIZATION CRITERIA
CRITERIA
1. Operating Nuclear PWR plants having a net
capacity greater than 300 MWE and have been in
operation prior to 1977.
2. Utility and Plant Manager are in a position to par
ticipate in a field survey and provide information,
appropriate documents and performance data during a
site vfsft.
3. Availability of records and performance data
where appropriate.
4. Plants included in EPRI programs RP404-l, RP704-
N
l,
I and, where appropriate, other units representative
of
en the three NSSS suppliers and foreign plants.
5. Plants which utilize condenser cooling water
from fresh, sea/brackish or cooling tower
sources.
6. Plants with either copper alloy or non copper
alloy secondary systems heat transfer tube
materials.
7. Plants which represent the extremes of steam
genera tor corrosion history i.e., tube denting,
thinning, cracking.
COMMENT
1. Domestic and foreign stations/units which meet
this criterion are listed in Table 2-4.
Crystal River 3, North Anna 1 and Ikata 1,
which were
not operating prior to 1977, are included because
they were of interest in related EPRI programs.
2. Favorable responses to mail questionnaire in this
regard were prerequisites to selection for site
visft.
3. As determined by mail survey.
4. EPRI Program RP404-1 includes Turkey Pt. 4,
Surry 2, Prairie Is. 1 a 2, Ginna and
Calvert
Cliffs 1. RP704-l includes AN0-1, Crystal River 3
and Rancho Seco. The latter provided a good
representation for plants having once through steam
generators (OTSG's).
5. A number of sites have either sea/brackish or
fresh cooling water. The number with
cooling tower is limited to Beaver Valley
1, Trojan, Palisades and Rancho Seco.
6. Note some OTSG plants have copper nickel alloy
90-10 condenser tubes. Also, San Onofre has re
tubed their condensers with titanium in the
past several years.
7. According to available data the units listed
in Table 2-4 adequately represent the extremes
of steam generator secondary side corrosion.
 The plant site selections reflect the variations in secondary system
cleanup and layup practice (as reported in the mail questionnaire re
sponse), the availability of condensate polishers and/or the practice of
returning heater drains to the condenser during startup. These consider
ations were important because they are relevant to the investigation of
secondary systems corrosion product formation and transport.

Site selection included plants which exhibited steam generator tube dent
ing, cracking, or thinning, thus assuring representation of plants exper
iencing significant steam generator corrosion.

Among the plant sites selected, both copper and noncopper condenser and
heat exchanger tube materials were represented. These material differ
ences affect the corrosion product formation and were reflected in the
layup and cleanup practices.

Feedwater and condensate systems employ AVT chemistry even where the steam
generators use phosphate chemistry. Thus, feedwater and condensate corro-
sion product formation and transport are not directly affected by the use
of phosphate chemistry in the steam generators.

To the extent possible, the plant sites selected included those using
fresh water, sea water, and tower water cooling sources. Inclusion of the
cooling water source also provides data for the EPRI study of the layup
of the condenser cooling water side and the study of condensate polishing.
This aspect of site selection is consistent with observed variations in
steam generator corrosion behavior at sea water and fresh water cooled
plants.

The frequency of feedwater heater tube leaks was thought to be indicative

of potential abnormal conditions that may impact layup implementation,
and/or major equipment repairs that could affect the maintenance of layup
conditions.

Of the above considerations, NSSS supplier differences, geographical

location, variations in cooling water, the presence or absense of condensate
polishers, method of heater drain handling, and heat exchanger tube material
differences proved to be significant to the layup and cleanup study. The
other factors

2-13
were of little significance. The final choices of site visits reflect all of
the significant variations.

It should be noted that specific plant data for Mihama, Zion, Beaver Valley
and Surry has not been reported either in the technical presentations or the
appendices of this report. However, the survey information from these plants
has been considered in formulating the reported results and conclusions, and
the latter reflect the impact of all of the survey responses. The appropriate
specific plant data for these plants will be contained in a subsequent adden
dum to this report.

In order to provide a guide to the utility personnel and the survey team mem
bers during plant site visits, and to obtain as much of the available informa
tion as possible, a detail field survey data form was prepared. This form was
forwarded to the cognizant plant personnel in advance of the site visits to
provide a basis for planning the visits and to facilitate information retriev
al. The information to be obtained through the use of the data form was to be
used to determine layup and cleanup practices and also to obtain background
information regarding plant equipment, operating chemistry data and mainten
ance experience in support of the layup and cleanup evaluation. In addition,
the Field Survey Data Form was also designed to support two other EPRI pro
grams: namely S164-1 on Condensate Polishing and S162-1 on Steam Generator
Wet Layup. For this reason, additional sections pertaining to these topics
were included in the form.

The Field Survey Data Form, which is shown in Appendix K, was organized into
four major categories reflecting the general physical organization of the sys
tems of interest in a nuclear generating plant and the specific projects cov
ered by the survey; namely Secondary System Layup and Cleanup (Sections 3 to
6), Makeup Water System (Section 7), Condensate Polishing (Section 8), and
Steam Generator Layup (Section 9). Within these broad categories, the form
was divided into design information, chemistry information, and operation and
maintenance information in order to more readily separate out sections accord
ing to specific departments within the utility. Items of information which
were available from the mail survey and/or sources outside the utility were
included for the sake of completeness and to assure that their inclusion in
the data was visible for subsequent utility review.
 TABLE 2-5 (CONT.)

Sec. Sys. l.lrd ln::;,

Agree to NSSS Cleanup Sec. Sys. Pumped Copper/ Partie!- SG Tube Dents. History of SG Wet
Supp11er. System Layup FWD/Back non-Cop pate In Location or Cracks or Condenser AVT feedwater Layup
Method Proced. Condensate to Con- per Hea Thinning Coo ling vs • Heater Mixing
Plant Program (b) Ava11able Available Polisher denser Exc. Ma • (High/Low) Deareator Water P04 leaks System

ANO 1 Yes RP 704-1 Yes No Yes FWD; Cu-Cond None No fresh AVT 1-2 years Yes
Not FWHT 30
Startup
Oconee 1, No B&W Yes Yes Yes FWD;
Not
No Cu r Low No Fresh AVT 100/yr/ht Yes
2& 3
Startup

Rancho Seco Yes B&W Yes Yes Yes FWD-ex. No Cu None No Tower AVT Rep laced CS Yes
MSR-- w/SS--1

Crystal No RP 704-1 No Report

Startup
I in 2 years

River 3 B&W
R1nghals 2 Yes Europe Yes Yes No FWD Cond. Ctj, low Yes Sea AVT None No
Ti FWH
Cu, CS
N
....... Tlhange 1 Yes Europe No Yes No Back Cond. Cq, Low Yes fresh AVT None No-Gas
....... fWHT, C
Doel 1 & 2 Yes Europe Yes No Yes Back Cond. C None No Brackish AVT Frequent No
Startup MSR Cu Thermal
FWHT Cs Mixing
Mlhama 2 Yes Japan Yes Yes No Back Cu Low Yes Sea AVT None No
Takahama 1 Yes Japan Yes Yes No Back Cu Low Yes Sea AVT None No
.. 2

Genkal Yes Japan Yes Yes Yes Back Cu, Tl air None Yes Sea AVT None No
removal
lkata 1 No Japan Yes Yes Yes Back Cu I None Yes Sea AVT None No
 TABLE 2-6
PLANT SITES VISITED UNDER FIELD SURVEY PHASE OF PROGRAM

1/8/80 - 6/30/80

P L A N T

1. Surry 1 and 2
2. Zion 1 and 2
3. Ginna
4. Trojan
5. Beaver Valley
6. Salem 1
7. Ti hange 1
8. Millstone 2
9. Maine Yankee
10. Arkansas 1
11. Rancho Seco
12. Ringhals 2
13. Doel 1 and 2
14. Mihama 2

2-12
Subsequent to forwarding the Field Survey Data Form to the utilities, the sur
vey team visited each of the sites listed in Table 2-6. Each survey team con
sisted of at least one chemist and a systems engineer. Where possible, in
order to facilitate the survey, the team work was divided according to either
the system maintenance or the chemistry category so that the inquiries to
these areas could proceed in parallel. As a result the survey was restricted
to less than two days at each site. The splendid cooperation received from
the operating personnel at all the sites visited greatly contributed to the
realization of the field survey objectives.

Subsequent to the field survey at each site the data form responses were or
ganized into suitable record copy form. The responses were then correlated
and evaluated. The results of the evaluation of the field survey data and
investigations related to secondary system layup and cleanup are reported in
Sections 3, 4 and 5 of this report. A summary of the major results and con
clusions are presented in Section 6. Detailed related and plant specific in
formation is reported;,, AppeRdiees A througt:l H.
 Section 3

SECONDARY SYSTEM LAYUP PRACTICES

GENERAL

The objectives of the secondary system layup study were to evaluate current
and proposed secondary system layup practices and to summarize pertinent sec
ondary system information obtained from the survey which is relevant to the
study. Accordingly, this section presents a summary of the secondary system
layup practices for the plants participating in the field survey, a discussion
of the results, an outline of the major considerations influencing these prac
tices, a limited evaluation of how the practices fulfill the layup objectives
and a basis for the selection of the layup treatment. Secondary system infor
mation relevant to layup treatments is presented in Appendices B and C.

PURPOSE OF LAYUP

Secondary system layup refers to the prevailing environment within the second
ary system equipment and piping during extended outages. The environment may
be the result of a special prescribed layup method or treatment in which the
environmental conditions are controlled, or it may be simply the consequence
of allowing the systems to reach equilibrium with the surrounding conditions.
The objective of a prescribed layup treatment, in the context of this study,
is to provide an environment which is noncorrosive to carbon steel and, there
fore, will significantly minimize the general surface corrosion of the inter
nal carbon steel surfaces of secondary equipment and piping during extended
plant shutdowns. A reduction in the iron oxide formation during plant shut
down is expected to result in an equivalent reduction in the steam generated
sludge burden. In this regard, it should be noted that the local corrosion of
carbon steel (e.g., pitting) is not a consideration, because such corrosion
does not significantly affect the steam generator sludge burden. Note also,

3-1
that the quantity of copper alloy corrosion products generated is expected to
be substantially less than the quantity of carbon steel corrosion products
produced when they are both exposed to the typical untreated secondary system
environments during a shutdown. For this reason the general surface corrosion
of copper alloy materials is not considered controlling. Under similar expos
ure conditions the corrosion of stainless steel and titanium materials are
expected to be negligible. Extended shutdowns or outages are arbitrarily as
sumed to be longer than ten days, because it takes from two days to a week to
implement layup treatments, and because the potential carbon steel corrosion
for periods less than ten days is considered insignificant. Also, the field
survey results indicate that where prescribed treatments are specified, plant
policy is to implement such treatments well within ten days.

SECONDARY SYSTEM LAYUP PRACTICE

The more common modes of secondary system layup may be designated as dry lay
up, which is subdivided into forced air drying and dehumidified air drying;
wet layup; nitrogen blanket or purge; steam blanket; drained; and "as-is".
These modes are described in Table 3-1. The layup modes may be separated into
prescribed layup treatments and "no treatment" layup. The prescribed layup
methods or treatments, which are the subject of most of the subsequent discus
sion, have evolved from fossil plant experience and, as noted in References
3-1 to 3-4, they have been the subject of considerable attention during the
last ten years or more in relation to efforts to reduce sludge deposits in the
tubes of supercritical boilers. The applicability of the prescribed layup
methods to PWR plants is discussed in Reference 3-5. A further discussion of
the prescribed layup modes listed in Table 3-1 and their use in PWR plants, as
determined by the field survey is in the remainder of this section.
The plants included in the f eld survey are considered to be ive of
PWR plants throughout the i

Layup Practice

The PWR secondary system layup
are summarized in Table 3-2.
and the related plant specific
addition to the layup
Table 3-2 includes the layup
denser water side systems.
ces as determined the field survey,
ion of these resu ts is below
on is ix D. In
the , the information in
ces for the steam generators and the con
lattepractices are included because of
 TABLE 3-1

SECONDARY SYSTEM LAYUP MODES

LAYUP MODES TYPES DESCRIPTION

Dry Layup Internal surfaces dry to touch, atmosphere well below satur
ation.

Forced Purge with air from surrounding; i.e. turbine

Air Dried hall, plant interior. Relative humidity below 85 percent.

Dehumidified Purge with dry air to reduce humidity below 50

Air Dried percent

Wet Layup Fill systems/equipment with water at pH_lO and containing

50 200 ppm hydrazine May he capped with nitrogen blanket
where filling is not practical.

Nitrogen Purge Fill and/or purge systems with nitrogen so as to

or Blanket reduce oxygen content of internal atmosphere to low values.
Often considered a form of dry layup in contrast to wet lay
up.

Steam Blanket Purge with oxygen free steam at high pH to displace air

Drained Equipment allowed to drain, usually back to condenser hot

well. Systems and equipment become exposed to moist air or
water in contact with air.

As Is As systems and equipment are secured they remain without

special treatment. If normally filled with steam, the
steam is replaced by air and residual condensate so that the
con dition is equivalent to the drained mode. Where systems
are normally filled with deoxygenated water, the water is
re tained but slowly absorbs air at the air-water
interfaces,
or the water slowly drains b ck to the condenser.
 TABLE 3-2
SUMMARY OF SECONDARY SYSTEM LAYUP PRACTICES
SYSTEM- Trojan Salem 1 Millstone 2 Ginna Tihange 1 Doel Arkansas 1 Rancho Maine Ringhals 2
EQUIPMENTI2) 1 and 2 Seco Yankee
(a) Ill (a) (a) (a) (a) (a) (a)

Main Steam FA I b) AI AI AI AJ(h) AI AI AI AI DA(k)

Turbines FA AI At AI Atlhl AI AI NB AI DA(k)

MSR's FA AI AI AI AJ(h) AI AI liB (j) AI DA(k)

F.W. Htr.
Shells NB,AI At lei Wl AI AI AI AI HB AI DA(k)

Condenser
Shell Ail b) AI AI AI AI AI AI AI AI DAikl

w Cond. Hot
I Well DR AI AI AI Wl AI,DR AI AI AI DA(k)
+:>
F .w. Cond.
System FA,wtlc) AI DR I g) AI Wl AI wtlll HB AI Wl

Total "AI's" 7 5 7 5 6.5 6 3 7

Steam
Generators Wl Wl Wl Wl Wl Wl Wl .fiL Wl Wl
Cond. Water
Sfde and
Cool Water
Syst. DR,FA(d) Atlfl AJ(f) AIIfl At If) DR If) Ail f) DR If) Atlfl DR(l)

(1) Types of layup are: FA - Forced Air; DA - Dry afr or dehumidified air; Wl - Wet Layup; NB - Nitrogen Blanket or Purge; DR -
Drafned; AI - as ls.
(2) Extraction systems are generally drained and vented, heater drafn lines may be drained or contain water since they are
nonnally left "as ls".
(3) See second sheet of table for lettered reference comment.
 TABLE 3-2
C011111ents
LAYUP PRACTICES fCONT.)
(a) These plants have full flow condensate polishers. Arkansas 1, Ra ho Seco, Trojan and Doel installations were prior to
{;OIIIIIerclal operation. Salem, Mill stone and Gi nna install at Ions backfl ts.
(b) Air is blown through the steam system from upstream of the turbine control valves and exits through the condenser manwa,ys.
If system is still warm, turbine path is dried out but condenser a r is moist.
(c) F11r periods less than 2 to 4 weeks, WI. 1s the la,yup mode. For pe ods > 30 da,ys, the system is subjected to forced air
injected near the condensate pump and blown forward through the he ters, exiting near the feedwater nozzles.
(d) For periods < 30 da,ys, water fs circulated with dally chlorination or ma,y be drained or stagnant. For periods > 30 da,ys
water boxes are drained and blown with air.
(e) Salem turbine deck fs open and deck equipment must be drained in freezing weather.
(f) AI in the coo1fng water systems means that water fs circulated at duced flow with or without normal chemical treatment.
See Appendix E.
w
I
U"l
(g) After shutdown, the systems are placed fn recirculation mode and hldrazfne is added to achieve 50-75 ppm residual. Then the
condensate pump Is secured. The system subsequently drains bad t hot well through leaky valves.
(h) The equipment Is open to the atmosphere. Tfhange has recently (10 80) Installed a dry air dehumidifier system for the main
steam piping, turbines and MSR's. It had not been operated as of /81.
(f) Usually WI., otherwise DR. The valves which isolate the condensate system from the hot well are tight and prevent draining
system back to the hotwell for long periods.
(j) Shell side of the MSR's.

(k) Orled air Is circulated through the systems using an installed dehf:idifled air system. Condenser hot well is drained and
dry forced air fs used to accelerate and maintain a dry condition !thin the shell.
(1) The cooling water side 1s drained and the tube flushed with fresh ater to remove residual sea water. Then plastic covers
are placed over cooling water channels (See Appendix E).
the interface relationship of the respective equipment to the sys-
tems, the data is of interest to the EPRI steam generator wet layup study and
provides a basis for comparison between the secondary system 1 practice
and the layup practice of the other major fluid system equipment in the bal
ance of plant. The evaluation of the steam generator layup practice is the
subject of a separate EPRI program Sl64-l, while a summary of the condenser
water side layup is presented in Appendix E.

The secondary system layup information reported in Table 3-2 represents the
practice most frequently in use. The practices indicated by the table shows
that for the plants surveyed, the "as is" layup mode is the usual mode for
approximately 70 percent of the potential applications for prescribed layup
treatments. For the 30 percent of the applications where a prescribed layup
is specified, actual implementation may not always be achieved, particularly
for forced outages of unpredictable duration, and if achieved, may be subject
to interruption during the extended shutdown in order to accommodate inspec
tion and/or maintenance demands. The data in Table 3-2 also shows that where
a prescribed layup treatment is specified, air drying or nitrogen layup is
used for all steam path systems and equipment, except for one plant where
wet layup is used for the heater shells. Wet layup is specified for the
feed
water-condensate systems for most of the cases where a layup treatment is
pre scribed, but air drying and nitrogen layup are also used in some instances
for these systems. Steam blanketing is not used, nor was it considered for
any extended shutdown applications.

The usage reflected by Table 3-2 indicates that wet layup is only practical
for the feed-water-condensate train and the feedwater heater shells in PWR
plants for reasons given in the subsequent discussion in this on. With
one exception, the condenser is usually left "as-is" or drai , the consensus
being that it is too large and too wet and/or open (during outages) for layup
to be practical. Steam blanketing is impractical for extended shutdowns be
cause the systems and equipment would have to be maintained hot (>220°F) in
a quasi operating mode which is inconsistent with the general plant shutdown
status. In addition, steam blanketing would require a source of oxygen free,
high pH steam (i.e. from auxiliary boilers). This is not
avai le in all plants. Steam blanket is similar to the
condition prevailing within the main steam path equipment during short
duration shutdown conditions when the plant is kept hot, sometimes for
periods of several days or longer. It should be noted that steam blanketing

3-1
for extended shutdowns was not referred to in any

3-2
of the literature on layup which was covered by the literature search; nor was
it considered by any of the PWR plants included in the field survey. For
these reasons steam blanket layup is not included in the subsequent parts of
this evaluation.

The "no treatment11 modes which include the drained and "as-is" modes leave the
steam path systems and equipment exposed to moisture laden air and/or water in
contact with air. This environment is normally conducive to the corrosion of
unprotected carbon steel surfaces. Following a shutdown a substantial part of
the feedwater train equipment initially contains water having a chemistry
close to that maintained during normal conditions and is, therefore, nominally
noncorrosive for as long as the system can be kept closed. If the condenser
isolation valves are not tight, the systems will drain back to the condensers
and the internal surfaces will be exposed to moist air, as is the case for
the steam path systems. Note that, although drained systems result in exposing
the carbon steel surfaces to conditions known to be conducive to corrosion
of steel at rates up to several mils per year, many of the surfaces initially
have a film of magnetite on them which was formed under the reducing condi-
tions associated with normal operating chem1stnes. lh1s magnet1te f1lm may
be expected to provide some level of general surface corrosion protection for
several weeks or longer.

The layup practices in Table 3-2 raise two immediate questions: 1)

What is the motivation for the use of prescribed layup treatments where they
are specified and 2) are the prescribed layup treatments seldom (or not)
employed in most of the plants in spite of the availability of tech-
niques known for many and the well established general use of wet layup
in steam I should be mentioned, in regard to these questions
that there was t among the plant personnel contacted during
the survey that system layup is a worthwhile objective.
In addressing the f on concerning the motivation for the use of pre
scribed layup treatments, a review of the field survey data implies
specific utility's plant or other plants, as
feedwater heater or turbine problemsindicated that a al
effort was warran cribed layup treatments are a response to
the concerns ing incipient or ser-
ious failures or 1oss of performance, as for example wet ayup
for the steam at all of the plants surveyed.
In addressing the second question, concerning why prescribed layup is less
frequently employed, a review of the field survey responses indicate that pre
scribed layup treatments for secondary systems are: a) frequently difficult
to implement b) likely to be more difficult to reestablish if interrupted c)
inevitably subject to interruption in order to accommodate maintenance and
inspection demands d) apt to place a substantial burden on plant resources,
particularly demineralized water e) likely to burden the maintenance manpower
resources during shutdowns f) known to require system changes or installation
of new equipment. In addition, there is the implied question concerning the
actual benefit which will be derived from a specified layup treatment, partic
ularly in view of the fact that a substantial part of the corrosion products
are generated during normal operation and that good cleanup practices are a
possible alternative for limiting corrosion product transport to the steam
generators. These considerations are examined further in the subsequent dis
cussion.

The kinds of circumstances which are apt to be encountered in implementing a

prescribed secondary system layup treatment during an extended outage are:

- The placing of the feedwater-condensate train in wet layup can only be

readily accomplished before the feedwater condensate systems are secured
following the shutdown. While the systems are still operative, and pro
viding there is a circulation loop from some appropriate point in the
feedwater system, such as the first point heater, back to the condenser,
wet layup may be implemented by increasing the quantity of hydrazine and
ammonia which is added at the normal injection point, such as the conden
sate pump discharge, to bring the feedwater to the wet layup concentra
tions. Sampling in the normal manner provides the control during this
initial process. Considering the time to establish the new optimum layup
chemistry, wet layup may take forty-eight hours or longer to implement
with a consequent delay in shuting down the system. Where wet layup is
used on the shell side of the feedwater heaters, jury rigged lines or
hoses must be installed connecting the heater water side to the shell side
(usually via drain connections) in order to fill the heater shells with
the layup solution. After the condensate pumps are secured and the plant
is in the fu11 shutdown mode, wet layup can no longer be readily implemen
ted because circulation flow and line pressure for mixing and sampling is
no longer available.
 The implementation of nitrogen layup requires running hoses from a nitro
gen supply manifold to the equipment, unless transfer piping is already
installed. Nitrogen layup, accomplished in this manner, without the bene
fit of specially installed piping and equipment, may be expected to take
two or three days. Implementation of air drying requires access ports at
injection locations and the availability of nearby sources of air so that,
once connected up, the ventilation will be able to proceed without much
attention until terminated. Implementation of dehumidification requires
dehumidifier equipment of sufficient capacity and the necessary air trans
fer lines. Most plants do not have this equipment; but once available,
implementation should not be excessively time consuming.

- Reestablishing a prescribed layup treatment following a period of inter

ruption is a consideration. For example, reestablishing wet layup with
current plant designs is likely to be difficult or impractical to accom
plish. Wet layup in the feedwater train equipment without flow
circula ting capability would of necessity have to rely on fill and
drain tech niques with provisions for a fill pump having suitable
chemical facilities. The onl
erat on and start a
drained, filling is a prequisite. Reestablishing nitrogen layup is a re
peat of the initial implementation. There is a reasonable likelihood that
forced air drying and dehumidified air drying will not have to be reestab
lished if the systems were adequately dried initially and maintainance or
inspection activities did not result in surface wetting or high humidities
within the system. If necessary, reestablishing dry layup will be the
same as for the initial layup implementation process.

- Prescribed layup treatments utilize plant resources, such as demineralized

water, nitrogen and compressed air in considerable quantities. Wet layup
of the feedwater-condensate train in those cases where draining of the
system is deemed necessary to eliminate residual contaminants, such as
sodium and chloride compounds, may require from 30,000 to 60,000 gallons
of demineralized water. Since the steam generators are also being put
into wet layup at about the same time, the secondary system wet layup may
severely burden the demineralized water supplies. Table 3-3 presents es
timated plant volumes for a typical 1100 MWe, plant and typical steam
gen erator wet layup volumes, secondary water storage capacities and
makeup
 TABLE 3-3
ESTIMATED SECONDARY SYSTEM VOLUMES
(For 1100 MWe P1ant(1))
Steam Flow Path(2) Volume
FT3 GAL,
Main Steam Piping and 10,400 77,800
H. P.
Turbine
14,800 110,700
MSR's (4 Units)
3,300 24,700
LP Turbines (2
Units) Extraction
System 3,100 23,200
Drain System
6,800 50,800
Feedwater Heater,
Shell Side (6 Heaters)
38,400 287,200
Subtotal
Feedwater-Condensate Train(2)
Piping 5,100 38,100
Feedwater Heaters, Water Side (6
Heaters) 3,400 25,400

Subtotal 8,500 63,500

Total 46,900 350,700(3)(4)(5)
NOTES:
(1) Volumes for other ratings may be approximated linearly with MWe.
(2)The condenser volume up to condensate pump discharge isolation val
ves is not included since it is not subject to layup.
(3)The operating PWR steam generator wet layup water volumes range from
about 40,000 to 130,00 gallons per plant.
(4) Secondary water storage capacities range from 34,000 to 450,000
gal
lons per plant, exclusive of auxiliary feedwater reserves.
(5) Make up plant capacities range from 80 to 350 gpm.
 water capacities for a range of plant sizes. This data is useful for com
paring layup treatment volumes with the available resources. For example,
when the water usage for steam generator layup is combined with that for
feedwater train wet layup, the resulting total may range from about
100,000 to 195,000 gallons. This quantity is a substantial fraction of
the secondary demineralized water supply at most plants. If the feedwater
heater shells are also placed in wet layup, another 30,000 to 60,000 gal
lons of demineralized water would be utilized. Furthermore, in addition
to the water demands for wet layup, a comparable burden is placed on the
disposal facilities when layup is terminated and the systems are drained,
since the water is likely to contain ammonia and hydrazine in excess of
local environmental release allowances.

- The resource demands of nitrogen layup cannot be readily estimated from

available information. A lower bound for the quantity of nitrogen re
quired for all systems, assuming the 1100 MWe plant of Table 3-3, would be
about 50,000 SCF, or approximately 550 gallons of liquid nitrogen. How
ever, in an actual plant situation, the quantity of nitrogen required may
be many times this amount, depending upon how long a continuous purge is
maintained. A continuous purge assumed to completely flush the systems on
an average of once each day (_ 0.2 ft/sec in a 24 inch diameter pipe)
would utilize 500,000 SCF in ten days, or 5,500 gallons, the equivalent
of about 80 to 90 percent of a liquid nitrogen truck load.

!heair drying layup mode may employ various types of air moving devices.
If compressed air is involved, the compressor capacity would likely be the
only limitation. Dehumidified air is a direct function of the dehumidi
fier unit capacity and standard size equipment should be adaptable to the
requirements. The only plant resource required in the latter case is the
electrical energy.

- The initial implementation or reestablishment of a prescribed layup treat

ment may be impeded by an insufficient number of remotely operated isola
tion valves separating major equipment and/or long sections of large pipe.
Figure 3-1 through 3-4 provide typical main steam and feedwater condensate
flow diagrams for two and three steam generator PWR plants respectively
which illustrate the limitations on isolation capability. Referring to
the system and equipment volumes in Table 3-3 it can be seen that layup
cannot be readily implemented or reestablished until all major equipment

3-11
 MSR
4

MSR
1

TURBINES

w
.....,
N

MSR
2

Figure 3-1. Flow Diagram - Main Steam System (Two Steam Generator Plant)
 GL. ST. COND.

EJECTORS

w
.......
()"1

CONDENSER

Figure 3-4. Flow Diagram - Feedwater CondensatSystem (Three Steam Generator Plant)
 is ready to be closed up. Also, opening one piece of equipment for in
spection and maintenance is apt to involve other large equipment in the
train and result in terminating the layup for a considerable portion of
the system. While manual valves are available to a greater degree, these
valves are very large and many are not easily accessible. Even where iso
lation valves may be available it is not uncommon for very large valves to
leak in situations where extremely low differential pressures prevail (<10
psi), a situation which is to be expected for typical layup conditions.

- Manpower required to implement, control and terminate a prescribed layup

during an extended plant shutdown may be difficult to allocate. Although
layup requirements usually originate in the plant chemistry group, carry
ing out the procedures is done by operations or maintenance personnel.
Since the major part of the shutdown effort is expended on the routine
maintenance of the NSSS part of the plant (including a considerable
amount related to regulatory requirements), the manpower available for
secondary systems work is limited, and this for obvious reasons will tend
to focus
on the most immediate concerns affecting plant operability. Thus, one can
envision layup processes which are manpower consuming and consequently are
apt to be relegated to a lower priority, such that the layup may not be
implemented. This situation can only be offset by a positive overall
maintenance layup policy.

In addition to the above circumstances which can be expected to affect the

application of a prescribed secondary system layup mode, other pertinent as
pects which merit discussion are treated below.

The suitability of the prescribed layup mode is a function of the practical

considerations regarding the system or equipment to be placed in layup; such
as the capability to retain water in the feedwater train, the total volume of
the system to be placed in layup and the difficulty of isolating the systems
from interfacing equipment (e.g. the turbines and condensers). Forced air
drying and dehumidification, for example, requires that the systems be drained
and entry and exit ports made available. Thus, since most secondary systems
can usually be drained and vented, implementation of air drying layup consists
of draining, assuring vents are open and making the appropriate connections
between the systems and the air supply. In some plants low point drains may

3-1
have to be installed in a few feedwater train piping loops. Thus air drying
can be made adaptable to all systems.

Wet layup, as noted previously, is suitable for the feedwater train and for
feedwater heater shells. Because of the large volumes of the steam path
equipment and isolation difficulties, it is not practical for these systems.
Also, wet layup is not suitable for feedwater trains which, because of leaky
valves, cannot retain water for long periods of time. Nitrogen blanketing
is suitable for all systems and/or equipment which can be kept closed or
which can accommodate a continuous purge. As is the case for air drying, the
sys tems must be drainable and free from low point water traps. Most of the
equipment can be purged back to the condenser. Purging of the condenser, be
cause of its volume and because it is apt to be open, is not considered prac
tical.

Corrosion Prevention

A fundamental consideration of any prescribed layup mode is its effectiveness

in minimizing corrosion. The prescribed layup modes listed in Table 3 1, if
properly implemented and maintained, have the potential capability of reducing
the secondary system carbon steel corrosion to insignificant levels during
extended shutdowns. In addition, all methods have been used in one or more
secondary systems or sets of equipment and they are feasible. Although a de
tailed search of the open literature, as described in Section 2, did not re
veal direct inplant test data on the effectiveness of these methods for the
protection of carbon steel in secondary systems during extended outages, data
from a number of sources, subsequently identified, support the adequacy of
forced air drying, dehumidified air drying, wet layup and nitrogen blanket
layup modes.

The forced air and dehumidified air drying modes accomplish their objective by
reducing humidities of the internal environment of the systems and equipment.
As shown in References 3-6, 3-7 and 3-8, relative humidity and surface
wetness are the controlling factors in the atmospheric corrosion of carbon
steel, and that in the absence of contaminants, carbon steel corrosion is
minimized when the relative humidity is reduced below 85 percent. The forced
air, assuming
it has a humidity well below 85 percent, should be capable of achieving this
objective, particularly if the ventilation of equipment takes place while the
equipment is still warm (110-200°F). The dehumidified air treatment systems

3-17
can be designed to reduce humidities below 50 percent with moderate size
equipment as noted in Reference 3-9. As reported in Reference 3-10, carbon
steel corrosion will be minimized in air atmospheres below 50 percent relative
humidity, even where the air contains typical contaminants such as sulfur di
oxide. Although many PWR plants are near industrial sites and/or marine sites
where air borne contaminants are apt to be prevalent, many other plants are
located great distances from sources of air borne pollutants. For this reason
one of the dry layup modes would be feasible for all plants. The major chem
istry concern with dry layup is how effective is the removal of pockets of
moisture from large, intricate systems which, if not removed, jeopardize the
effectiveness of the layup. Although specific information which addresses
this concern is not currently available, field observation as noted in Appen
dix 0 suggest that reasonably thorough implementation of the air drying pro
cess will diminish this concern.

The wet layup mode, which consists of filling the applicable systems and
equipment with water containing a well mixed excess of hydrazine and estab
lishing a pH between 9 and 10, usually by the addition of ammonia or amine, is
frequently proposed as the layup method for boilers, steam generators and
pre boiler equipment as noted in References 3-1, 3-4 and 3-12. Although the
meth od may be applied to other systems, as previously noted, it is only
considered practical in current PWR plants for the feedwater-condensate
systems/equipment and the feedwater heater shells. From a chemistry point of
view, properly implemented and maintained wet layup is a highly regarded layup
mode because there is greater confidence that the carbon steel corrosion
protection is apt to be more complete. This confidence is supported by a
number of laboratory investigations, such as reported in References 3-11 and 3-
13, which demon strate the adequacy of the wet layup chemistries as prescribed
earlier. The wet layup mode has also shown apparently favorable results from
the extensive field experience represented by its wide use in steam generators
and boilers
as reported in Reference 3-13. The principal concern with wet layup for any
application is how effective is the initial mixing and particularly the mixing
following subsequent chemical additions. Where chemicals are injected into a
recirculating fluid stream as when initially implementing of the layup, there
is probably little doubt that the layup is adequate. However, where subse
quent additions of chemicals are called for and where circulation is either
not available or only available at low rates, and when controls are not effec
tive, the adequacy of the layup may be subject to uncertainties.

3-1
-
w
I

Figure 3-2. Flow Diagram - Main Steam ystem (Three Steam Generator Plant)
 HP HEATERS

TO STEAM
GENERATOR

LP HEATERS

w
,l_.
+:>

LP HEATERS

GLAND STEAM
TO STEAM COND.
GENERATOR

CONDENSATE
POLISHER
HP HEATERS

Figure 3-3. Flow Diagram - Feedwater Condensate System (Two Steam Generator Plant)
The nitrogen blanket or purge layup consists of admitting nitrogen gas into
one end of the systems or equipment which are fully or partially drained in
such a manner that the air is purged out of down stream vents, or the nitrogen
is admitted prior to air entry such as during venting of steam while depres
surizing. The nitrogen is maintained at a slight positive presure (_5 psig)
within the system, or at the injection point for cases where the purge is
maintained continuously throughout the layup. Nitrogen as a layup method
and/or as a cover gas for wet layup has considerable usage as noted in Refer
ences 3-12, 3-14 and 3-16. Also, experimental results as reported in Refer
ences 3-11 and 3-13 attest to the capability of nitrogen layup to protect car
bon steel from corrosion. The effectiveness of nitrogen layup depends on how
well the air has been purged from the system and how low the oxygen content is
in any residual water in the system.

SUMMARY

From the preceding discussion of secondary system layup practices and related
information the results of the layup evaluation may be summarized as follows:

1. The secondary system layup modes identified by the field survey for
extended shutdowns, are forced air drying, dehumidified air drying,
wet layup, nitrogen blanket, drained and "as-is". The first
four are prescribed or specified layup treatments while the latter
two are classified as "no treatment" layups. Steam blanket
layup is a poten tial mode, but is not identified for extended
shutdowns. No other layup modes were identified or suggested by the
field survey.

2. Of the plants surveyed, approximately 70 percent of the secondary sys

tem equipment which are potential candidates for layup, are not rou
tinely placed in a prescribed layup mode. Of the 30 percent where a
prescribed layup is specified, air drying or nitrogen blanket layup
are the usual modes for steam path equipment, and wet layup is the
usual mode for the feedwater train. Dehumidified air systems for the
major steam path equipment have recently been installed in one plant.
Layup of the condenser is not considered practical.

3. All four of the prescribed layup methods identified above are consid
ered feasible, have had some degree of usage, and if properly imple
mented and maintained, have the potential for reducing carbon steel

3-1
 corrosion within secondary systems to very low values during extended
outages (>10 days).

4. Although the expressed opinion of the utility personnel contacted dur

ing the survey was that good secondary system layup practices are a
worthwhile objective, the major deterrent to positive layup policies
is that secondary system layup in PWR plants poses significant prac
tical problems. Specifically, PWR secondary systems are not designed
to facilitate implementation, maintenance and control of prescribed
layup treatments and do not provide for the necessary resources.
Thus, the prescribed layup modes are apt to be difficult to implement
and time consuming, and subject to conflicts with maintenance and in
spection schedules, as well as water and manpower resources. In order
to alleviate these problems, system changes and special equipment must
be considered which can range in scope from the installation of appro
priate layup connections on equipment and the installation of appro
priate layup piping, to major valve modifications or the installation
of dehumidification equipment and/or increase in the demineralized
water resources. Other considerations, in addition to these practical
problems, which possibly are partly responsible for the lack of posi
tive layup policies are the judgement that good prestartup cleanup
practices are a reasonable alternative to good layup practices and/or
the benefits derived from layup are not controlling in so far as cor
rosion product transport to the steam generator is concerned.

5. In regard to the positive layup policies identified for 30 percent of

the secondary systems applications reported by the survey, the motiva
tion for many of these cases was influenced by specific equipment pro
blems such as heater tube leaks or sludge accumulations and/or the
urgent concerns of equipment suppliers. The principal example of the
latter is the universal practice of wet layup for PWR steam generators.

6. On the bases of the results of the field survey and other information
related to secondary system layup, a set of criteria hav& been identi
fied for the purpose of comparing the four prescribed layup treatments.

• Corrosion prevention capability

• Suitability for the specific secondary system application

3-20
 • Relative ease of implementing, controlling, maintaining and rees
tablishing the prescribed layup treatment

• The burden imposed on available resources

• The degree of system changes and/or new equipment additions re

quired to implement the selected method of layup.

Using these criteria, a categorization of the four prescribed layup modes has
been made, as shown in Table 3-4. This categorization gives equal weight to
all the criteria because, despite appearances to the contrary, they all bear
on the degree to which corrosion control is likely to be achieved in the prac
tical situation. For example, the low pressure turbines obviously cannot be
placed in wet layup. Therefore, in this case, air drying as a viable method
of achieving corrosion control is suitable, while wet layup is unsuitable be
cause it cannot be implemented. Another example is nitrogen blanket or purge
which is relatively easy to control and, therefore, may provide better overall
protection than wet layup which is difficult to control in present systems.

The categorization of the layup modes presented in Table 3-4 consists of mak
ing value judgments regarding how well each of the layup modes would be expec
ted to measure up to each of the criterion noted in Item 6 above. The
results of the categorization lead to the conclusion that the indicated
secondary sys tem layup choices are dehumidified air drying, forced air
drying, nitrogen blanket and wet layup in that order. This or er, as well as
the limited suit ability of wet layup, leads to a second conclusion that the
development of layup method recommendations to be conducted under task 400 of
this program should be primarily devoted to the air drying and nitrogen
blanket layup mode.

In addition to the order of preferred choices in selecting prescribed layup

modes for further study, another conclusion of the layup evaluation is that
the adoption of positive layup policies by the PWR plants depends upon the
actual benefits to be expected, particularly in view of possible cleanup al
ternatives provided by the installation of condensate polishers. Sections 4
and 5 of this document report on cleanup practices and corrosion product tran
sport respectively with the intent of providing a basis for formulating over
all conclusions regarding layup and cleanup practices.

3-1
 TABLE 3-4
CATEGORIZATION OF PRESCRIBED LAYUP MODES
FORCED AIR DEHUMIDIFIED AIR NITROGEN
CRITERIA DRYING DRYING WET LAYUP BLANKET
Corrosion FAIR GOOD VERY GOOD GOOO
Prevention (Susceptable to Atmo. (Proven Method) (Highest Assurance) (Proven Method)
Capabi 1f tyl ll Contaminants l
Sui tabf 1 i ty for VERY GOOO VERY GOOD FAIR VERY GOOD
Secondary (All Systems) (All Systems) (limited Appl1cat1on (All Systems)
System to Feedtrain and Htr.
Layup shells)
wI Ease of Imple- VERY GOOD VERY GOOD FAIR GOOD
N mentation, (Set Alr Flow untfl (Connect up units, (Difficult to (Little Control
N Control, Dry, Reestab. Unlikely) Auto Contro1 , Maintain Control & Requl red, Must be
Mal ntenance and Reestab. Unlikely) Reestablish) Mal ntal ned, Systems
Reestablishing Kept Closed)
Plant Resource GOOD VERY GOOD FAIR GOOD
Demands {Can Use House Air (Only Requl res (High Demineralized (Moderate Lf quid
with Eductors) Electrical Energy) Water Usage l Nitrogen Usage)
System Changes GOOO FAIR FAIR GOOD
and New (Requires Few Connections (Requires Installed (Requires Equipment (Requires Equipment
Equipment and Compressor Capacity Systems or 4 to 5 Connections, Improved Connections, Piping
with Pipe Lines) Mobile Units) Isolation Capability, to Convenient
Circulating/Fill Pump, Locations, Improved
Tight Condensate Valves) Isolation Capability)

(1) Assumes proper implementation

REFERENCES

3-1. F. Gabrielli, W. R. Sylvester; Water Tr J: !i -fCycli

Ope at!_ -f Uti 1 ity Boilers, International Water Conference; Pitts
burgh, PA October 31-November 2, 1978.

3-2. F. Gabrielli, W. R. Sylvester, G. W. Thimot; Contamination

Prevention of Superheaters and Rehe ter _Q_uri g !_ itial Startup a <!
_Oper !j_on, Proc. Am. Power Conf. 38 (1976} p. 296.

3-3. F. Gabrielli, J. J. Kurpen; Secondary Cycl - he istrt_ ntc _fo

t::. t::.iz <!- er eactor, Proc. Am. Power Conf. 34 (1972) p. 651.

3-4. L. H. Vaughn, C. V. Runyon; Corrosi - r !io _Qf_ Boilers and Asso

i <!l._g i_p_ ent During_!_<!! J:. r::.jods, Proc. Am. Power Conf. 1l (1971)
p. 721.

3-5. Subcommittee Report of EPRI CAC on Control Monitorina=a 1- ater Chern-

_!_ trt_f_ t::. Startup, Sh down, - <! Layl!.e of PWR and BWR
Systems, Raleigh, N.C., January 12-13, 1978.

3-6. W. H. J. Vernon; tuc!y_of Atmo h t::.ic Corr::.os:! -Metals, Trans.

_o_r:! Faraday Soc., 2l {1935) p. 1678.

3-7. Herbert Guttman, P. J. Sereda; surem -of Atmospheric Factors Af

fecting_ the Corrosion of Metals, ASTM STP 435 American Society for
Testing and Materials {1968) pp. 326-359

3-8. P. J. Sereda; Weather Factors Cor::.rosio of_ tals, ASTM STP

Affecting
558, American Soceity for Testing and Materials (1974) pp. 7-22.

3-9. H. Steger; Steam Power Plant- Corrosion Preventio DuriShutdown

Periods, Der Maschinenschaden, 49 (1976} pp. 23-27.

3-10. F. H. Haynie, J. B. Upham; Correlation Between Corrosion Behavior of

Steel and Atmospheric Pollution Data. Corrosion in Natural Environ
ments, ASTM STP 558, American Society for Testing and Materials
(1974) pp. 33-51.

3-23
3-11. J. A. Armentano, V. P. Murphy; Stanc!_by_P_rotecti2_1!_2_f High Pr ssur
C!_ lers,
Internati
onal
Water
Conferenc
e 1964.
-
Including
Discussi
on
Section
of Paper.

3-12. R. R.
Beach, M. J.
Bell, J. H.
Hicks, F. J.
Pocock; Preo
erat 2.'!
Wat
r::.J:
.I:!
_em
str._
-
2_nt
r._o_
l_
2.r::.
J!
ear:_
2te
ll!_
e.el
Sy
tems
,
Proc
.
Am.
Pow
er
Con
f.,
 35 (1973) p. 892.

3-13. Niculau Figueiredo De A lmieda; Anti-:<:_C!_rro Jiet':!

_C!_ds_ior J!. !. r::. c!..
P_rot <:_!_ion _2_f._Q. !:-_2.f.-Serv <:_ _ oilers, Proc. Am.
Power Conf. 40 ( 1978)
p. 964.

3-14. B. T. Hagewood, H. A. Klein, D. E. Voyles; The

Contr:_C!_l._of_!_l!t r::.'! l
2.r::.r:.<?. iol!_i_r!._High-:_P_::_ ur ea - nits,
Proc. Am. Power Conf. 30 (1968) p. 939.

3-15. F. X. Brown, W. T. Lindsay, Jr.; Environrl! '!tal_ f.f.

<:_ on_!_'! -Q. 9.'!
n_<!_QR.er tion of Feedwater Heaters, Proc. Am.
Power Conf. (1967).
 Section 4

SECONDARY SYSTEM CLEANUP PRACTICES

GENERAL

The secondary system cleanup study has been directed towards determining the
current methods utilized by the utilities for the cleanup of PWR secondary sys
tems following extended outages, and particularly the cleanup of corrosion pro
ducts which would otherwise contribute to the sludge accumulations in steam gen
erators. The information obtained from the study is intended to form the basis
for the cleanup recommendations to be formulated as part of a subsequent task of
the overall program. This section includes the highlights of secondary system
cleanup development based on the review of the open literature described in Sec
tion 2, a summary of the secondary system cleanup practices for the PWR plants
participating in the field survey and an evaluation of the effectiveness of
these practices in minimizing the transport of corrosion products into the steam

Experience has demonstrated that the principle constituents of the corrosion

products found in the feedwater are the oxides of iron and copper and/or
elemen tal copper (where copper alloys are used) and that these materials
account for the bulk of the steam generator sludge and similar accumulations of
deposited material in other secondary equipment. These oxides are formed on the
internal surfaces of the piping and equipment, flushed off by flowing steam
and/or water during startup and power operations, and transported through
several paths to
the hotwell and high pressure (HP) drains, and then into the feedwater.
The
purpose of secondary system cleanup, therefore, is the removal of these
corro sion products from the turbine cycle systems during the return to power
proce dures following extended shutdowns, before they can be transported into
the steam generators. The movitivation for emphasis on secondary system
cleanup
during the process of returning the plant to power is that substantial increases
in the concentrations of iron and copper in the feedwater are frequently obser
ved during plant startups, and that these concentration have been observed to be
extremely high during startups following long outages. Also, there have been
some incidents where the time required to reduce excessive iron and copper con-

4-1
centrations to levels more compatible with normal operating limits have been
unreasonably long. A second motivation is that in recent years it has been rec
ognized that these corrosion products are not totally removed by steam generator
blowdown. The accumulation of these corrosion products in the form of sludge on
steam generator tube sheets has provided a site for steam generator corrosion
reactions.

In addition to the removal of corrosion products, an equally important cleanup

objective, from the plant operating point of view, is the control of oxygen,
carbon dioxide, sodium, chlorides and similar soluble contaminant
concentrations in the feedwater. Since the corrosion product cleanup methods
overlap and/or
are interrelated to those for controling the soluble contaminants, the
control of the latter will also be discussed where appropriate.

There are a few functional maintenance type cleanup techniques either in use or
being considered for the removal of corrosion products which are not within the
defined scope of this study. These include sludge lancing of steam generators,
hydrolazing of secondary systems and chemical cleaning. Although these are via
ble techniques, the time required to perform them is not always available
during maintenance periods. Chemical cleaning of secondary systems is both an
exten sive and involved operation, usually restricted to preoperational-post
construc tion circumstances. Steam generator sludge lancing is not applied to
secondary systems themselves, although it is a useful treatment for removing
after-the fact accumulation of secondary system corrosion products from the tube
sheets of steam generators. Hydrolazing is usually limited to feedwater train
piping and equipment if it is done at all on operating plants and, therefore,
has limited scope and cloes not fulfill the intent of complete secondary system
cleanup.
Many plants follow the practice of cleaning up accumulations of sludge from the
hotwell' deck when the condenser is open and drained. However, this is also
lim ited in scope.

CLEANUP PRACTICES

The cleanup of secondary systems is dependent on some mode of transport of the

corrosion products, or other contaminants, from their point of residence
to·lo cations where they can be removed from the systems by some suitable
mechanism. The evident mode of transport is via steam and/or water flow, and
for this rea son, cleanup can be accomplished in the various secondary system
regions only when adequate steam or water flows can be made available. Water
flow by blow-
down, by draining and filling, or by circulation is possible in the hotwell and
the feedwater and condensate systems once they are filled and are being prepared
for plant startup. On the other hand, the provision of significant steam or
condensate flows in the other secondary systems is less practical prior to
startup. Appreciable steam generation, in most plants, is required before such
flows can be realized. Because of these circumstances, and their impact on pre
sent day practices, it is convenient to distinguish between prestartup cleanup
and startup cleanup as the two principle contaminant removal modes prior to
steady high power operation. For the purpose of this study, prestartup cleanup
is arbitrarily defined as secondary system cleanup performed at zero to 10% pow
er, and startup cleanup is performed between 10% and 50% power. Of course, con
taminant reduction and control is an ongoing effort during steady power opera
tion, as noted below, but more often by blowdown of the steam generators after
the contaminants have entered. The practices discussed below generally fall
within either the prestartup or startup cleanup modes.

Background

S9cond ry system cleanup concepts were first proposed ir1 the early 1960 1 5 and
were an outgrowth of prior recommendations to install condensate polishers in
supercritical plants for the purpose of reducing the concentrations of feedwater
contaminants which were causing excessive boiler and turbine fouling. These,
and related recommendations, are described by Klein and Kurpen in Reference 4-1
published in 1965. The cleanup methods proposed consisted of the installation
of cleanup recirculation paths which would permit prestartup flushing by water
flow of the feedwater-condensate train, economizer and furnace water wall so
that the flushing water could be returned, either immediately or at a later
time, to the condensate hotwell and then be passed through the condensate pol
isher before again entering the feedwater system. A number of cycles of recir
culation through these paths not only made possible the flushing of soluble con
taminants from the systems and equipment, and the removal of loose oxides and
similar particulates; but also provided a convenient means for bringing all the
water initially in the system within the required chemistry limits for normal
operation before actual startup operations began. The feedwater flushing rates
proposed ranged from 20% to 30% of the maximum continuous flow rate (MCR)
typi cal of full power operation. These cleanup concepts, proposed in 1965,
have subsequently been confirmed and improved upon since that time as reported
in References 4-2, 4-3 and 4-4, where the effectiveness of the recirculation
clean-
up concepts have been demonstrated for the supercritical and once through fossil
fueled units.

With the advent of PWR plants having once-through steam generators (OTSG's) and
the utilization of condensate polishers in these plants to reduce the potential
for steam generator and turbine fouling during normal operation, the applicable
cleanup features of the fossil fuel plants were incorporated in these plant de
signs as indicated in Reference 4-5. Thus, the prestartup recirculation cleanup
capability was provided so that feedwater system flushing and feedwater cleanup
could be accomplished prior to startup. In addition to the prestartup features,
provision was also made in the OTSG plants to permit returning the high pressure
(HP) drains to the condenser during startup power ramps, a capability useful
for the cleanup of steam path systems, as subsequently discussed. More
recently, in efforts to cope with condenser leaks, condensate polishers have
been installed
in a number of PWR plants having recirculating steam generators. In most of
these installations, the prestartup recirculation cleanup features have also
been included as a means of reducing the ingress of corrosion products into the
steam generators. The various aspects of PWR secondary water chemistry and cor
rosion product transport, and some of the experience to date in the use of con
densate polishers during startup have been reported in the EPRI PWR water chem
istry studies reported in Reference 4-6. Also, the cleanup recirculation fea
ture in plants with condensate polishers are discussed in the Corrosion Advisory
Committee Subcommittee Report in Reference 4-7. The results of the field
survey of secondary system cleanup practices described below elaborate on the
existing information outlined above.

Prestartup Cleanup

The prestartup cleanup includes those feedwater-condensate cleanup processes

carried out during the preparations for returning the plant to power operations
following an extended outage (> 10 days). The cleanup may be initiated while
the plant is cold, and continue during heatup, but is concluded before any
sig
nificant power level is attained; i.e., less than 10% power while the steam gen
erators are being supplied by the auxiliary feedwater system or its equivalent.
The objective of the cleanup is to bring the condensate-feedwater chemistry
within the specifications set by plant guidelines for startup. These
specifica tions are derived from the specific plants• experience and reflect
those re quirements necessary to meet the steam generator and turbine suppliers'
recom mendations for their equipment. Prior to startup, the cleanup emphasis is
us-
ually on the reduction of feedwater oxygen, cation conductivity, sodium,
chlor ides, and suspended solids levels, including iron and coppeto below
specifica tion values before feeding the steam generators with the main
feedwater system.

Prestartup cleanup is directed to the water in the hotwell and the feedwater and
condensate systems, and may be accomplished by 1) continuous blowdown or feed
and bleed, 2) complete drain and refill, 3) recirculation through a recircula
tion filter system and back to the condenser or 4)recirculation through full
flow condensate polishers, the condensate-feedwater train, and back to the con
denser through lines provided for that purpose. The flow paths for these four
methods are shown schematically in Figure 4-1. It is apparent that the latter
two require the installation of a filter system, or the availability of a full
flow condensate polisher and a recirculation loop. In contrast, the blowdown or
feed and bleed, and the drain and refill methods require only appropriately lo
cated blowdown or drain lines and a sufficient supply of demineralized water.

Summary of Practices. The prestartup cleanup practices of the plants included

in the field survey are summarized in Table 4-1. The table reflects the cleanup
method, design features, clea11Up cl1e111istry objectives, cleanup time, and tlie
features which facilitate deaeration. Additional detail on the specific plant
equipment and cleanup methods is provided in Appendix F. Information on the
quantity of makeup water available and the capacities of the makeup systems is
reported in Appendix C.

The information in Table 4-1 shows the trend towards the installation of conden
sate polishers in PWR plants as previously noted. With the installation of con
densate polishers, invariably, a feedwater cleanup recirculation loop has also
been installed, or existing lines back to the condenser have been utilized for
the cleanup task. All but two of the condensate polishers were backfitted,
either late in the construction period or after several years of operation. Two
plants have, or will have placed, condensate polishers in operation during the
last two and a half years. Thus, more than half of the plants surveyed
current ly have the facilities for prestartup cleanup of the entire
feedwater/condensate train using installed condensate polishers.

One plant has backfitted a condensate filter system solely to cope with the sus
pended solids (primarily iron and copper corrosion products) encountered in the
feedwater during startup. Prior to the installation of the filter at this
plant, the hotwell and feedwater-condensate systems were cleaned up, following

4-5
 ....

-
STEAM GENERATORS
/
.....
.... -..... -...... ,...- CONDENSER

r··..,-··-u-·,- .

. DOD
1/ '' I '\ II '\

f'
\ } \ J \ }
',...... ,,....... / ' ...... / / '-_,_.../ HOTWELL

v .... )(
o J ..
t
tF'r : t
1!:::-A ;, ..
)('-!> ii . .Jb_.,l·-, NDENSATE (.;',
.If:{"' - 4
o§"'-1':".'...•,
( 1:.,. .J
,, )
. J
·-·7-'ci)LTERS ;_ OR

_/ t
MAIN FEED ..,.. GLAND COND. +
r
-I'>
HEADER
I
(j)

t·
FEEDPUMP

t
HP DRAIN PUMP
1 TYPICAL CLEANUP RECIRCULATION PATH
2 CONDENSATE FILTER PATH- NOT USED IF COND. POLISHER AVAILABLE
3 SHORT RECIRCULATION PATH TO CONDENSER
4 AlTERNATE PATH TO CONDENSER SHELL
5 ALTERNATE PATH TO CONDENSER (LOWER SHELL)
6 SLOWDOWN OR DRAIN TO WASTE
7 DOTTED LINES DESIGNATE ALTERNATE CLEANUP PATHS (I.E., 2, 3, 4, 5,6)

Figure 4-1. Schematic of Feedwater Train Prestartup Cleanup Paths

 TABLE 4-1
SUMMARY OF PRESTARTUP SECONDARY srsTEM CLEANUP PRACTICES
Chemistry Time to
Objective Clean up
Take-off Entrx {In hes) I ut'M/%MCR I (ms/cm or 2b) Oeaeration Features
Plant Cleanup Method

Recirculation through FW-Cond. Down Stream of Hotwell 10 3000-6000 cc(al<o.3 < 24 Condenser, after draw-
Trojan Train & through condensate H.P. heaters 9-18 02<5,1l"a<1 ing vacuum with air
polisher SS lO ejectors

Recirculate through FW-Cond. Main FW Header Condenser 16 8000 cc(al<o.1 24-36 Vacuum pumps, hot well
Salem 1 steam spargers,
Train and through condensate up steam of Shell 25 o2<5
poll sher. FW pumps have 16" S.G. 1 ines. SS<100 recirculate to con-
bypass around them. denser shell.

Millstone 2 Recirculate through FW-Cond. Downstream or HP Hotwell

heaters
- 3000-4000
15
SS<100 24 Condenser, after draw-
i ng vacuum.
Train and through condensate
polisher.

Ginna Recirculate through FW-Cond.

Train and through condensate
Downstream of
HP heaters
Hotwell - 3200
2l
cc(al<0.4
Na 0.3
24 Condenser, after draw-
1 ng vacuum with air
ejector•
...,. polisher. Cl 0.3
I
'-J Ooel 1,2 Recirculate through Cond.
System and through condensate
F eedwater pump
discharge
Hotwell 8 ( wo) - Na<1
02<300
- Condenser, after draw-
ing vacuum with air
polisher. ejectors.

Red rculate through FW-Cond. Main FW header Condenser 10 3000 cc(alqo 24 Vacuum pumps , hot we11
Arkansas 1
train and throug condensate stream of HP Shell 12 o2<7 spargers, recirculate
poll sher. to condenser shell.

Rancho Seco Reel rculate through F\1-Cond. Steam generator Condenser 12 6000 cc(al<l.O - Use aux11 fary steam to
1) est. vacuum 2} heat
Traf n and through condensate feed 11 nes Shell 23 02<100
polf sher. upstream of Fe<lOO reel rcul ati ng feed-
manual stop water In llo. 4 heater.
valves

Red rculate hot well water Between gland Condenser 8 100 SS<500 <48 Establish condenser
I
Maine Yankee vacuum and rec1 rcul ate
through cleanup filter loop vfa seal condenser Shell
condensate pumps previously to condenser shell.
used drain and refill method.

Ringhals 2 Feedwater-condensate system

blowdown using hydrazf ne as
NA(b} NA IIA I IIA o2<5 48 Establfsh vacuum with
vacuum pumps.
surfactant.

NOTE: a} CC • cation conductivity

b) NA • not applicable
extended outages, by complete draining and refilling a number of times over per
iods in excess of one week. The result was that startup was subject to undesir
able delays. The installation of a condensate filter enabled the plant tore
duce the time required to bring the feedwater suspended solids concentrations
within specification to less than 48 hours, and consequently took feedwater
cleanup off the critical path during startup operations.

Without either condensate polishers or filters, prestartup cleanup is accom

plished by the blowdown method, which takes time and large quantities of water,
or simply is not done. About one third of the plants surveyed are among those
which do not perform a prestartup cleanup.

The deaeration features listed in Table 4-1 are intended to provide an indica
tion as to the oxygen removal capability during prestartup cleanup. Only one of
the plants included in the survey had an inline deaerator in the feedwater
train. Most of the PWR plants rely on the condenser to remove the air dissolved
in the water or otherwise trapped in the system during startup. Since the feed
water is initially cold, the addition of hydrazine alone is not likely to be
effective for oxygen scavenging. Thus, features which promote deaerating
condi tions in the condenser during the prestartup cleanup, when most of the
fluid inventory is recirculating through the condenser, help reduce the oxygen
content of the feedwater at the most favorable time. Otherwise, higher oxygen
levels have to be tolerated longer in the power operating period. Deaeration is
likely to be enhanced during prestartup cleanup where a vacuum can be drawn
during the prestartup period by the use of vacuum pumps, or auxiliary steam for
the air ejectors, and where steam sparging with auxiliary steam is available to
heat the hotwell water.

Further comment on each of the cleanup practices is presented below.

Recirculation Through Condensate Polishers. The condensate polisher recircula

tion combination provides the most complete prestartup cleanup method currently
in use. For example, very nearly all of the condensate-feedwater, which at
this stage may include greater than 90% of the turbine cycle fluids (exclusive
of the steam generator water), are passed through the condensate polisher where
both dissolved and suspended solid impurities can be removed. For examble Table
4-1 identifies that the. take off point of the recirculation lines is from the
feed water header downstream of the high pressure heaters in most of the plants,
and in one plant the recirculation line take off point is downstream of the main

4-1
feedwater stop valves. These arrangements provide the highest degree of invol
vement of feedwater train systems. For the most part, only the individual
feed water piping to each steam generator and the steam generators themselves are
treated separately. The feedwater piping to each steam generator is estimated
to contain less than 10% of the total secondary system water volume in a typical
plant.

Another advantage of the condensate polisher recirculation prestartup cleanup

method is the potential for moderate velocities which provide some flushing ac
tion for the removal of loose deposits and/or accumulations of insoluble corro
sion products from the internal surfaces of the feedwater pipe and heater tubes.
The transport of these deposits via the recirculation line and hotwell to the
condensate polisher provide the opportunity for their removal by the filtering
action of the polisher resin. Also, where a vacuum is achievable and the hot
well water can be heated, removal of air and noncondensibles is facilitated.
These features accelerate the cleanup and the realization of the chemistry ob
jectives, so that the approach to power operation is not delayed because of sec
ondary water chemistry deficiencies. Although the prestartup chemistry proce
dure is initiated at most plants two to three days before the scheduled day for
star tap, it was consistently reported that the chem1stry objectives could be
attained within twenty four hours.

Recirculation Filter Method. The recirculation filter system, as a method for

prestartup cleanup, has the advantages of relative simplicity, minimum capital
investment, and an effectiveness for removal of particulates approaching that of
the condensate polisher resins during the prestartup cleanup. Although, the
filter system listed in Table 4-1 is limited to filtering the hotwell water and
a small section of the condensate system, and therefore does not involve a major
part of the feedwater inventory, there is no technical reason why the filter
system could not be installed across the entire feedwater train. In this man
ner, most of the feedwater inventory could be circulated through the filters
a number of times and most of the feedwater train particulates could be
removed.
In addition, if the hotwell water has facilities for heating and a vacuum can be
established by use of vacuum pumps or auxiliary steam, then the potential for
deareation of the circulating feedwater is also available. Some reduction in
the soluble contaminants might be accomplished by blowdown of the feedwater sys
tem during the recirculation phase. A cleanup time of about 48 hours has
been reported, and this time expenditure does not delay startup operations.
The principal disadvantage of the filter system as a prestartup cleanup method
is that removal of soluble contaminants cannot be achieved other than by blow
down. Also, if only a condensate filter is used, a substantial amount of the
feedwater inventory does not have the opportunity to pass through the filters,
although, as discussed in Section 5 and indicated below, such limitations may
not have a large effect on the total secondary systems corrosion product remov
al. The major drawback of the bypass filter concept compared to the condensate
polisher is that its function is terminated once the prestartup phase is past,
and thus, corrosion products from the steam path systems and heater drains
which enter the feedwater during the subsequent startup phase are likely to be
trans ported unimpeded into the steam generators. A full flow condensate
filter, on the other hand, would function to remove corrosion products through
both the prestartup and startup phases, and might have real merit where
corrosion pro ducts are the major concern (e.g. where leak tight titanium
condensers are in stalled). A full flow filter, where applicable, may be less
costly to install
and operate, and may avoid some of the operational risks of the condensate pol
ishers, such as sodium throw and loss of resin to the feedwater.

Blowdown Cleanup Method. The blowdown, or bleed and feed, method of feedwater
cleanup has the primary advantage of not requiring the installation of substan
tial secondary auxiliary equipment. In principal, given the time and the demin
eralized water supply, both soluble and insoluble contaminants may be removed
from the feedwater inventory before they can be transported into the steam gen
erator and, if the makeup water is deaerated, the specification requirements
with regard to oxygen content might be realized in a reasonable period of time.
The disadvantages are the large quantities of water required, the very low vel
ocities through the system during blowdown, and the longer cleanup time required
compared with recirculation through a condensate polisher or filter. In some
plants the water usage, which can amount to several hundred thousand gallons,
may exceed the makeup water system and secondary water storage capacities.
Also, the very low velocities may result in little, if any, significant
flushing action. Furthermore, the time required to achieve reasonable
cleanliness is likely to be three days or more.

Drain and Refill Method. An alternate to the blowdown method is to drain and
refill several times with demineralized water. Like the blowdown method, the
quantity of makeup water required is high and dependent on the number of drain
fill cycles. However, assuming equal initial concentration of impurities, the
quantity of clean water consumed would be expected to be substantially less than
that used by the blowdown cleanup method. On the other hand, the cleanup time
will be much longer. One plant reported that using this method took over a week
following one extended outage, while a plant which uses the blowdown method re
ported cleanup in less than three days. The drain-fill method, like the blow
down method, does not provide vigorous flushing action.

Prestartup Cleanup Evaluation. The cleanup of soluble ionic species such as

sodium and chlorides during the prestartup phase is potentially very effective
where condensate polishers and recirculation cleanup lines are available. The
blowdown or the fill and drain methods are also likely to be effective in remov
ing these impurities. One reason for their effectiveness is that these methods
treat the hotwell and condensate-feedwater systems water after being filled to
the operating condition, and this water constitutes more than 90% of the
second ary operating fluid outside the steam generators. Thus, most of the
soluble ionic impurities in the secondary systems are subject to cleanup during
the pre startup cleanup phase. The recirculation filter cleanup method, or any
other purely filteration method, is not designed to remove soluble ionic
impurities.

The removal of oxygen and noncondensible gases from the secondary systems is
primarily dependent on the deareation conditions which can be established during
the prestartup cleanup; e.g., a vacuum in the condenser, and heated hotwell
water. The recirculation cleanup and bypass filter method provide an opportun
ity for the removal of oxygen from the feedwater since they recirculate the
water to the condenser where deaeration is taking place. The blowdown and fill
drain methods rely on deareation at some other time.

The removal of secondary system corrosion products during the prestartup phase
is limited to the hotwell and the condensate-feedwater system which, as discus
sed below and in Section 5, contain only a small portion (< 20%) of the total
secondary system internal surface area. The iron and copper corrosion products
in the secondary system originate on all the internal surfaces and most of them
can only be removed by fluid flushing actions not available prior to the
startup phase. Therefore, only that smaller portion of these surfaces in the
conden sate-feedwater systems is subject to cleanup during the prestartup phase.
How ever, any corrosion products removed from the latter systems will not be
trans ported into the steam generators and, since these systems cannot be
cleaned up
by subsequent operations, they must be cleaned up during the prestartup phase if
they are to be cleaned at all.
Startup Cleanup

The startup cleanup phase, as noted earlier, is arbitrarily defined as the sec
ondary system cleanup which may be accomplished when the plant is operating be
tween 10% and 50% power. Operation in this power range may last for one half
day to several days or more during the return to normal power operation follow
ing an extended outage, and the length of this period is usually dictated by
other considerations. During the startup phase there is substantial fluid tran
sport in all the major secondary systems, and these systems are being flushed
for the first time since the extended outage began, unless the condensate-feed
water train has been flushed during the prestartup phase. Thus, the main steam
system, the turbines, the MSR's, the extraction systems, the feedwater heater
shells, the heater drain systems, and the condenser shells, as well as the hot
well and feedwater-condensate systems, are now subject to significant steam
and/or water flow rates. The steam paths and condensate drain regions exclusive
of the condensate feedwater train, in a typical turbine cycle, as estimates de
veloped in Section 5 show, contain approximate 80% of the internal surface area
and, therefore, can be expected to be the source of most of the iron and copper
corrosion products residing in the secondary systems. Consequently, the poten
tial quantity of corrsion products susceptible to being transported and removed
from the cycle before entering the steam generators during the startup phase is
substantially greater than that which might be removed during the prestartup
phase. For this reason, those plant features which can facilitate the removal
of corrosion products during the startup phase are likely to contribute the most
to the task of reducing sludge transport to the steam generators when the plants
return to power operation, particularly following long outages.

The full flow condensate polisher makes the most important contribution to the
cleanup of corrosion products from the secondary systems during startup and, as
subsequently discussed, during normal power operation. More than half of the
surface area of the regions itemized above are flushed by fluids which pass
through, and are filtered by, the condensate polishers prior to proceeding
through the feedwater-condensate systems to the steam generators. In addition,
experience has shown that the condensate polishers act as effective filters in
removing corrosion products from the condensate (References 4-6, 4-8), and
therefore, from the secondary systems. It is also reasonable to expect that a
suitable full flow filter would perform in a similar manner, since suspended
solids make up the bulk of the secondary system corrosion products. It is
also evident that without a condensate polisher, or an equivalent full flow
conden-
sate filter, the corrosion products will inevitably end up in the steam gener
ators.

In those plants which have full flow condensate polishers, the potential second
ary system surface areas subject to flushing by fluids which can be filtered by
the condensate polishers is increased from 50% to 80% by returning the high
pressure drains to the condenser during the startup phase. Thus, this plant
feature extends the corrosion product cleanup coverage achievable by the conden
sate polisher during the startup phase to all the secondary system except the
feedwater-condensate systems. However, the latter systems presumably have been
subjected to cleanup by recirculation flow during the prestartup phase and, at
this point in the return to power, have already been flushed. Hence, the con
densate polisher is the plant feature which, through appropriate system align
ments during both the prestartup and startup phases, makes secondary system cor
rosion product cleanup following extended outages practical. It should be noted
that a high pressure drain filter of suitable characteristics could serve as an
alternative to returning the high pressure drains to the condenser. However,
with the present state of the art, a suitable high pressure drain filter has not

From the above, it is clear that among the plants listed in Table 4-1, those
having condensate polishers have the potential capability of cleanup of a sub
stantial portion of the secondary systems corrosion products, which might
otherwise be transported into the steam generators, during the startup phase.
Furthermore, plants such as Trojan, Salem, Ginna, Doel 1 and 2, Arkansas 1,
and Rancho Seco, have the capability of returning the high pressure drains to
the condensers routinely up to 35% to 50% power. Thus, corrosion product
cleanup is further increased during the startup phase when returning the plant
to power operation. It should be mentioned that the internal surface areas of
the MSR's and high pressure heater shells are a significant part of the total
areas and
are the reason why the high pressure drains influence corrosion product removal
capability during the startup phase.

In regard to cleanup of other feedwater contaminants during the startup phase,

the residual or hide out return impurities present during this phase are likely
to be soluble ionic species from the main steam paths and heater drains, those
from the hotwell and feedwater-condensate systems having been removed during the
prestartup phase. These impurities are subject to cleanup by the condensate
polisher, where one is installed, in the same manner as described above for the
corrosion products. The oxygen and carbon dioxide in the secondary systems pre
sent at the startup phase are controlled in the normal manner by the addition of
hydrazine to the feedwater and by pH control respectively, and to a varying ex
tent by the deaeration function of the condenser, which at low power is not
always efficient.

A consideration that should be recognized is that, in spite of the best startup

cleanup practices employed, there will be spikes in the feedwater iron and cop
per concentrations upon reaching high power operation. These may be the result
of the high flows and/or thermal transients involved. However, with positive
cleanup practices routinely employed, these spikes are likely to be relaively
small and of short duration. Conversely, in plants where positive cleanup prac
tices are not routinely employed the spikes in the feedwater iron and copper
concentrations are apt to be higher and of longer duration. These observations
were reported by a number of respondents during the field survey and are also
qualitatively discernable in the field survey chemistry information. The magni
tude and duration of the feedwater iron concentrations spikes which may occur
immediately following a startup are illustrated in Table 4-2. The data in the
table is derived from information reported in the NWT water chemistry studies
(Reference 4-6 and Appendix H)for a number of plants, and correlated with the
appropriate power history. The data in Table 4-2 shows that the feedwater iron
concentrations for the circumstances recorded, are above the average steady op
eration levels for periods of from 2 to 10 days.Since the Turkey Point, Surry
and Prairie Island units did not have condensate polishers installed at the time
the data was taken, the feedwater iron concentration represents corrosion pro
duct contributions from all of the secondary systems. Calvert Cliffs and Crys
tal River did have condensate polishers at the time the data was taken, thus the
feedwater iron concentration represent corrosion product contibrutions primarily
from the high pressure drains and feedwater train. It should be noted that the
data presented in Table 4-2 is intended simply to illustrate the type of iron
concentration spikes which have been observed, and that any further interpreta
tion of the data is subject to a number of other variables not included in the
table or discussed above.

Cleanup During Normal Operation

Although the evaluation of corrosion products transported in the secondary

sys tems during normal operation is beyond the scope of this study and is being
ad dressed in other investigations (e.g. as reported in Reference 4-6), the
fact is
 TABLE64-2
FEEDWATER IRON CONCENTRATI NS FOLLOWING STARTUP(a)

Time Period Iron

Steady Opera(iyn Startup Cone. Above Stefd1 Average Power
Iron Cone. b Iron Conc.(c) Operation Valued During Period(e)
Plant (QQb} (QQb) (Da s} (%)
Turkey Point 14.1 129 (1/16/76) 4 39
Unit 4 96 (8/4/77) 3 48
Surry Unit 2 8.5 89 (10/13/75)
57 (6/9/76)
I 3
10
65
89
Prairie Island 13.7 49 (11/23/75) I 7 83
-!':> Unit 1 127 (5/4/77) 5+ 56
.......
U1
Prairie Island 13.0 53 (12/1/75) 3 97 (steady)
230 (1/20/76) I 6 55
Calvert Cliffs 16.6 58 (9/6/76) I 3 70
Unit 1
Crystal River 17.6 37 (1/6/79) I 2 90
Unit 3

Notes::ii) Representative 1ron concentration during startup power ramps and the first several days of high
power operation. (See Table H-1 footnote(f), Appendix H.)
b) Steady operation iron concentration averaged ver long periods of high power operation.
c) Average iron concentration for transient samp e period (transient dates shown) adjusted
for feedwater variations.
d) Time above 10% power until iron concentration!drops to steady operation value.
e) Feedwater flow assumed proportional to power.
that substantial quantities of the corrosion products which enter the steam gen
erator via the feedwater are produced while the plant is at high power for long
periods of time. Estimates of the relative amounts of corrosion products trans
ported during power operation are given in Section 5. In view of this fact, one
solution to corrosion product control is the installation of either high temper
ature, high pressure filters in the main feed line, or the installation of fil
ters both in the condensate system and in the high pressure drain system. It is
equally apparent that the availability of such filter capability would minimize,
if not eliminate, concerns related to the production of corrosion product sus
pended solids during layup and/or cleanup prior to and during startup.

The plants which currently have full flow condensate polishers installed already
have, in such equipment, a reasonably effective filter for iron and copper cor
rosion products originating in the condenser and the upstream low pressure tur
bines, extraction system, heater shells and drains. The results of studies re
ported in Reference 4-6 demonstrate that condensate iron and copper concentra
tions are substantially reduced when flow is passed through the condensate pol
isher. However, these same studies indicate that the iron and copper concentra
tions in the high pressure drains are significant and since the flow in these
drains constitute 30% to 40% of the total feedwater flow, a considerable quan
tity of the corrosion products enter the feedwater and are transported into the
steam generators. Thus, a high pressure drain filter would, in conjunction with
a condensate polisher, have the capability of filtering out most of the second
ary system corrosion products without regard to the plant mode at the time the
corrosion products were released. Because of this, high pressure drain
develop ment would appear to be a worthwhile short term goal.

SUMMARY

Secondary system cleanup associated with the return to power procedures follow
ing extended outages is conveniently categorized as prestartup cleanup and
startup cleanup. Prestartup cleanup precedes significant power and involves
water flow through and flushing of only the hotwell and the condensate and feed
water systems up to the main feedwater isolation valves. The startup cleanup is
accomplished during the power ramps from low power ( 10%) to the approach to
normal power (<50%). It involves steam and/or water flow through, and flush
ing of, all of the major secondary fluid systems except for the condensate feed
water piping and equipment downstream of the condensate polishers. The pre
startup, and startup cleanups establish system alignments and conditions which,

4-1
when performed in sequence, make possible the removal of a significant quantity
of suspended and dissolved solids from the secondary systems. Without these
cleanup processes significant amounts of suspended and dissolved solids would
otherwise be transported via the feedwater into the steam generators. Normally,
iron and copper make up the bulk of the suspended solids. Furthermore, it is
often the practice to implement deaeration and oxygen control during both clean
up phases, with the result that overall oxygen control is improved. In
general, from the operating point of view, secondary system cleanup before and
during startup is directed toward eliminating dissolved ionic species and oxygen,
and establishing the required pH as well as eliminating iron and copper
corrosion products. However, since the primary interest in this study is the
elimination of corrosion products from the systems before they can enter the
steam gener ators, the emphasis in the cleanup and related discussions is on
corrosion pro duct transport.

The field survey study and evaluation of secondary system cleanup show the fol
lowing:

The four prestartup cleanup methods identified by the field survey are 1)
blowdown or feed and bleed, 2)drain and refill, 3) recirculation through
a filter loop and 4)recirculation through a full flow condensate
polisher. All of these methods serve to reduce the suspended corrosion
products con centrations in the hotwell and feedwater and condensate
system water. The blowdown, drain/fill and recirculation/condensate
polisher methods also serve to reduce the concentrations of soluble
impurities.

More than one half the plants surveyed have condensate polishers, most of
them backfitted since 1974; one utilizes a filter recirculation loop back
fitted to supplant a drain/fill method which was excessively time consuming;
two plants blowdown the feedwater train, consuming large quantities of de
mineralized water in the process, approximately one third of the plants sur
veyed do not have a prescribed prestartup or startup cleanup procedure.

The upper limit objective for suspended solids concentrations in the feed
water vary widely from plant to plant and cover a range of <10 ppb to
<500 ppb. This would appear to indicate considerable variation in the
adverse experience encountered or expected as the result of corrosion pro
duct transport. The bulk of the suspended solids are iron and copper corro
sion products.
Startup cleanup of the low pressure major steam paths, drain systems and
condenser shells automatically occurs in plants which have full flow conden
sate polishers, and is not possible in those plants which do not have pol
ishers. In five of the plants included in the survey, the high pressure
drains are returned to the condensers until 35%-50% power is attained. This
arrangement enables the cleanup of the main high pressure steam path equip
ment, MSR's and heater shells, as well as the low pressure regions mentioned
above during the one to five days the plant usually remains below 50% power
following extended outages. The latter arrangement in conjunction with a
prestartup cleanup, provides corrosion product cleanup for 100% of the sec
ondary systems. This capability is only possible in those plants which have
condensate polishers.

The cleanup combination involving a condensate polisher, high pressure drain

return lines to the condenser, and a recirculation cleanup loop is the most
effective secondary system cleanup method in use because it removes both
soluble and insoluble feedwater impurities, it is operating during prestart
up cleanup, startup cleanup and normal operation for taking corrosion pro
ducts and other impurities out of the secondary systems, and the demineral
ized water expenditure is relatively low.

The recirculation/filter loop combination in the current concept is limited

to corrosion product removal during the prestartup phase when most of the
secondary regions are not subject to flow. However, a full flow filter in
place of a condensate polisher might approach, if not equal, the
effective ness of the polisher in removing suspended corrosion products.
This alter nate may be worth considering where condenser leakage is not a
concern and the function of the condensate polisher is substantially
reduced.

The blowdown, drain/fill and recirculation/condensate polishers prestartup

cleanup methods, are considered to be effective during the prestartup
clean up for minimizing soluble impurities in the feedwater. This
capability is assumed because they treat 90% of the secondary system fluids
(not including the steam generator water) during the cleanup operation.
However, the pre startup
cleanup using any method is less than 20% effective for the removal of
corrosion products because those regions subject to prestartup cleanup have
20% of the secondary system surface area. Startup cleanup, by con
trast, involves more of the secondary systems contributing to corrosion

4-1
pro-

4-2
 duct formation. Where no cleanup is provided the corrosion products trans
ported during startup enter the steam generators.

The advantages to be gained, as noted above, by returning the high pressure

drains to the condenser during the startup cleanup provide added emphasis to
current and past proposals to filter the high pressure drains during normal
operation. The availability of such a filter in conjunction with a conden
sate polisher or full flow condensate filter would be a significant step in
reducing steam generator sludge inventories. For this reason the develop
ment of a suitable high pressure drain filter appears to be a worthwhile
goal.

The above evaluation leads to the conclusion that the most effective corrosion
product cleanup practice is one which provides for full flow filtering of the
condensate and high pressure drains during startup power ramps, and prestartup
flushing of the feedwater train. This practice, in current applications, util
izes a full flow condensate polisher in conjunction with the capability of re
turning the high pressure drains to the condenser below 50% power, and also em
ploys a feed ater recirculation line back to tl1e condenser for pr·estar tap clean-
up of the feedwater train. In principle, a full flow filter might prove to be a
suitable alternate for the condensate polisher for this purpose since the bulk
of the corrosion products are insoluble. Cleanup of only the feedwater train
water during the prestartup phase, while potentially effective for the removal
of soluble ionic impurities, is less effective for corrosion product removal.
This is because only part of the secondary systems is involved, even though
the bulk of the secondary fluid outside the steam generators is included.

The field survey and the open literature provided little quantitative data by
which the effectiveness of the secondary system cleanup methods described above
may be directly measured. However, their relative effectiveness can be estim
ated from other information which is available, particularly that provided in
the EPRI RP-404-1 and RP-704-1 reported in Reference 4-6. The following sec
tion, Section 5, presents an evaluation of secondary system corrosion product
distribution and transport which is intended to provide quantitative support for
such estimates.
REFERENCES

4-1. H. A. Klein, J. J. Krupen, W. G. Schvetzenduebel; Cycle Cleanup for

Supercritical-Pressure Units, Proc. Am. Power Conf. XXVIII (1965)
p756.

4-2. W. W. SChroedter, H. A. Klein, B. F. Love, D. E. Lyons; Bull Run

Steam
Generator Operating Experience, Proc. Am. Power Conf. XXIX (1967)
p316.

4-3. J. J. Kurpen, D. L. Dixson; Operating Experience in Cycle Cleanup for

Supercritical Pressure Units, Proc. Am. Power Conf. 30 (1968) p883-
896.

4-4. F. Gabrielli, W. R. Sylvester, Water Treatment Practices for

Cyclic Operation of Utility Boilers, International Water
Conference; Pitts burgh, PA October 31-November 2, 1978.

4-5. R. R. Beach, J. J. Bell, J. H. Hicks, F. J. Pocock; Preoperational

Water
Chemistry Control for Nuclear Steam Supply Systems, Proc. Am. Power
Conf. 35 (1973) p892.

4-6. EPRI Programs RP-404-1 and RP-704-1, NWT Corp. PWR Secondary Water Chem
istry Study, Quarterly Reports No. 116-3 to 9 and No. 133-1 to 6.

4-7. Subcommittee Report of EPRI CAC on Control Monitoring and Water Chemis
try for Startup, Shutdown, and Layup of PWR and BWR Systems, Raleigh,
N.C., January 12-13, 1978.

4-8. P. Sturla, Performance and Value of Condensate Treatment, Including

Dis solved Oxygen Removal During Startup at LaSpezia Thermoelectric
Power Plant, Proc. Am. Power Conf. XXV 1963 p 635.
 TABLE 5-l
ESTIMATES OF THE QUANTITY OF SECONDARY SYSTEM CORROSION PRODUCTS(l)

PLANT CORROSION PRODUCT TRANSPORT IN FE1DWATER CARBON STEEt )CS)

RATING(2) PER TEN MONTH'S OPERATION(3 CORROSION 4
FEEDWATER IRON COPPER IRON COPPER ESTIMATf IRON
FLOW CONC.(5) CONc.(5) OXIDE(6) OXIDE(6) CS AREA 7) OXIOE(6)
(Fe) (Cu) (Fe304) (CuO) (Fe304)
MWE ppb ppb LBS/YR LB/YR Ft2 LBS/YR
LBS/HRxl06
1100 15 10 2 1511 274 114,000 642
900 11 10 2 1108 201 100,000 564
500 7 10 2 705 128 68,000 384

NOTES:
(1)-The corrosion product estimates in this table are hypothetical. They are intended
to illustrate the range of iron and copper corrosion products that may be produced
in secondary systems.
(2) Plant ratings are representative of PWR plants.
(3) The feedwater iron and copper constituents are assumed to enter the steam generator.
(4) This data was calculated assuming a corrosion rate of 0.1 mil/yr.
(5) Typical iron (Fe) and copper (Cu) concentrations recorded in operating logs
for normal operation are: <10 ppb Fe, <5 oob Cu,
(6) Feedwater corrosion products are primarily magentite and copper oxide; steam
generator sludge is primarily magentite and elemental copper.
(7) Estimated areas based on detail study of one plant and adjusted for plants of
different rating. Piping and equipment are assumed to be carbon steel and the
surface areas are assumed to vary as the power rating ratio raised to the two
thirds exponent. Heat transfer tubing is assumed to be copper alloy and the
surface areas are assumed to vary directly as the power. The heat transfer surface
area is approximately 14 x the pipe and equipment carbon steel area.

5-3
year steel corrosion rate and that all of the corrosion is released during the
year. The iron oxide release determined on this basis is presented simply as
a comparison and to furnish another index useful for evaluation purposes.

For the purpose of obtaining another check on the quantity of corrosion pro
ducts released in a given period of time, the reported amounts of sludge re
moved by water lancing from the steam generator tube sheets of a number of the
plants included in the survey have been recorded in Table 5-2. It would ap
pear from this data, when allowance is made for plant size and the time be
tween lancings, that the quantities of sludge removed is in the same range as
the hypothetical values presented in Table 5-l. However, it should be noted
that the sludge lance data is subject to significant uncertainties such as the
period of accumulation, the relative effect of copper alloy vs. ferrous heat
transfer surfaces, and the effectiveness of the lancing process.
Normaliza tion
of the data according to plant was made as shown in Table 5-3, but as can be
seen, a discernable trend is not apparent, possibly because of insufficient
data.

CORROSION PRODUCT DISTRIBUTION

In order to be effective, secondary system layup and cleanup methods must

rea sonably conform to the distribution of the iron and copper corrosion
products throughout the turbine cycle equipment and systems, and with the
transport paths to the steam generators. While layup methods address the
means for re ducing the quantity of corrosion products formed during extended
outages, cleanup methods are concerned with corrosion products formed during
both ex tended outages and normal operations. As noted in Appendix H and
below, the corrosion products released during normal operations and during
shutdown and startup transients associated with short duration shutdowns ( 10
days) make
up the major portion of the corrosion products transported by the condensate
and feedwater. For these reasons the corrosion product distribution patterns*

* Corrosion product distribution refers to how the corrosion products are appor
tioned among the various secondary systems. Distribution patterns refer to the
characteristic manner of distribution to be expected. Relative distribution is
the fractional division among the various systems. It is assumed that the cor
rosion products reside on and are released from the surfaces from which they
originate. There is evidence, as noted in Table H-3 of Appendix H, that a por
tion of the corrosion products may redistribute throughout the secondary systems
and deposit on such surfaces as heater tube walls and flow nozzels, later being
released into the feedwater by a sequence of operational events. However, such
conditions are not considered to be at variance with the distribution and trans
port model being proposed in this section.
 Section 5

SECONDARY SYSTEM CORROSION PRODUCT DISTRIBUTION AND TRANSPORT

GENERAL

The purpose of the secondary system layup and cleanup studies is to develop
recommendations for layup and cleanup procedures and systems design guidelines
useful to the utilities for minimizing the steam generator sludge burden. A
lower steam generator sludge burden conceivably could reduce the susceptabil
ity of the steam generators to certain types of corrosion. The principle con
stituents of the steam generator sludge are the corrosion products of steel
and copper alloy secondary system (turbine cycle) components.

It has long been established that a considerable part of the corrosion pro
ducts released in the secondary system enters the steam generators by way of
the feedwater during normal operation. This has been confirmed more recently
by information reported in References 5-l, 5-2 and 5-3. However as reported
in Reference 5-3, there is evidence that feedwater iron and copper concentra
tions increase substantially during the plant's return to power, and particu
larly the return to power which follows extended outages. Estimates derived
from information reported in References 5-l and 5-2 indicate that corrosion
product ingress into the steam generators during return to power operations
may be as much as 25% to 30% of the total corrosion products delivered to
the steam generators in a given year. This additional corrosion product
burden has been partially attributed to secondary system internal surface
corrosion resulting from the exposure of these surfaces to atmospheric
conditions (air, moisture, contaminants)during the preceding shutdown.
In this regard, it
should be noted that wherever or whenever the corrosion products are formed,
they get into the feedwater by being flushed off the internal surfaces by
flowing steam and/or water during startup and power operations and subsequent
ly transported through several paths to the feedwater via the hotwell/conden
sate system and high pressure drains respectively.

A prerequisite for establishing effective layup treatments and cleanup methods

is a clear understanding of 1)the quantities of corrosion products formed, 2)
the probable distribution of the corrosion products throughout the secondary
systems, 3)the quantity of corrosion products released which can be attribu-
5-2
ted to shutdown periods versus operational periods, and 4) the principal
tran sport paths from the regions where they are released to the feedwater
being supplied to the steam generators. With these considerations in mind, an
eval uation of the information from the field survey, the literature search,
and related EPRI programs has been made in order to formulate guidelines for
the layup and cleanup recommendations to be made in the subsequent tasks of
this program. This section summarizes the results of this evaluation and is
di vided into subsections which discuss estimates for the corrosion products
formed, the distribution of corrosion products throughout the secondary sys
tems, the corrosion attributable to plant outages and the corrosion product
transport through the secondary systems to the steam generators. As noted
elsewhere, it is important to re-emphasize here that the only corrosion that
is the subject of discussion in this study is general surface corrosion, the
products of which, it is assumed, will eventually be released and flushed into
the steam generators.

CORROSION PRODUCT FORMATION

The general corrosion of the internal surfaces of the turbine cycle equipment
and systems of modern power systems is extremely low. However, because the
internal surface areas of the turbine cycle equipment and systems are very
large, the quantity of iron oxide and copper oxide, where copper alloys are
used, which can enter the steam generators over a period of time is substan
tial, and may amount to hundreds of pounds in the course of a year's opera
tion. In order to visualize the magnitude of the secondary system corrosion
products transported by the feedwater, estimates based on assumed particulate
iron and copper concentrations in the feedwater have been made for a range of
PWR plant ratings and are shown in Table 5-1. The table shows that the iron
oxide released each year may be in the range of 700 to 1500 pounds while the
copper oxide released may range from 100 to 300 pounds. The iron and copper
feedwater concentrations assumed in calculating the respective quantities
transported by the feedwater are in the same range usually reported in the
operating chemistry logs of most of the plants surveyed and are considered
representative of PWR plants in general. If the estimated corrosion product
release during the return to power operation is 25% to 30% of the yearly re
lease, then the objective of layup and cleanup operations is to reduce the
yearly amount transported to the steam generator by 200 to 500 pounds.

In addition to the yearly corrosion product release estimates in Table 5-1 the
results of a calculated iron oxide release is also shown assuming 0.1 mil per
 TABLE 5-2
PWR STEAM GENERATOR SLUDGE LANCING DATA*

SLUDGE REMOVED
DATE OF (Total lbs. for all SECONDARY HEAT TRANSFER
PLANT COMM. OP. steam generators} TUBE MATERIALS
1977 1978 1979

GINNA** 3/70 1137 578 489 Heat Trans. Surf.

CuNi, Adm.

ZION I 10/73 2294 1001 Ferrous Heat Trans. Surf.

Except MSR's CuNi

ZION II 11/74 270 1178 Ferrous Heat Trans. Surf.

Except MSR's CuNi

RINGHALS II 5/75 599 2606 MSR's HP HTR-CS

LP HTR, Cond. - Al Bronze

OOEL I** 2/75 221 HP & LP HTR-CS; MSR's

Cond. CuNi

DOEL II** 11/75 .174 HP & LP HTR-CS; MSR's

Conel. CUN1

TIHANGE I 9/75 2077 Cond.-Admiralty;

MSR, LP/HP HTR's - CS

TROJAN** 12/75 2338 Cond. - Adm; MSR,

LP/HP HTR's - CuNi

BEAVER VALLEY 4/77 513 Cond, HP/LP HTR-SS

MSR CuNi

SALEM I 12/76 1564 Originally Cond. CuNi

HP/LP HRT's-SS; MSR CuNi

* Data available is limited to steam generators of Westinghouse design because,

due to the more open tube bundle design, these have been the only steam
generators routinely sludge lanced to date (1981).
** Condensate polisher installed at Ginna in 1977. Ooel I & II and Trojan
condensate polishers were installed prior to power operation.

5-1
 TABLE 5-3
NORMALIZED SLUDGE LANCE DATA

DATE OF
PLANT COMM. NORMALIZED WEIGHT OF SLUDGE-LBS *
OP. 1977 1978 1979
GINNA 3/70 1990 1012 856
ZION I 10/73 2431 1061
ZION II 11/74 286 1249
RINGHALS II 5/75 743 3231
DOEL I 2/75 449
DOEL II 11/75 353
TIHANGE I 9/75 2472
TROJAN 12/75 2338
BEAVER VALLEY I 4/77 621

SALEM I 12/76 1595

*Normalization is based on plant size as determined by relative secondary

system internal areas. The secondary side areas are assumed to vary as
the ratio of the MWe's to the two thirds power.
throughout the secondary systems must be defined for both the operating and
the shutdown modes if appropriate layup and cleanup methods are to be identi
fied. The subsequent discussion describes a generic approach for defining
distribution patterns for general surface corrosion throughout the turbine
cycle equipment and systems.

In the formulation of the general surface corrosion product distribution and

transport patterns for normal operation applicable to all PWR secondary sys
tems it is reasonable to assume that, for the purposes of layup and cleanup,
these systems are generally the same. That is, they include the same basic
types of equipment in very similar arrangements, differing only in size and
number; that the operating environment is similar, (i.e., high pH, reducing
atmosphere of deoxygenated steam and/ or water); and that the operating chem
istry is all of volatile treatment. While there may be some differences in
the degree of chemical control and/or detail treatment (e.g., o2 concentra
tion, morpholine vs. ammonia), these differences would not be expected to be
significant in determining the relative merits of layup and cleanup concepts.
The major differences from plant to plant are in the heat transfer tube mater
ials aRd the fact tflat some plants have condensate polishers wh1le others do
not. It is expected that the effects of these fixed variations can be ac
counted for where their influence is considered significant in the distribu
tion of corrosion products in the different regions. Therefore, in the con
text of layup and cleanup, the PWR secondary systems can be considered gener
ic, and the relative general surface corrosion product distribution and the
corrosion product transport paths to the steam generators are potentially the
same on a plant to plant basis.

In estimating the distribution and transport patterns within a given plant it

is assumed that the significant corrosion product inventories are primarily
the result of general surface corrosion of the internal steel and copper alloy
surfaces. It is also assumed that during normal operation a reducing environ
ment meeting chemistry specifications (high pH, low oxygen and some excess
hydrazine in the feedwater)will result in a reasonably uniform initial oxide
film thickness on the internal surfaces of the secondary systems and equip
ment. It is further assumed that these surfaces will subsequently be subjec
ted to a very low and reasonably uniform average corrosion product release
rate per unit area during operating periods. The latter assumption is corro
borated by evidence derived from inplant data as described in Appendix G and
discussed below, although some qualification may be appropriate where persis-
tent excessive air inleakage occurs in the low pressure end of the cycle.
These assumption permit estimating approximate secondary system corrosion pro
duct distributions, sufficient for the purposes of layup and cleanup, in
terms of the relative internal surface areas of the respective carbon steel
and heat transfer materials. The corrosion product distribution and the
transport
paths can then be readily related to the major secondary equipment and systems
which include these surface areas. Using this concept, six major secondary
system regions have been defined according to the principal transport paths
from which the corrosion products can be released and transported to the steam
generators during the plants return to power and during normal operations.

The six secondary system regions, which are listed ;Table 5-4 are defined
as follows:

Region A; the high pressure drain cycle, the flow from wdich is
normally pumped into the feedwater and then into the steam generators,
consisting of the main steam piping to the HP turbines and MSR's, the HP
turbine, MSR's, MSR drains, HP extraction system, HP heater shell sides
and the HP drain system.

Region B; the low pressure drain cycle, from which steam and condensate
flows to the condenser, consisting of the MSR crossover pipe. LP
extrac tion system, LP heater shell side, LP heater drain system and the
LP tur bine.

Region C; feedwater system pipe and HP heater tube sides.

Region D; condensate system pipe downstream of the condensate polisher

(where installed); LP heater, gland steam condenser, drain cooler and
air ejector condenser tube sides.

Region E; condensate system pipe upstream of the condensate polisher.

Region F; condenser shell, tube region and hotwell

The described regions have been selected as the basis for estimating the rela
tive secondary system corrosion product distribution and potential release
into the feedwater. In selecting the systems and equipment to be included in
each region, consideration was given to those which are flushed by steam and
 TABLE 5-4
RELATIVE INTERNAL SURFACE AREAS FOR MAJOR SECONDARY
SYSTEM REGIONS ASSOCIATED WITH CORROSION PRODUCT
TRANSPORT (REPRESENTATIVE PLANTS)(a)

INTERNAL SURFACE AREA (%OF TOTAL)

DESCRIPTION
CARSON 5TEEL REAT TRANS ER 5URFACE(b)

Main Steam Pipe 38 19

HP Turbine
MSR's
MSR Drains
HP Extraction System
HP Heater Shell Side
HP Drain System
B
MSR Crossover Pipe 18 10
LP Extraction System
LP Heater Shell Side
LP Heater Drain Pipe
LP Turbine

HP Heater Tube Side

D
Condensate System Pipe; 5 9
(Downstream of Polisher)
LP Heaters, Gland System
&
Air Ejector Cond.Tube
E Sides
Condensate System Pipe 3 0
(Upstream of Cond.
F Po 1isher)
Condenser 28 53
Shell/Tube Region (26%)
Hot Well (2%)
NOTES: Total 100 100
(a) The representative plant upon which these relative areas are based has a
thermal capacity of approximately 2800 MWt. The estimated total carbon
steel surface area is 97,000 Ft.2 and heat transfer surface area is
1,400,000 Ft.2 (See Note 7, Table 5-l for adjusting actual surface areas
to other power ratings)
(b) Heat transfer surfaces are assumed to be either stainless steel, copper
alloy, or carbon steel except that the condenser tubes may be stainless
steel, copper alloy or titanium.
condensate that is subsequently returned to the feed system via the high pres
sure drains, those which are flushed by steam and condensate which subsequent
ly flows to the condenser, and the regions respectively upstream and down
stream of the condensate polishers. The condenser shell tube region and hot
well are separately identified because the latter, along with the condensate
feedwater train, are subject to recirculation cleanup flushing prior to opera
tion as described in Section 4. Table 5-4 identifies the percent of the total
carbon steel surface area and the total heat transfer surface area associated
with each region. The heat transfer surfaces may be copper alloy, stainless
or carbon steel, except that condenser tubes may be stainless steel copper
alloy or titanium. Where the heat transfer surfaces are carbon steel they are
not included with other carbon steel surface areas. Region A represents a
relatively high percentage of the total secondary system carbon steel surface
area, principally because of the MSR's. In addition as noted above, this re
gion is not subject to flushing via a recirculation cleanup system during the
prestartup phase of a plant's return to power.* In Region B the steam and
condensate flow is normally returned to the condenser and, because of this,
it is filterable by a condensate polisher during normal operation. However, it
is not filterable during the prestartup cleanup prior to startup because the
condensate flow, if any, is apt to be too low to efficiently flush these
sur faces. Regions C, 0, E and F (hotwell part)are in the cleanup flow
path where a cleanup loop and condensate polisher are provided or where
extensive
feedwater train blowdown is employed as a cleanup procedure. Region F (above
the hotwell), the condenser shell and tubes, not only includes a major portion
of both carbon steel and copper alloy (where used)surface areas, but also
most of these surface areas are neither subject to current concepts of
pre startup condensate-feedwater train cleanup nor subject to practical
layup schemes.

During normal operation and during ramp power changes associated with the ap
proach to shutdown and the return to high power operation, 30% to 50% of the
total feedflow is supplied through the high pressure drains having passed
through Region A. Because Region A contains almost 38% of the carbon steel
surface area and conducts approximately 40% of the feedwater flow,
comparable portions of the feedwater iron inventory are to be expected to come
from this

5-1
* See Section 4 for the description of cleanup modes.

5-2
region. For similar reasons the contribution to the feedwater copper inven
tory would also be expected to be significant where copper alloy MSR and high
pressure heater tubes are used. Thus, Region A is considered a major trans
port path to the steam generator.

A second major corrosion product transport path involves Regions B, E and F,

through which 60% of the feedwater flows and which contains about 49% of
the total carbon steel surface area and 63% of the heat transfer surface
area. The remaining regions, Regions C and D, account for 13% of the carbon
steel
surface area and 18% of the heat transfer area. These latter regions are
con sidered separately from the others because their location in the cycle
permits them to be included in a prestartup cleanup loop and also because
during low power startup (>10% - <50%) they will be excluded from the
benefits of
either the filter action of the condensate polisher or the cleanup action of
returning the high pressure drains back to the condenser. That is, they are
in the direct flow path to the steam generator without an easy way for flush
ing them during startup power ramps.

Table 5-5 presents the regional groupings in tabular form and the correspond-
ing relative distribution and transport. Also shown in Table 5-5 is a distri
bution derived from transport data from the NWT studies of several operating
plants as described in Appendix G. In the context of layup and cleanup the
distributions derived from the internal surface areas is considered to compare
favorably ( 25%) with those from the plant data. Also, qualtitative
support
of the Table 5-5 results relative to the distribution and transport of iron
and copper corrosion products via the high pressure drains is indicated by the
information in Table H-3 of Appendix H. This information shows that high
pressure heater fouling has occurred at Trojan and Millstone. Since both
these plants have condensate polishers which limit iron and copper transport
into the feed system via the condensate system, and since the low pressure
heaters were not fouled, the high pressure drains are indicated to be the
likely transport path for the corrosion products responsible for the fouling
of the heat exchange surfaces.

The secondary system corrosion product distribution model described above for
power operation relates the potential corrosion product release from any sys
tem or region to the internal surface area of the corresponding system or re
gion. The relationship is conveniently expressed in Table 5-5 on a percentage
basis. The next step is to determine the applicability of the model to paten-
 TABLE 5-5
SECONDARY SYSTEM CORROSION PRODUCT RELATIVE DISTRIBUTION
(NORMAL OPERATING CONDITIONS)

RELATIVE DISTRIBUTION AND TRANSPORTa

DERIVED FROM(b) AVERAGE OF(c)
MAJORb MAJOR REGION PLANT OPERATION
TRANSPORT ROUTE REGIONS SURFACE AREA DATA
Carbon Steel
HP Drains to Feedwater System A 38 32
(28)d
LP Extraction and Drains to B +E + F 49 52
Condenser and then to the (56)
Condensate Pump Discharge
Condensate and Feedwater C + D 13
Systems to Steam Generator (16)

Heat Transfer Surfaces (Copper)

HP Drains To Feedwater System A 19 25
LP Extraction and Orains to B + E +F 63 66
Condenser and then to the
Condensate Pump Discharge
Condensate and Feedwater C + D 18
Systems to Steam Generator

NOTES:
a The relative distribution is the percent of the total potential iron or copper
corrosion products released to the feedwater from the respective secondary system
carbon steel or copper alloy surfaces.
b The major regions are defined in Table 5-3.
c Average plant data is the gross average from Table G-2 in Appendix G.
d Numbers in parenthesis illustrate the possible effect where heat transfer surfaces are all
ferrous alloys such as in Prairie Island 1 & 2.
tial secondary system corrosion product formation occuring during extended
shutdowns and which become subject to release during the subsequent return to
power operation. In other words, is the distribution of corrosion products
attributable to extended shutdown, in systems not subject to a special layup
treatment, similar to the distribution of corrosion products formed during
power operation? While the actual corrosion rate is expected to be quite dif
ferent, since the environment is different, the various surfaces of the
mater ials at the beginning of the shutdown are expected to have a similar
uniform oxide coating resulting from the preceding power operation. Also these
same surfaces during the shutdown period, are to be exposed to similar
environ ments; i.e., moist air or water in contact with air, plus any
atmospheric con taminants typical of the geographical location. Thus, for
example, carbon steel surfaces in a drained MSR are exposed to the same moist
air as the car bon steel surfaces in the feedwate heaters in an untreated
system. Therefore, the carbon steel corrosion rate per unit area
during the shutdown will be the same and the corrosion product formation and
subsequent potential release will be proportional to the surface areas. Using
this rationale, it is concluded that the corrosion product distribution model
is applicable to outage corro-
slon 1n untreated systems. S1nce the corros1on product d1str1but1on 1s the
same for shutdown as it is for power operation, the transport paths during
the return to power will also be the same.

In summary, it is concluded that the above described relationship between in

ternal surface area and general surface corrosion product formation and re
lease, both during normal operation and extended outages, provides a reason
able basis for estimating the general surface corrosion product distribution
and also provides a useful tool for assessing the merits of specific layup and
cleanup practices.

CORROSION DURING OUTAGES

Estimates of the general surface corrosion of secondary system equipment dur

ing outages are needed so that the function of layup may be placed in perspec
tive. Although a thorough evaluation of corrosion rates for the outage
condi tion is a difficult undertaking, and beyond the scope of this study,
gross estimates have been made as discussed below in order to more clearly
indicate the function and benefit of special layup treatments.
The corrosion products transported into the steam generators during return to
power operations consist of some proportion of accumulated material deposited
during prior operation plus that formed during the preceding outage, and re
leased by the subsequent return to power transients. As discussed earlier in
this section, the amount of corrosion products transported in this manner
has been variously estimated to be in range of 25% to 30% of that resulting
from all operational modes (References 5-l and 5-2). In regard to layup,
the ob
jective is to minimize that portion of the potential release indicated for the
return to power operations which can be attributed to the general surface cor
rosion of secondary system carbon steel during the extended outages. Extended
outages in this context are those longer than ten days but less than six
months, since implementation of special layup treatments is apt to take most
of a week and the majority of PWR plant outages are less than six months.

Secondary system surfaces of the major equipment are carbon steel, while the
heat transfer surfaces are usually stainless steel, copper alloys, carbon
steel, or titanium. Stainless steel and titanium exhibit negligible corrosion
under atmospheric conditions and are, therefore, not of concern during out
ages. Copper alloys are less susceptible to atmospheric corrosion than carbon
steel, and for this reason corrosion of carbon steel during extended outages
is considered to be controling insofar as layup is concerned. In formulating
corrosion estimates, the assumption has been made that the secondary systems
during outages, in the absence of special layup treatements, are exposed to
moist air and/ or water in contact with air at ambient temperatures. It is
also assumed that any general surface corrosion that occurs is reasonably uni
form in extent and average thickness. It is further assumed that initially'
most of the carbon steel surfaces subject to layup treatment are covered with
a film of adherent magentite in the range of 0.1 to 0.6 mils, formed during
prior operation. The condenser, as noted elsewhere, is not readily
adaptable to practical layup treatment, and for this reason the carbon steel
and heat transfer surfaces in the condenser are excluded from layup
considerations.

In order to obtain an estimate of the potential corrosion of the secondary

system carbon steel which is attributable to extended shutdown conditions,
reference is made to the postulated iron corrosion product transport data pre
sented in Table H-2 of Appendix H. This table lists the yearly corrosion pro
duct release estimates derived from the NWT secondary water chemistry studies
reported in Reference 5-3. The corrosion product release in Table H-2 calcu
lated for a two month long extended shutdown averaged 37 kg (82 lbs.).
Assum-
ing that the corrosion product release shown in Table H-2 is reasonably repre
sentative of the corrosion products formed during a typical outage and that
2
the carbon steel surface area for the plants involved averages 94000 ft
(based on correlation in Table 5-1), then the corrosion rate would be approx
imately 0.13 mil per year (MPY), with a maximum rate indicated by the Table
H-2 data of 0.17 MPY.

It should be noted that corrosion data applicable to secondary system carbon

steel materials was not found during the detail review of the open literature
described in Section 2. While the literature does list numerous investiga
tions of the corrosion of carbon steel exposed to a wide variety of atmospher
ic conditions, as exemplified by References 5-4, 5-5, and 5-6, these studies
were invariably orientated to the exposure of initially clean steel specimens
to outside environments not considered typical of secondary system
conditions.

To demonstrate the relationship between the corrosion product release attribu

table to extended shutdowns and that of plant operational modes, the calcu
lated release/transport of iron corrosion products listed in Table H-2 is pre-
sented graphically in Figure 5-1. In this figure the yearly release attribu
table to steady operation of ten months duration, transient operation assuming
one transient per month for ten months, and one extended shutdown of two
months duration is shown for Turkey Point 4, Surry 2, and Prairie Island 1 &
2, the latter being taken together. These data indicate that the average cor
rosion product release for all the plants resulting from a two month
shutdown, is approximately 6% of the total yearly average release (i.e. 37
kg vs 581
kg). The corrosion product release for a six month shutdown would be about
three times this value, or 19%. Thus, on the basis of these estimates, the
benefit to be derived from special layup treatment is about a 6% reduction
in the corrosion product release for a two month shutdown, and about 19%
reduc tion for a six month shutdown.

CORROSION PRODUCT TRANSPORT

In order to more clearly understand the functions of layup and cleanup, the
role of secondary system flow and temperature transients in the release of
surface corrosion products into the steam and/or water fluid streams must be
appreciated. These transients typically accompany plant power transients,
including those associates with startup and shutdown operations. The role of
5-15
these transients in corrosion produce release is clearly demonstrated by the

5-15
 1Qr-*R-E-F-E-R-T-O--T-AB-L-E-H--2, -AP-P--
H
---------------------------------------------------------
F<<>J EXTENDED SHUTDOWN

TRANSIENT OPERATION

- STEADY OPERATION
TEN MONTHS OPERATION, TWO MONTHS
"?i L 18 kg SHUTDOWN, ONE TRANSIENT /MONTH
Cl
..:.1:
0
0
.-
1-
a:
0
a.
CA
U"1
I
z
<(
.......
0'> a:
1-
z
0
a:

0
TURKEY PT4 SURRY 2 PRAIRIE IS 1 & 2

Figure 5-1. Normalized Yearly Iron (Fe) Transport

data reported by the NWT secondary water chemistry studies (Reference 5-3)
and has also been mentioned from time to time in the literature on the subject
(References 5-2 and 5-7). Secondary system transients consistently result in
substantial increases in the amounts of iron and copper corrosion products
transported by the feedwater, condensate, and high pressure drains. These
corrosion product transport increases, as they are related to transients, are
illustrated by the corrosion product transport data presented in Table H-1 of
Appendix H and reproduced in a condensed form in Table 5-6. The data show
that for an average transient event the corrosion product release into the
feedwater, except for the iron release in the case of Crystal River, is equiv
alent to from 30% to 90% of that released during an entire month of
steady operation. This data infers the following:

There is a surface accumulation of loose corrosion products up to some

threshold during steady power operation, not necessary at the location
formed, and possibly to a greater degree in heat exchange equipment.

The threshold for retention of these loose corrosion products is signifi-

cantly lower dYring traMients.

The increase in the corrosion product release is caused by the transient,

but the corrosion products were formed during the prior steady operation.
Furthermore, it is probable that an even lower threshold of retention and
hence, greater release, is to be expected where the transients are signi
ficantly more severe; such as startup of a cold plant following extended
outages, where pumps are cycled and heatup and cooldowns occur several
times in the course of a few days.

The mechanism of corrosion product release suggested by the above lead to the
conclusion that secondary system corrosion products are primarily formed dur
ing normal steady power operation, will be released into the steam/water
streams and, baring barriers such as condensate polishers, will end up in the
steam generators. Thus, cleanup methods applied both during return to power
operation and during normal operations are the princ.ipal means for reducing
steam generator sludge inventories.

Another corrosion product transport consideration, which is important in as

sessing cleanup methods, is the corrosion product transport paths from the
regions where they are formed to where they enter the feedwater. In this
re-
5-1
 TABLE 5-6
IRON AND COPPER FEEDWATER TRANSPORT ASSOCIATED
WITH STEADY AND TRANSIENT OPERATIONS

AVERAGE TRANSPORT AVERAGE QUANTITY TRANSPORTED

PLANT FOR STEADY OPERATION(a) DURING TRANSIENT EVENT(b)
Fe Cu FE Cu
kg/mo kg/mo lL
Turkey Pt. 4 42.2 5.3 24.4 4.4
Surry 2 27.4 5.2 23.6 4.6
Prairie Is. 1 29.3 (c) 20.4 (c)
Prairie Is. 2 26.0 (c) 11.7 (c)
Calvert Cliffs 2(d) 64.5 2.0 23.1 1.0
Crystal River 3(d) 53.0 0.3 3.9 0.13

NOTES:
(a) Steady operation is power above 50% for extended periods of time. The
average excludes any input due to transient events.
(b) Transient events include startup power ramps associated with short
duration shutdown, reactor trips and significant power
perturbations. The average includes those events recorded in Table H-
(c) 1, Appendix H. Prairie Is. plants heat transfer tube materials are
(d) stainless steel. Calvert Cliffs and Crystal River plants have
condensate polishers.
gard, as noted in Section 4, the cleanup of the secondary systems is
dependent on the availability of adequate steam and/or water flow in the
several major regions defined in Tables 5-4 and 5-5. Except for the hotwell,
condensate and feedwater systems (Regions F-Hotwell, C and D), significant
steam and water flow is not available during return to power operations until
startup power ramps are initiated. For this reason, and to account for the
two flow reg imes, the arbitrary distinction was made in Section 4 that;
1. prestartup cleanup would apply to that accomplished by either recircu
lation flow, blowdown, or bleed and feed through Region C, 0 and
F (Hotwell) up to 10% power levels and
2. startup cleanup would apply to the startup power ramps in the 10% to
50% power range.
3. Steam and water flows above 50% power are defined as power operation
conditions.

Using these designations, the transport paths of iron and copper corrosion
products to the steam generators from the six major secondary system regions
defined in Table 5-4, as influenced by the plant operation modes, are summar
ized in

The information in Table 5-7 provides a useful guide for estimating the
poten tial impact that specific layup and cleanup methods will have on
minimizing corrosion product transport into the steam generators. For
example, the layup and/or prestartup cleanup of the condensate system (Region
0 and E) and feed water system (Region C) affects less than 20% of the
corrosion product distri bution. On the other hand full flow condensate
polishers, when effective, affect 49% of the iron oxide and 63% of the copper
oxide distribution during power operation modes. Similarly, during the
startup mode (10%- 50% power), if the high pressure drains are returned to
the condenser, the condenser pol isher will process 84% of the iron and 82%
of the copper corrosion product distribution. Considerations similar to these
will be included in formulating the layup and cleanup guidelines for
subsequent tasks of this program.

SUMMARY

The purpose of the evaluation of the secondary system corrosion product trans
port described in this section was to provide a clearer understanding of the
quantity of corrosion products formed, their probable distribution, the
amount attributable to outages, and a determination of the paths by which they
are
 TABLE 5-7
SECONDARY SYSTEM CORROSION PRODUCT TRANSPORT
Secondary Estimated
System Distributi?n Plant Transport Path to Steam
Region {Percent) a) Mode Generators(b)
Carbon Heat
Steel Transfer
A 38 19 Power Op. Heater Drain System to Feed
System
Startup Heater Drain System to Feed
System or Back to Condenser
Prestartup Zero
B 18 10 Power Op. LP Extraction & Drain
Systems to Condenser
Startup LP Extraction & Drain
Systems to Condenser
Prestartup Zero
c 8 9 Power Op. To Steam Generators
Startup To Steam Generators
Prestartup To Feedwater Slowdown.or
Cleanup Loop to Condenser.
D 5 9 Power Op. To Feedwater System
Startup To Feedwater System
Prestartup To Feedwater System and/or
Cleanup Loop to Condenser
F 28 53 Power Op. To Condensate System/
(Above Hotwell) Condensate Polisher
Startup To Condensate System/
Condensate Polisher
Prestartup Zero
Hotwell & E 5 0 Power Op. To Condensate System/
Condensate Polisher
Startup To Condensate System/
Condensate Polisher
Prestartup To Condensate System.
Feedwater System, Slowdown
or Cleanup Loop.

NOTE:
(a) The percent of the total corrosion product release based on relative
internal surface area defined in Table 5-4.
(b) Note·that zero transport means that the relative quantity released
proportional to the distribution will be transported during one of the
other operating modes.
transported into the steam generators. To this end the evaluation has yielded
the following:

An estimated 700 to 1500 pounds of iron oxide and 100 to 300 pounds of
copper oxide are transported through the feedwater system each year as
the result of steady plant operation. The actual amount depends on the
size
of the plant and the availability of installed cleanup features. An es
timated twenty-five to thirty percent additional transport may be expected
as the result of startup operations.

A corrosion product distribution concept has been formulated based on the

relative internal surface areas of carbon steel equipment and the second
ary heat transfer surface areas. This concept provides a useful tool for
estimating the relative corrosion product distribution throughout the
major secondary systems and their associated equipment, and the relative
potential corrosion product contribution of each system to the steam gen
erator sludge inventory.

The extent of corrosion of carbon steel attrib table to outages of s1x

months or less has been estimated to consitute twenty percent or less of
the total secondary system corrosion product release for any one year.

Using the corrosion product distribution concept, major transport paths

have been described for the plant modes associated with the plant return
to power operation.

The above information is to provide to supplement the secondary system layup

and cleanup evaluations presented in Sections 3 and 4.

REFERENCES

5-1 Report of the Subcommittee for Control, Monitoring and Water Chemistry
for Startup, Shutdown, and Layup of PWR and BWR Systems. EPRI
Corrosion Ad visory Committee - Raleigh Meeting, January 1978.

5-2 S. G. Sawochka, R. A. Burns - Feedwater System Chemistry in the Nine Mile

Point Boiling-Water Reactor. Proc. American Power Conference 34 1972,
610-671.

5-22
5-3 EPRI Program RP404-1 and RP704-1, NWT Corp.PWR Secondary Water Chemistry
Study; Quarterly Reports Nos. 116-3 to 116-9 and Nos. 133-1 to 133-6
(Jan.
1976 - Sept. 1979).

5-4 Herbert Guttman, P. J. Sereda, Measurement of Atmospheric Factors

Affect ing the Corrosion of Metals, ASTM STP 435 American Society for
Testing and Materials (1968) pp. 326-359.

5-5 P. J. Sereda, Wheather Factors Affecting Corrosion of Metals, ASTM STP

558, American Society for Testing and Materials (1974) pp. 7-22.

5-6 F. H. Haynie, J. B. Upham, Correlation Between Corrosion Behavior of

Steel and Atmospheric Pollution Data, Corrosion in Natural Environments,
ASTM STP 558, American Society for Testing and Materials (1974) pp.
33-51.
5-7 J. Brown, N. J. Ray, R. R. Harries, E. Reeves; The Waterside
Chemistry of
a Supercritical Unit, International Water Conference, Gieirs, France,
Sep
tember 1974.
 Section 6

TECHNICAL RESULTS AND CONCLUSIONS

GENERAL

Secondary system corrosion products of iron and copper (where copper alloys are
used) are transported into the steam generators in signficant quantities via
the feedwater. These corrosion products, in the form of sludge, have been
known to contribute to conditions conducive to steam generator tube corrosion
and have been associated with the tube denting phenomenon. In addition, the
corrosion products may possibly contribute to the loss of secondary system
and/or turbine performance by tube or turbine blade fouling. Feedwater iron
and copper concentrations have been observed to be in excess of normal values
by as much as two orders of magnitude during plant startups, particularly fol
lowing extended shutdowns. For this reason secondary system layup treatments
applicable during the shutdown periods and/or secondary system cleanup proce
dures for use during a plant's rett:lrfl to power liave been cons1dered or applied
in order to help minimize the transport of these corrosion products into the
steam generators. The investigation described in the preceeding sections of
this report evaluates the layup and cleanup practices in the operating PWR
plants, as well as related information in the literature and related EPRI pro
grams. The results of the evaluation are intended to provide the bases for
layup and cleanup recommendations to be formulated in the subsequent tasks of
this program.

The investigation consisted of a field survey of fourteen PWR plants including

European and Japanese as well as domestic plants. The information obtained
from the field survey was supplemented by a review of the open literature and a
detail study of applicable corrosion product transport data reported by NWT
Secondary Water Chemistry Studies for the EPRI RP404-l and RP704-l programs.
The principal results and conclusions of this evaluation are presented in the
subsequent subsections which discuss layup practices, cleanup practices and
corrosion product distribution and transport.

The functions of layup and cleanup, in the context of this evaluation, are to
significantly minimize iron and copper corrosion product transport into the
steam generators, primarily following extended outages, for the overall
purpose
6-2
of reducing the steam generator sludge burden. Layup fulfills this function by
minimizing the corrosion of carbon steel internal surfaces in the secondary
equipment during extended shutdowns. The benefit which can be expected to ac
crue from a layup treatment is dependent on the degree to which atmospheric
corrosion of carbon steel is likely to be reduced by the treatment. This in
turn is dependent on the portion of the total secondary systems internal sur
face area subjected to the treatment and/or, inversely, the extent to which
corrosion would have occurred without the layup treatment. The latter is pri
marily a matter of time and the conditions of exposure.

The function of cleanup is to remove corrosion products from the secondary

sys tems before they can be transported into the steam generator, regardless
of their source or when they are formed. The benefits which accrue to cleanup
processes/procedures are directly dependent on the degree of system flushing by
secondary steam and/or water which can be subsequently effectively purified
before becoming part of the steam generator feed water. This, in turn, is sub
ject to secondary system features which promote suitable flushing and
filtering at appropriate times during the startup operations. Because the
objective of cleanup is to eliminate all iron and copper corrosion products
from the second ary systems that are transportable without regard to when they
were formed, cleanup provides a broader range of benefits than layup and,
therefore, poten tially is capable of a greater reduction in the steam
generator sludge burden. However, both treatments serve complimentary or
supplementary functions.

SUMMARY OF RESULTS

Layup Practices

The secondary system prescribed layup treatments which have had varying appli
cation in PWR plants are forced air drying, dehumidified air drying, wet
layup and nitrogen blanketing or purging. Of the plants surveyed,
approximately 70 percent of the secondary system equipment which are potential
candidates for layup, are not routinely placed in a prescribed layup
condition. This means
that the secondary systems in most plants are left in the as-is mode during
11 11

extended shutdowns, while in the remaining plants one or more systems (but
not all)will receive a prescribed layup treatment on a routine basis, but not
at all times. All four prescribed layup treatments, if properly implemented
and maintained, have the potential for reducing carbon steel corrosion within
the secondary systems to very low values during extended shutdowns.
Most of the utility personnel contacted generally favor prescribed secondary
system layup treatments as a worthwhile goal. However, they invariably noted
the inherent practical difficulties encountered in both establishing, and sub
sequently controling, prescribed layup treatments. The most significant of
these are that the secondary systems are not especially designed to facilitate
implementation, maintenance, and control of prescribed layup treatments; the
implementation is difficult and time consuming; plant resources (e.g. deminer
alized water) are not always adequate; and conflicts with equipment inspection
and maintenances schedules are inevitable. System, and possibly other BOP mod
ifications, are required to offset these difficulties. In addition, underlying
the lack of positive layup practices in some plants was the judgement that sec
ondary system cleanup may be a suitable alternative to layup. In those minor
ity of plants where positive layup policies are evident, the motivation was
either specific equipment problems or the urgent concerns of the equipment sup
pliers. The prominent example of the latter is the across the board wet layup
of steam generators.

A comparative evaluation of the four prescribed layup treatments identified

earlier has been mad€! coAsideriflg the cr iterla of corros10n prevention, suit-
ability of application, relative ease of implementation and control, the
burden imposed on available resources, and the degree of system changes and/or
new equipment additions. The results of the comparison were that the indicated
secondary system layup choices are dehumidified air drying, forced air drying,
nitrogen blanketing and wet layup, in that order. Wet layup, in any event, is
only applicable to the condensate-feedwater train and the feedwater heater
shells. It was also the consensus of survey respondents that layup of the con
denser shell is not practical with current plant designs because of the large
volume involved and the difficulties in assuring closure for the duration of
the outage.

Cleanup Practices

Secondary system cleanup may be conveniently defined as either prestartup

cleanup or startup cleanup. Both of these cleanup modes consist of establish
ing system alignments and conditions, and the utilization of specific plant
features which make possible the removal of suspended and dissolved solids from
the secondary system fluids. The objective is to reduce feedwater impurities
to the lowest possible levels in order to minimize transport of these impuri-

6-3
ties into the steam generator. Prestartup cleanup precedes significant power
and involves flushing of the hotwell and condensate-feedwater train. The
startup cleanup is accomplished during the up power ramps from low power
( 10%) to the approach to normal power (<50%) and involves steam and/or
water flushing of the steam path equipment, heater shells, drains and conden
ser. In current practice, a pre-requisite plant feature for startup cleanup is
the availability of a full flow condenser polisher. For both modes of cleanup,
the emphasis in this study is on the reduction of feedwater corrosion product
transport into the steam generator, although from a plant operating point of
view, the reduction of feedwater soluble ionic impurities and dissolved
oxygen, and the establishing of the required pH are normally concomitant
concerns.

The currently employed prestartup cleanup practices identified by the field

survey are recirculation of hotwell and feedwater train water through a full
flow condensate polisher, recirculation of condensate through a filter loop,
blowdown (bleed and feed) of the hotwell and condensate-feedwater system water
and drain and refill of the condensate-feedwater systems. Over one half the
plants surveyed have full flow condensate polishers and have the capability of
recirculation cleanup of the feedwater. One plant replaced the time consuming
fill and drain method with a condensate filter loop for removing suspended sol
ids from the condensate. Two plants blowdown the hotwell and feedwater train
until dissolved and suspended solids concentrations are below acceptable val
ues, utilizing large quantities of demineralized water. Approximately one
third of the plants do not have a prescribed prestartup or startup secondary
system cleanup policy.

The startup cleanup practice is restricted to those plants which have full flow
condensate polishers. The condensate polisher treats the condensate from the
low pressure steam path equipment, extraction system, low pressure heater
shells and drains, the condenser shell and hotwell. Soluble and transportable
suspended corrosion products are removed with high efficiency from the conden
sate originating in these regions. In addition, one third of the plants sur
veyed have the capability of returning the high pressure drain water back to
the condenser at power levels up to 50% power. Since this capability permits
the condensate polisher to also treat the condensate from the high pressure
steam path equipment such as MSR's, heater shells and drains, the startup
cleanup is substantially more comprehensive than where the high pressure drain
return feature is not available. The combination of condensate polisher, high
pressure drain return and the prestartup feedwater recirculation loop features
lease is a strong function of the interval between transients during
operation, a somewhat lesser function of the severity of the transient, and
only a minor function of layup corrosion during outages of normal duration.
This supports the position that most of the corrosion products are formed
during normal oper ation, and that cleanup is a viable way of removing them
from the system. Lay up, on the other hand, only addresses the corrosion of
carbon steel during out ages and, contrary to appearances, corrosion reactions
occuring during these outages are not the principal cause for the high
corrosion product release
rates observed during startups following extended outages.

CONCLUSION

The layup and cleanup evaluations described in this report are intended to form
the bases for more specific recommendations on layup and cleanup methods in
Tasks 400 and 500 of the secondary system layup and cleanup evaluation pro
gram. The overall conclusions indicated by the results of the evaluation sum
marized above are:

Those cleanup and/or layup methods which do 11uL Involve the major steam
path regions of the secondary systems are not efficient in minimizing cor
rosion product transport to the steam generators. Unlike other secondary
system impurities which originate externally and whose ingress is apt to be
localized, corrosion products are internally generated on the surfaces of
all the secondary equipment. Therefore, those systems with the largest
surface areas, such as the steam piping, turbine, MSR's, heater shells and
condenser shells, can be expected to release substantially proportional
amounts of corrosion products to the secondary fluids for eventual trans
port to the steam generators.

Full flow condensate polishers in conjunction with system features which 1)

permit return of the high pressure drains to the condenser up to 35% to
50% power and 2) provide feedwater recirculation cleanup paths for
prestartup cleanup, provide the most efficient cleanup of secondary systems
likely to be attained during the return to power operation procedures
following ex tended outages. These combinations involve all the secondary
systems in
the flushing process, with subsequent filtering of suspended corrosion pro
ducts and removal of soluble impurities from the system fluids before they
can be introduced into the feedwater going to the steam generators. The
6-7
condensate polisher in conjunction with the high pressure drain return to

6-8
the condenser during startup operations (10% 50% power), involves as
much as 80% of the total secondary systems internal surface area, while
the feedwater train involves the remaining 20%. These considerations
support the known position that the basic corrosion product cleanup
function is largely a matter of filtering the condensate at suitable
locations. This
in turn indicates that the cleanup recommendations to be developed as part
of the subsequent tasks of this program should concentrate on the applica
tion of alternate filtering methods and potential plant features or
proce dures which will enhance the effectiveness of the filters.

The most feasible layup treatments for secondary systems during extended
shutdowns are dehumidified air drying, forced air drying and nitrogen
blanketing or purging. Wet layup is applicable only to the feedwater train
and heater shells. Special layup treatment for the condenser shells, as
noted earlier, is not considered practical. The dry layup and/or nitrogen
layup treatments are adaptable to all the secondary system steam path re
gions, as well as the feedwater train and heater shells. Since steam path
regions contain a major part of the carbon steel surface area, layup treat
ments suitable to them have the highest potential for limiting the forma
tion of iron corrosion products during extended shutdowns. In addition,
dry layup and/or nitrogen layup treatments are flexible in regard to
initi ation of the layup, subsequent interruption for maintenance, ease of
con trol, and ease of termination. These considerations indicate that the
em phasis, for layup recommendations to be developed in subsequent tasks of
this program, be placed on dry layup and nitrogen blanketing treatments.

The benefits which accrue to the use of special secondary system layup
treatments in reducing corrosion product formation during extended shut
downs are apt to be limited. They are dependent on the length of the shut
down, the extent to which all the secondary system regions can be involved
in the layup treatment in an uninterrupted manner, the potential for atmos
pheric corrosion, the presence or absence of carbon steel heat transfer
tubes, and the adequacy of the plant cleanup processes. For example,
with out the benefit of a special layup treatment the potential secondary
system corrosion product release for systems which do not include carbon
steel
heat transfer tubes is estimated to be < 0% for outages under two months
duration and <20% for outages under six months duration, of the total
releases in a normal year. Using these values as the maximum prevention
provided by the special layup treatment, it can be seen that (a)where
make it possible to subject all the major secondary systems to the cleanup pro
cess. A full flow condensate filter could conceiveably serve the same
function as the condensate polisher.

The effectiveness of the four prestartup cleanup practices in reducing corro

sion product transport into the steam generators is judged to be less than 20%
because the secondary system regions involved represent less than 20% of the
surfaces subject to corrosion product formation; i.e., the hotwell and conden
sate-feedwater systems. Startup cleanup, by contrast, involves regions which
contain 40% to 80% of the secondary system surface areas subject to corrosion
product formation and, therefore, is potentially capable of reducing
transport of corrosion products into the steam generator by proportionately
larger amounts.

Corrosion Product Distribution and Transport

An estimated 700 to 1500 pounds of iron oxide and 100 to 300 pounds of copper
oxide (where copper alloys are used) are transported to the steam generators
by the feedwater each year d11ring steaEiy plaRt opel atio11. These est1mates
were made based on representative average iron and copper concentrations
obtained from secondary water chemistry operating data. The actual amount is
dependent on the plant size and installed cleanup features. An additional
amount ranging
from about 10% to 80% of the steady power operation value may be transported
during startup operations associated with short duration shutdowns. The amount
of transported iron corrosion products attributable to extended shutdowns of
six months or less has been estimated to be less than twenty percent of the
total for any one year.

A simplified generic corrosion product distribution model has been formulated

which relates corrosion product release to the internal surface areas of carbon
steel equipment and to the secondary system heat transfer surface areas. The
model assumes that the corrosion product release and transport is approximately
proportional to the relative internal surface areas of the major secondary sys
tems and equipment, including heat transfer surfaces. Comparisons of the rela
tive corrosion product release derived from available plant data with the re
lease estimated by use of the model indicate agreement sufficient for the layup
and cleanup evaluation purposes. The model provides a useful tool for asses
sing the potential corrosion product relase from the major secondary regions

6-5
and the degree to which layup or cleanup practices can be expected to reduce
corrosion product transport into the steam generator.

Using the model to estimate the relative corrosion product release during
startup and normal operation, 38% of the iron and 19% of the copper (where
used) corrosion products are released from the high pressure steam and related
systems and equipment via the high pressure drains; 18% of the iron and 10%
of the copper are released from the low pressure steam and related systems and
equipment via the low pressure drains to the condenser; 28% of the iron and 53%
of the copper are released from the condenser; and 16% of the iron and 18% of
the copper are released in the condensate-feedwater train.

The internal surface area model is also useful in estimating the relative con
tribution of the major secondary system regions to potential (carbon steel)
corrosion product release attributable to extended outages. The assumption for
applying the model, in this case, is that in the absence of a prescribed layup
treatment, the major secondary systems during extended shutdowns are exposed to
moist air or water in contact with air and, therefore, the general surface cor
rosion and the subsequent corrosion product release, under the influence of
steam and/or water flows during startup is proportional to the carbon steel
surface area. It is judged that carbon steel corrosion during extended shut
downs or outages is controlling, that corrosion of copper alloys is very low,
and that the corrosion of stainless steel and titanium is negligible. The ap
plication of the model to corrosion product formation during extended outages
leads to the conclusion that the high and low pressure steam path systems,
equipment and drains, potentially contribute 56% of the corrosion products
formed during extended outages, and that layup treatments must take this into
account. As noted elsewhere, it is the consensus of operating personnel that
layup of the condenser, which according to this model potentially contributes
28% of the outage corrosion product release, is impractical. The condensate
feedwater train potentially contributes 13% to 16% of the corrosion product
release attributable to extended outages. Note that these estimates would be
different for plants with carbon steel feedwater heater tubes.

An important consideration in the understanding of the relative functions of

layup and cleanup in the corrosion product transport control of secondary sys
tems is the role of power transients (flow and temperature transients)on cor
rosion product release. An evaluation of the NWT secondary water chemistry
study data noted in Section 5 shows that the amount of corrosion product re-
 either the duration of the shutdown, or the period of uninterrupted treat
ment, is short or (b)where the surface areas of system regions subject
to treatment are relatively small, and where carbon steel heat transfer
tubes are not used; the degree of prevention to be expected will be low
unless the potential for corrosion attributable to the specific plant
environment is unusually high. Furthermore, although layup may supplement
cleanup in corrosion product control, cleanup is the preferred method
because, unlike
layup, it exerts control over corrosion products formed during operation as
well as during shutdown. For this reason, where adequate cleanup is avail
able, layup may not be warranted. Thus, the possible benefits of layup
for a given application at a particular time must be determined by an
evalua tion of these considerations on a specific plant basis.

The above conclusions were mainly derived from information obtained from the
field survey of representative PWR plants, the open literature, and the EPRI
RP404-l and RP704-l programs on secondary water chemistry. These sources were
not expected to provide quantitative data directly applicable to this layup and
cleanup evaluation program. Consequently, the conclusions reflect a strong
dependence on qualitative information and inferences drawn from the quantita-
tive data available from these sources. For this reason, the quantitative re
sults presented in this discussion are not intended to be precise. Neverthe
less, the general conclusions are not expected to change greatly in the light
of better information. For example, steam path vs feedwater train corrosion
rates would have to differ drastically, either during normal operation or dur
ing extended shutdowns, to affect the cleanup objective of flushing all
systems and filtering the condensate during the return to power operations.
Similarly, where layup is desireable, the layup objective of treating all
systems is still applicable inspite of postulated wide variations of corrosion
rates from system to system. If untreated layup general surface corrosion
rates are substantial ly higher than those derived in the study, then layup may
play a larger part in corrosion product control. However, the preferred
position of cleanup in cor rosion product control is not altered because, as
noted above, cleanup removes corrosion products released irrespective of there
being formed during layup periods or normal operations.

The foregoing study is considered to have fulfilled the objective of Task 200
to evaluate current and proposed layup and cleanup practices applicable to PWR
plants, and to summarize pertinent relevant information of potential interest
to the industry. In this regard, the results and conclusions of this evalua-

6-9
tion may be considered to provide support for concepts either already known or
intuitively understood, rather than to provide new knowledge. However, in the
course of gathering the pertinent information on layup and cleanup, the func
tion of both activities, and the relationship between them has been highlighted
in a manner not evident in the available literature. This may contribute to a
clarification of the many interrelated factors involved in the respective pro
cesses. In addition, the "relative surface area - corrosion product release"
model, although approximate, has been formulated, and provides a useful tool
for estimating the potential impact of layup and/or cleanup methods on second
ary system corrosion product control. The model may aid utility personnel in
making estimates appropriate to their specific plants.
 Appendix A

SUMMARY OF LITERATURE SEARCH

1. F. Gabrielli, W. R. Sylvester, Water Treatment Practices for Cxclic

Opera tion of Utility Boilers, International Water Conference;
Pittsburgh, PA October 31-November 2, 1978.

Outlines the basic cleanup practices recommended by CE including full flow

condensate polisher and pre-boiler cleanup loop. Filters for condensate
downstream of LP heater described. Layup procedures for drum units summar
ized. Article addresses fossil boiler plants. (See 13 and 18 below).

2. Subcommittee Report of EPRI CAC on Control Monitoring and Water Chemistry

for Startup, Shutdown, and Layup of PWR and BWR Systems, Raleigh, N.C.,
January 12-13, 1978.

Outlines major issues on corrosion product and other contaminants in the

feedwater. Ontario Hydro reports a number of insights in their evaltHltion
of corrosion product transport.

3. Niculau Figueiredo De Almieda; Anti-corrosive Methods for Waterside Prote

tion of Out-of Service Boilers; Proc. Am. Power Conf. 40 (1978) p. 964.

Provides laboratory results of a variety of layup boiler chemistries and

reports on results of field application of the laboratory methods which
have good results. Test times were one year. Provides useful corrosion
rate data for carbon steel.

4. P. H. Effertz, P. Forchhammer, A. Heinz., AZT-Allianz Zentrum fur Technik

Ismaning SOG of Chern: Ind, London, England 1977, p. 343-348.

A-1
 Discusses pitting and erosion/corrosion of feedwater heaters. Mentions
effect of magnetite film cracks due to the startup/shutdown transients and
their effect of anodic corrosion of base metals.

5. J. A. Kelley, T. R. Filipowski, ontr llin[_n Oxide Deposition in Boiler

Systems, Technical Association of Pulp and Paper Industry (TAPPI) 1978.

Good review of the nature of secondary system corrosion products. Discus

ses chelation and dispersion programs.

6. F. Gabrielli, W. R. Sylvester, G. W. Thimot; Contamination Prevention

of Superheaters and Reheaters Duri Initial Startup and Operation; Proc.
Am. Power Conf. 38 (1976) p. 296.

Outlines wet layup procedures and use of nitrogen overpressure.

7. G. Gibson: Minimizing Iron and Copper Deposition; "Proc. Am. Power Conf.,
37 (1975), p. 781.

Discusses control of oxygen by hydrazine. Points out that excess hydrazine

may be counter-productive.

8. J. Brown, N. J. Ray, R. R. Harries, E. Reeve; The Waterside Chemistry of

er-Critical Unit, International Water Conference, Gieirs, France, Sep
tember 1974.

Informative article on corrosion product transport and demineralization of

feedwater in supercritical steam plants.

9. R. R. Beach, M. J. Bell, J. H. Hicks, F. J. Pocock; Preoperational

Water
Chemistry Control for Nuclear Steam Supply Systems; Proc. Am. Power Conf.,
35 (1973) p. 892.

Propose wet layup and nitrogen blanket. Recommends the use of hydrazine
(200 ppm initially) and ammonia (10 ppm).

10. S. G. Sawochka, R. A. Burns; Feedwater System Chemistry in the Nine Mile

Point Boiling Water Reactor; Proc. Am. Power Conf. 34 (1972) p. 660.
 A detail analysis of corrosion product formation and transport in BWR cy
cles. Preceeds the NWT studies in technique and results. Emphasizes the
low input of iron in feedwater due to carbon steel pipe and stainless steel
heater tubing in condensate feedwater train. Also, refers to the deposi
tion of corrosion products on feedwater system surfaces, and their subse
quent release into the feedwater, particularly during transients.

11. F. Gabrielli, J. J. Kurpen; Secondary Cycle_ChemistrControl for a Pres

uri ed W ter Reactor, Proc. Am. Power Conf. 34 (1972} p. 651.

Proposes wet layup to the extent possible for all secondary equipment.
Places considerable emphasis on deaeration during startup to reduce copper
corrosion product transport into the boilers.

12. L. H. Vaughn, C. V. Runyon; Corrosion Protection of Boilerand

Associated
Equipment During Idle Periods; Proc. Am. Power Conf. 33 (1971) p. 721.

Discusses layup schemes, including wet and dry. Describes nitrogen layup
system. Reports on the cleanup at the W. H. Sammis Plant following 11se
of layup and cleanup (recirculating loop) concepts. The latter
report men tions that high iron levels were observed in the feedwater
after flow was established through the reheaters. Implies good layup
practice reduced startup iron concentrations.

13. J. J. Krupen, D. L. Dixson; Operating Experience in Cycle Cleanup for

Supercritical Pressure Units, Am. Power Conf. Proceeding 30 (1968} p.
883-896.

Basic cleanup philosophy and early experience by CE is presented. Includes

an evaluation of condensate polisher. Article addresses supercritical
units. (See no. 18 below).

14. B. T. Hagewood, H. A. Klein, D. E. Voyles; The Control of Internal Corro

sion in High-Pressure Peaking Units, Proc. Am. Power Conf. 30 (1968) p. 939.

Discusses peaking unit corrosion experience, copper transport and relation

to oxygen control during startup and operation. Suggests nitrogen blanket
for long outages.

A-1
15. R. R. Noe, H. W. Peterson, L. J. Wyzalek; CorrosionJxperiencwith
Carbon
Steel-Tubed Feedwater Heaters; Proc. Am. Power Conf. 30 (1968) p. 974.

Refers to copper deposit experience in high pressure heaters. Mostly con

cerned with local corrosion of carbon steel heater.

16. F. X. Brown, W. T. Lindsay, Jr., Envir nmental Effe !_ the_Q_

nd
Operation of Feedwater Heaters, Proc. Am. Power Conf.(1967).

Discuss the effect of thermal transients during startup. Also, refers to

the use of nitrogen blanketing during outages.

17. W. W. Schroedter, H. A. Klein, B. F. Love, D. E. Lyons, Bull _Run_Steam

Ge
erator Operating Experience, Proc. Am. Conf. XXIX (1967) p. 316.

Reviews experience with preboiler cleanup loops proposed in References 18

and 20 below.

18. H. A. Klein, J. J. Krupen, W. G. Schvetzenduebel; Cycle Cleanup for

Supe
critical-Pressure Units, Proc. Am. Power Conf. XXVIII (1965) p. 756.

Develops recirculating cleanup loop concept and shows the value of conden
sate polishers for iron and copper removal. Recommends carbon steel for
feedwater heater tubes to eliminate copper deposition in supercritical
boilers. Mentions the need for layup during long outages. Stresses the
need to pump all drains back to condenser during startups following extend
ed outages.

19. J. A. Armentano, V. P. Murphy, Standby Protection of Hh Pressure

Boilers,
International Water Conference 1964.

Develops wet layup chemistry based on laboratory tests of layup chemicals,

particularly that using hydrazine. Subsequent meeting discussion includes
reviews VEPCO's and Ontario Power's experience with dry layup and nitrogen
blanketing fossil fuel boilers.
20. P. Sturla, Performance and Value of Condensate Treatment, Including
Dissol ved Oxygen Removal During Startup at LaSpezia Thermoelectric Power
Plant, Proc. Am. Power Conf.1963, p 635.
 Discusses iron transport during startup and operation and the effectiveness
of condensate polishers in removing corrosion products. Also discusses
oxygen and other feedwater contaminants.

Z1. J. Brown, P. McSweeney, Feedwater ine Corrosion Proc. Am. Power Conf.
39 (1977) pp. 918-924.

Describes an investigation of corrosion product transport in operational

fossil-fueled boiler, including the effects of oxygen on corrosion product
levels and the impact of condensate polisher operation on corrosion product
transport.

22. F. J. Popcock, J. A. Lux, R. V. Seibel, Control of Iron Pickup in Cycles

Utilizing Carbon Steel Feedwater Heater, Proc. Am. Power Conf. 28 (1966) p.
758-772.

Study of cycle iron concentration in supercritical units and the impact of

condensate polishers. Discusses iron corrosion product transport in sys
tems with carbon steel feedwater heater tubes at pH >9.0.

23. Herbert Guttman, P. J. Sereda, Measurement of Atmospheric Factors

Affecting the Corrosion of Metals, ASTM STP 435 American Society for
Testing and Mat erials (1968) pp. 326-359.

Extensive atmospheric test results from numerous sites on the corrosion of

metals, the effect of contaminants and some possible correlations are dis
cussed.

24. P. R. Grossman, Investigation of Atmospheric Exposure Factors that Deter

mine Time-of-Wetness-of-Outdoor Structures ASTM STP 666. American Society
for Testing and Materials (1978) pp. 5-16.

Describes factors which will cause wetness of surface, particularly outdoor

exposures.

25. P. J. Sereda, Weather Factors Affecting Corrosion of Metals, ASTM STP

558, American Society for Testing and Materials (1974) pp. 7-22.
 Discusses various weather factors in relation to corrosion of metals. The
time of wetness is indicated as a critical factor in such corrosion. The
effect of industrial and marine site contaminants is also discussed.

26. U. R. Evans, C. A. J. Taylor, Mechanism of Atmospheric Rusting, Corrosion

Science 1£ (1972) pp. 227-246.

Describes research on atmospheric rusting relating atmospheric corrosion to

the electro-chemical mechanism.

27. F. H. Haynie, J. B. Upham, Correlation Between Corrosion Behavior of

Steel and Atmospheric Pollution Data, Corrosion in Natural Environments,
ASTM STP
558, American Society for Testing and Materials (1974) pp. 33-51.

Provides broad data base for atmospheric corrosion (57 sites) showing
the effect of relative humidity and contaminants on corrosion of steel.

28. W. H. J. Vernon, Study of Atmospheric Corrosion or Metals, Trans. Faraday

Soc., 1l (1935) p. 1678.

Presents the results of classical experiments demonstrating the effect of

relative humidity on corrosion of steel.

29. H. Steger, Steam Power Plant-Corrosion Prevention During Shutdown

Periods, Der Maschinenschaden, 49 (1976) pp. 23-27.

Describes a dehumidification method and system for drying turbines and

other turbine cycle equipment.

30. Burns and Roe Monthly Progress Report, January 1981, Evaluation of Second
ary System Oxygen Control in PWR Plants.

Brief review of Russian field test results on iron and copper transport in
feedwater system.

31. C. Ribon, J. P. Berge; Magnetite Deposits in Boilers from Iron in

Solution, Proc. Am. Power Conf.(1970) p. 721-728.

A-7
32. D. E. Lyons; Supercritical Boiler Startup and Operations Experience, Com
bustion (1967) pp. 36-43.

Outlines the purpose of condensate polishers in supercritical units and the

concept of prestartup cleanup using the polisher and recirculation loops.

33. EPRI Program RP404-1 and RP704-1, NWT Corp. PWR Secondary Water Chemistry
Study; Quarterly Reports Nos. 116-3 to 116-9 and Nos. 133-1 to 133-6 (Jan.
1976- Sept. 1979).

These studies report a wide variety of data on all phases of PWR secondary
water chemistry. The corrosion product transport data is the best avail
able for PWR plants.
 Appendix B

SECONDARY SYSTEM DESIGN INFORMATION

The secondary system design information contained in this appendix is a compen

dium of turbine cycle technical data for the plants surveyed which is related
to the layup and cleanup study. There are eight tabulations of turbine cycle
equipment details, most of which relate either to the evaluation of layup and
cleanup practices or to the subsequent tasks on layup and cleanup. The tabular
information is as follows:

Table

Secondary System Technical Data B-1

Steam Generator Information B-2

pment B-3

Feedwater Heater Data B-4a - B-4e

Auxiliary Steam, Feedwater System and B-5

Condensate System Equipment

Condenser Design Data B-6

Cooling Water and Heater Drain Systems B-7

Equipment

Secondary Water Volumes B-8

The major use of the data presented in the appended tables was for determining
equipment sizes, volumes and internal surface areas. In addition, the presence,

B-2
or absence, of certain equipment is indicative of possible non-generic situa
tions. For example the presence or absence of condensate polishers and cleanup
features has a direct bearing on cleanup capability. Less direct, but nonethe
less significant in assessing cleanup capability, is the knowledge of the avail
ability of deareators, auxiliary steam supplies, and whether air ejectors or
vacuum pumps are used. The tabulations presented in this appendix also serve as
a useful source of support information for a variety of technical judgements not
identifiable to particular problems. In as much as the data became available
through the survey, it was decided to summarize as much as could be conveniently
included in a series of tables appropriate for this report.
 GENERAL SECONDARY SYSTrM TECHNICAL DATA
Salem Mill stone Tlhange Doel Arkansas Rancho Maine R lnghal s
Trojan _1_ 2 Glnna 1_ !._U 1 Seco Yankee 2

Normal Operating
Parameters
Steam Pressure, psfa 910 750 900 782 826 904 925 900 900 800
6 14.4x106 6 6
Steam flow, lbs/hr 15.1x10 11.8xlo 6.6xto 11.5x106 5, 2x106 10.6xto
6
10.8x1o
6
1D.7x1o 6 10.6xl06
Condensate flow, lbs/hr 10.5x10
6
12.d0
6
8.4xto
6
4.5x10
6
11.5x106 - 7.8xlo
6
8.55xl06 7.61xlo
6
-
Feedwater Temp., •F 442 437 430 415 426 446 460 463 525 430

I
Condenser Vacu1111,
in Hg. Abs. 1.62 1.5 1.0 1.35 1.45 1.6 2.5 1.9 1.2
1.33
Slowdown Rate, % .25 .16-.53 .2 1.6 .5 .85 N/A N/A 1.0
Condenser Cool. Flow, gpm 450,000 1,110,000 548,000 334,000 520,000 185,000 760,000 446,000 440,000 679,400
O:J
I
w Secondary System
Features
Deaerator No No No No No No No No No Yes

I
Condensate Polf sher Ffl ter Type Deep Bed Deep Bed Deep Bed No Deep Bed Deep Bed Deep Bed No No
Condensate Cleanup Filter N.A.* N.A. N,A. N.A. No N.A. N.A. N.A. Yes No
Feedwater Reclrculat1on
Cleanup Loop Yes Yes Yes Yes I Yes No No Yes Yes No
HP Dra1 ns to Condenser
During Startup Yes Yes No Yes I No Yes Yes Yes <20% No

*N.A. - Not applfcable

 TABLE B-2
STEAM GENERATOR INFORMATION(l)
Salem M111stone Tlhange Doel Arkansas Rancho Maine Ringhals
_1
Trojan _1_ 2 Glnna 1 !.!1. Yankee 2

Steam Gen. Info.

llo. of Steaa Generators 4 4 2 2 3 2 2 2 3 3
Supplier !! !! C-E !! Cockerill Cockerill B&W B&W C-E !!
3 5759 5759 8000 4580 5759 4580 2700 2700 4947 5759
Total Voluae ( ft l
Wet Layup Water Vol. (gals) 30,124 30,124 45,000 24,000 30,124 - 40,400 40,400 37,000 30,124'
Overa11 Length and
Dlameter-11111x ( ftl 67.7xl4.6 67.7x14.6 62.4x19.3 63x13.3 67.7x14.6 63x13.8 73.2xl2.6 73.2x12.6 54xl5.6 67.7x14.6
Total Number of Tubes 3388 3388 8520 3260 3388 3260 15,535 15,535 5703 3388

Steaa Gen. Corrosion Info.

NUIIIber of Tubes:
-Dented SG 1 None None 100(361( 2 1 <16 678 None/None None None -10%
2 None None 100(29) <16 678 None/None None None -10%
co
I
3 None None - - 383
4 None
""" -Cracks SG 1
None
2 None None 33 None 0/68 7 None None

-
2 2 None None 33 None 0/1 None None None
3 1 None 33 2 - - None

·Thinned SG 1
4 5
None
None
None
-
None
33
66 None None/None None 212 None
2 None None None 66 None None/None None 172 None
3 None None - - 47
4 None None
-Plugged SGl 2 None 354(418) 120 1 10/121 7 None None
2 2 None - 65 2 27/26 None None None
3 1 None - - 46 - - - None
4 5 None

Total Amount of 2388 1564 2.18" - 1650 43.7/55 - None 4"-9"

Sludge per Year llbsl (In 1978) (In 1979) (Avg. 4 yrsl (ln7yrs.)

Ill Data as of l/80

(2) Tube Support Plate (egg crate support strips)
 Main Turt>lne

Inlet Stiaa MSR's Turbine for Main Feed Punti!:S

Plant Inlet Sf rea•
!!!s:.. Pressure
u e
Flow Flow
llb. )xto6 Pressure Pressure Exhaust
ill!iL Manufacturer (lb./hr.)
.!WiL
TI"Qlan General IS 888 2 GeneraJ lst-2.6x105
J!!h l.e!!iL
Electric 175 6xlo6 90-10 72.Sx!2.2
Electric 2nd-3.3x!o5 Delanl 2 .392
2-stage Cu-NI 160 dfrect to
condeni&r
Sal.. 1 Westinghouse 13.8 735 6 Wes tt nghouse
- -
9.9xlos 175
-
12xto6 90-10 35x13 Delaval
M111stone 2 General 11.8 800
256 9.6xlo6Cu-NI direct to
condenser
-
2 General 4xtos
Electric 90-10 57.3x 12.25 General
Electric per stage Cu-NI .016 for 824 HP
Electric direct to
Gtnna Wes tt nghouse 6.2 715 4 low pressunt 180 lP condenser
Wes tf nghouse 4.5hlo5 175 4.81x!O 90-10
CJ::l Tlhange I Alstlloao 11.4t
I
U1
827 8 Stein
lndustrfe 9.9xto5
- 7.6xto6 Carbon
Steel
18xll.1
Doel 1&2 franco Tosf 5.1t - 2 Cockerill 178 - 90-10
Cu-NI
- N/A N/A N/A N/A
Artc.ansu 1 Westt nghouse 10.6 875 4 Wes t1nghouse 9.5-ll.4x!04 193 2.21xl0 90-10 46.1x11.l
Cu-NI liestf nghouse .. 0.11 162 direct to
Rancho Seco Westinghouse 10.8 condenser
880 4 Westf nghouse 8xto5 194 B.6xto6 Carbon 46xll.l
Steel Westinghouse .0655 187
Matn Yankee Vas tf nghouse 9.91 800 4 Wes t1nghouse 7 .4xtoS 172 8.52xto6 N/A H/A
N/A N/A
-
Cu·NI
-
4l.6x9.5
Rlnghals
Shl·ltval
10.57
870
- N/A N/A N/A N/A
N/A
N/A

t IrKTudes Dual Turbine Input

* N/A .. Not appltclble; these plants do not have SteM drhen p . ps.
 TABLE B-4a
FEEDWATER HEATERS AT TROJAN

HP LP
7 6 5 4 3 2 1

Manufacturer BLHa South West Engin ering

Model ----------------------------Not ava1lable---------------------
Steam fl C'lll ( r tedl
lbs/hr x 10 375 299 309 197 334 61 122
Steam pressure
(normal),
psia 429 270 167 91 54 17 8.6
Tube material 90-10b 90-10 90-10 --------Admiralty Brass----------
Tube diameter, in. 5/8-16 3/4-15 7/8-18 1-18 3/4-18 3/4-18 5/8-18
No. of tubes 3134 2080 896 669 1272 423 670
Tube surface area, 16320 18618 14397 12761 17762 5795 7265
ft2 SA 516-70-----------------------------------------SA 515-65-----
Channel head material SA 336 SA 350 SA 516-70--------------------SA 515-65-----
Tube sheet material 6'-11" 7'-2" 5'-0 4'-9" 5'-1" 5'-3" 5'-3"
Overall diameter, ft. Each is vented separately to the condenser
Venting Method

a - Baldwin Lima Hamilton Design, Foster Wheeler

Manufacture b - 90-10 copper nickle alloy
c - BWG wall thickness
FEEDWATER HEATERS AT SALEM 1

_1H_P6_ LP
15 14 13 12 11
Manufacturer w w w w w w
Model
Steam flC'III (rated), 400,783 302,979 209,948 204,597 134,815 221,196
lbs/hr each
Steam pressure (inlet
design) psia 391 181 82.7 36.5 13.6 6.4
Tube material 304 ssa----------------------------------------------
Tube diameter, in. 8 U4 U4 U4 8 8
No.of tubes 1805 845 782 896 1119 1659
Tube surface area, ft2 23140 14455 13285 15270 13880 23350
Channel head material bcs cs cs cs cs cs
Tube sheet material cs cs cs cs cs
Overall diameter, ft
Venting method Each is vented separately to the condenser

a - 304 SS is 304 stainless

steel b - CS is carbon steel

B-6
 TABLE B-4b
FEEDWATER HEATERS AT MILLSTONE 2

LP HP
7 6 5 4 3 2 1
Manufacturer
Model 35-235 69-408
Steam flow (rated), N/A 63-422 61-368 58-252 74-406 76-296
210, 253, 303,
970 157, 281, 392,
e 043 192 108 180 475
lbs/hr (normal), N/A 5.5 5 53 97
(psig)
Steam pressur 190 375
Tube material psia
Admir. Admir. Admir. 304 ss 304 ss 90-10 90-10
CuNi "CuNi CuNi CuNi
Tube diameter 3/4" 3/4" 3/4" 3/4" 3/4"
No. of tubes 1141 3/4" 5/8"
1140 1140 1140 1140 1620
Tube surface area, ft2 4230 1 5, 2658
1 6, 1 4, 1 0,
Channel head material cs cs c135s c565s c100s
2 2,
c155s 2 2, 245
605
cs cs cs cs
cs cs
Tube sheet material
Overall diameter, in.
cs cs
35" 69" 63" 61" 58"
Venting method 74" 76"
Vented separately to the condenser

FEEDWATER HEATERS AT GINNA

_HP_ LP
5 4 3
Manufacturer
Model w w w w
Steam flow
(normal)
lbs/hr
Steam pressure (normal) 5.9x105 4.9x1o5 2.6xlo5 2.3x1o5 2.5xlo5
psig
Tube material 371 148 43 16 5
80-20
CuNi ----------Admiralty----------------
Tube diameter,
in. No. of tubes
Tube Surface area, ft2
Channel head material 12836 11000 7750 6540
Tube sheet material 6540
Overall diameter, ft
Venting Method
Vented to condenser through common manifold.

B-1
 TABLE B-4c
FEEDWATER HEATERS AT TIHANGE 1

HP LP
6 5 4 3 2 1
Manufacturer WEIR ITAM
Steam flow (rated),
tonne/hr 98 143 171 122 107 55
Steam pressure (normal),
bar 24.5 16.4 8.7 2.8 0.78 0.17
Tube materiala A42 A42 A42 A37 A37 A37
Tube diameter, mm 00. 18 18 20 20 20 20
No. of tubes 1280 1280 625 625 625 625
Tube surface area, ft2
Channel head material
Tube sheet material
Overall diameter, m. 1.08 1.08 1.30 1.40 1.40 1.05
Venting method Cascaded to next heater.

a - All carbon
steel
FEEDWATER HEATERS AT DOEL I & II

HP LP
R6 R5 R4 R3 R2 R1 SR1
Manufacturer
Model
Steam flow
(rated), lbs/hr
Steam pressure
(normal), psig
Tube material 15 Mo 3 Carbon Steel Din. 1715 *
Tube diameter, 7/8 3/4 3/4 3/4 3/4 3/4 3/4
in. No. of tubes 1044 576 -----------577----------- 576 578
Tube surface area, 1450 659 687 610 781 708 709'
m2 4 2 2 2 2 1
No. of tube passes 1 1 1 1 1 1
No. of shell passes
Channel head material
Tube sheet material
Overall diameter, ft Cascaded to next heater.
Venting method

w D1n l/175 0.15% C. 0.30% mo.

Note: There are 2 feedwater trains per each Doel I & II
 TABLE B-4d
FEEDWATER HEATERS AT ARKANSAS 1

p
HP
8 6 5 4 3 2 1
Manufacturer -----------------------So. West Eng. Co.(SWECO)-----------------
Model
Steam f1ow Water
(rated), lbs/hr 834,307 258,176 158,907 217,103 126,909 169,073 543,014
Steam pressure
(normal), psia 7.1 7.1 17.3
Tube material 45.7 72.7 190 485
304 ss 304 ss 304 ss 304 ss 304 ss 304 ss 304 ss
Tube diameter, in 3/4" 5/8" 3/4" 5/8" 7/8" 5/8" 5/8"
0.0. No. of tubes 798 2322 1582
Tube surface area, ft2 2478 998 2832 2328 u
4,871 16,411 13,933 13,989 9 687 13,618 26,768
Channel head material A516 A516 A516 A516-70 AS16-70 A516-70
Tube sheet material A516-70
Overall diameter, ft A516 A516 A516 A516-70 A516-70 A516-70 A350-62
3.2' 00 4.4' 00 4.3" 00 4.4' 00 3.8' 00 4.5' 00 6.75' 00
Venting method
Vented separately to the condenser

FEEDWATER HEATERS AT RANCHO SECO

Manufacturer -----------------------Westinghouse-------------------
Model
Steam flow (rated),
lbs/hr 2.97
xl05 2.06 2.39 1.43 3.69 6.84
xl05 xl05 xlo5 xl05
Steam pressure (normal), x1o5
psia 8.1 19.5 51 81 204 537
Tube material 304 ss 304 ss 304 ss 304 ss 304 ss
Tube diameter, in. .625 .625 .625 .625 .625 .625
No. of tubes 1732 1609 1484 1506 2410 3002
Tube surface area, ft2 18,515 16,925 16,051
Channel head material 11,620 20 803 35,650
A515-70 A575-70 A515-70 A515-70 A5i5-70 A516-70
cs cs cs cs cs cs
Tube sheet material A515-70 A515-70 A515-70 A515-70 A350 LF2
cs cs cs cs cs
Overall diameter, ft 4.7 4.5 5.2 5.1 7.1 7.2
Venting method Vented directly to the condenser
 TABLE B-4e
FEEDWATER HEATERS AT MAINE YANKEE

HP LP Drain
1 2 3 4 5 6 Cooler
Manufacturer --------------------Foster Wheeler---------------------------------
Model Verti. Horz. Vert. Vert. Vert. Horz. Horz.
Steam flow (rated),
lbs/hr 421,550 332,710 234,754 224,737 137.727 264,203
psig 411 197 91.2 40.3 14.9 7
Tube material tf 70-30 90-10 90-10 Admir. Admir. Admir. Admir.
CuNi CuNi CuNi
Tube diameter, in. 5/8 3/4 3/4 3/4 3/4 3/4 3/4
No. of tubes 2088-U 986-U 986-U 986-U 986-U 986-U 986-S
Tube surface area, ft2 19485 9795 10090 12190 11975 14230 3725
Channel head materiala cs cs cs cs cs cs cs
Tube sheet material cs cs cs cs cs cs cs
Venting method Vented directly to the condenser

A - No. 1 & 2 heaters retubed with stainless steel

a - CS is carbon steel
 TABLE Bi5
AUXILIARY STEAM, FEEDWATER, AND CONDENSATE SYSTEM EQUIPMENT
Aux11ta!l Stea. Sxstell
F edwater P s Condensate P s
Heat Feedwater
!1!!!! Rlt1ns SO\Irce
Equipment
Serviced Ava11abilltl
No. of 0 •
Flow H.. d No. of Flow Head
Ma ufacturer
Trojan .ill!!!.
- ID.:l
6400 lb/a Manufacturer
150 pslg Diesel
fuel
Condensate
Storage - 2 Bl lngb.. Wire 19800 2020 2 Blnolngbam Wire
1!!tlft
11-IZ.3xlol
1f.hl

-
980-1020
Stl• I fossil D•tneral1zed Ste011 Startup
Storage 2 Wo hlngton
Sparger 18613 2320 3 Ingersoll-Rand 8000 1155
Millstone 2 SO ps1g Aux. Boners Closed Heating. IOOS 2
l Reboner In rso11-Rand 15,000 3
Systea Evaporators 2100 Babcock & Wilcox 9200 1050
Degasstf1er (I standby) Canada

c:o Dotl11
Glnna 2N//ll'*. N/A N/A
N/A N/A
- - .
-
zt

. .
2 lines
. 7220

...... Tlhonge I . .. . . . . 3t Byron Jackson 6600 660

2 per Su zer
line!
14,100 16110 3 In I line Sulzer 7800 148
2 In I line

lb/•

+ 1901 3 half Byron Jade son 8665 1166

100l 1 per line

Artansu 1 240,000 12,060
Other Unit or 2 lines
Aux. Boilers 2 lines

12 Fuel 011 . . Startup 2 14,750

flow

Rancho Slco 220,000 2-011 Fired

 Storage
Condennte House Heat hogging for
lb/111- Air EJectors Standby 2 Byron Jackson
Boilers By n J1etson 15,600 1320 3 9200 1020
Waste Evap. ejectors
F.w. Heaters

.
De.tnera11zed Startup When 2 By"f" Jackson 14,000 s
Main Yontee Boner Water Storage 2058
on fired Heattng and NSSS not 9060 966
Aux. Stea aV11lable

*Difa on fiidWater heaters available 1n Tables through

t Glnna has 3 booster """ps by Blnh.. that provides 4800 gpa at 210 ft held.
t,. · ::l ::b lne booster PIIIIPS by Sulzer that gives 4800 gpa at 960 ft. water
 TABLE B-6
CONDENSER DESIGN DATA
Hot well

Plantt Rating
Tube Sheet Tube No. of Surface
Area (tt2)
' Vol-/
Shell
Method of A tr Removal
Manufacturer Tubes ...full_
Trojan Westinghouse Multi-pressure 7.7lxto9 Muntz Admiralty 64128 865,700 20,660 Main: 2 untts - 1 internal, to 1 after condenser
3 Shell Btu/hr (single layer) Brass 26,660 t t• Hg. Ab. saturated, 710f:60SCM; Steam 125 ps1g, 3530f
AR* 90-10 32,660 Pr!Biry: 3 untts t 15• Hg vac. 1200 CFM; off gas flows toward lowest
Cu-N1 bact pressure; air flow 1s reverse to cooling water flow
Sal.., 1 Foster-Wheeler Triple Shell 7.64x1o9 Muntz Al.-6X 68,301 800,000 Wash YICUUtl S
Single Pass Btu/hr (single layer)
M111stone 2 Westinghouse Two Shell 6.06x109 8-171 90-10 30,720 430,000 .t!iO,OOO Startup: 2 rotary water runs VICUUII pus t 1400 cf11
Btu/hr (single layer) AR*70-30 """"'1: 2-two stage steam-air ejectors t 20 scfm wtth 200 ps1g 1nlet
Cu-81 steam pressure

co Glnna Westinghouse Two Shell

Single Pass
3.78x10g
Btu/hr
- Admiralty
Brass
.r1200 125,650 Westlnrouse F-300 air ejector unit

.....
N Tlhange I We1r1ta• Single Pass 5.3x!09 A-23 Admiralty 35,928 283,000
Btu/hr Carbon Brass
Steel AR* Cupro-
Hickel
Doe! 1 & 2 HlUIIOil·Sobelco Twin Shell - lnox1da 3P
(Single Layer)
Altn1nunt
Brass
20,640 - Startup:
Noraal:
1 steam ejector t 3 tonne/hr with 30 Kg/trtl
1 of 2 steam ejectors f .35 tonne/hr with 58 Kg/CM2
AR* Cupro..
Hickel
Arhnsu 1 westinghouse Stngle Pass
Z Shell
5.8xl09
Btu/hr
Muntz Admiralty 19,600 254,000 - 2 Nuh Ylcuutl s rated 25 scfm. actual 15 sefm

Rancho Seco Westinghouse Single Pass 8.51xJ09 304 Stainless 304 41,400 732,000 42,325 Startup: l hogging air ejectors
Z Sholl 8tu/hr Steel Sta1nless Horul: 2-two Westinghouse air ejectors t 12.5 cf11/element
Steel t 700F 1• Hg; 780 lb/hr steam t 170 pslg/ejector
Ha1n Yankee lngerso1 l·Rand Twin Shell 6.32xJ09 Muntz AL-6X 30,660 400,000 60,000 1 hogging ejector
Single Pass Btu/hr Ste110 (Single Layer) 2 &1r ejectors f 8-10 scfm

iA.It Air fieoova 1 TU6es

tR1nghals Information not available
 Appendix C

MAKEUP WATER SYSTEMS

INTRODUCTION

The field survey of the PWR plants included obtaining information applicable to
the makeup water system. This information is summarized in this appendix. The
makeup water system information reported herein is intended to provide an over
view of current practices of the plants included in the field survey. Thus,
the intent is to highlight the.principal characteristics so that the differences
and similarities will be evident. In fact, the information presented shows that
the makeup water systems are generally similar in their arrangement and the type
of equipment included, as illustrated by the typical flow diagram shown in
Figure
C-1. There are, however, wide variations in size and other features as noted
below. It should be noted that the actual system performance is not revealed by
a survey of this type. Such evaluations would require an in depth study of the
day to day operation which was beyond the scope of the field survey.

The information of the makeup water plants obtained in response to the field
survey inquiries is summarized in Tables C-1, C-2 and C-3. Table C-1 lists
makeup water system water source, system parameters and storage capacities.
Table C-2 presents representative monitoring and water demand information.
Table C-3 lists typical operational practices. Note that in some instances
there are a number of responses which were formulated in a manner that makes
direct comparisons between plants difficult. An example of this is where the
steam generator fill and drain water useage in Table C-2 is reported for one
plant but not others. However, it is judged that there is sufficient informa
tion provided in the tables to furnish useful comparisons of interest to oper
ating personnel. A number of extreme variations in operational parameters or
other data from plant to plant is also apparent, such as the recorded normal
water usage rates and the water storage capacities in Table C-2. The reasons
for these and other similar variations are not obvious, and no attempt has been
made to identify them.

C-1
 RAW WATER CATION
SOURCE BEDS

RAW WATER
FILTER

n
I
N

TO REGENERATION
TO CONDENSATE 111( 1 DRAIN
STORAGE TANK

TO PRIMARY
WATER STORAGE
DEMINERALIZED
WATER STORAGE

Figure C-1. Schematic of

Makeup Water Plant
 TABLE -7
COOLING WATER AND HEA ER DRAIN EQUIPMENT

High Pressure Heater Drains

Number ow At Temp. Type of Chemical Number of Size Vent
Plantt of Pumps {gpm) (OF) Coolin2 Water Addition Drain Tanks Method Filters
Trojan 2 450,000 75 Columbia Chlorine 2 11750 To #5 None
River Injection each heater
Salem 1 - 1,000,000 62
Millstone 2 4 548,000 60 Salt Water None 1 12965 - None
Ginna 2 334,000 - Lake Water Hypochlorite
Solution
co
.......
w
Tihange 1 2 - 54 Meuse River
Doe11&2 2 184,830
Arkansas 1 4 761,300 64 Fresh Chlorine 2 17700 Separately None
each to condenser
Ranch Seco 4 446,000 78 American River Chlorine 8 .r760 1st pt. Heater None
by Canals and H S04 (1 per each or HP Section
for p each stage Condenser
of 4 MSR's)
Maine Yankee 4 440,000 48 Montsweag
Bay
'Chlorine
Ferrous
1 - To drain
pumps
None
Solphate

tR1nghals 1nfonnat1on not available.

 TABLE B-8
SECONDARY WATER VOLUMES

Steam Generator
No. of Total Wet Layup (Sec. Storage, CST or DWST) Hotwell
Plant Steam Generators (Ft3) Gals.) {Gals.) {Gals)
Trojan 4 5759 30124 450000 79980
Salem 1 4 5759 30124 2 X 500000
I
.......
-!»
Millstone 2 2 8000 "'45000 250000 "'50000
Ginna 2 4580 24000 2 X 30000
Tihange 1 3 5759 30124 2 X 6600
Doel 1 & 2 2 4580 - - 134000
Arkansas 1 2 2700 40400 200000
Rancho Seco 2 2700 40400 450000 42325
Maine Yankee 3 4947 37000 143000 60000
Ringhals 2 3 5759 30124
 TABLE -1
MAKEUP WATER PLA T PARAMETERS
Demfneral fzed Storage
Raw Water Raw Water Catton Anion System Tank Tank o2
Plantt B d Capacity Sfze(Gal)/
Source Filter Resin Resin R sfn Sfze(GAL)*/ Exclusion
Deaerator (GPM) Material Materf al Method
Trojan Columbia Activated 2-trafns fn 2-trafns fn 2 trains in No -100 66,000/-- 450,000/
River Carbon parallel parallel p rallel Floating
coated Diaphragm
Calfjlco 102 Calf!lco 301 C lfflco carbon
45ft ; 3.5 ft. 45ft ; 3.5 ft. 1 2. 301 steel
1 ft3;3.6ft.

Salem 1 On-Site
Well Clarifier 3 tanks fn 3 tanks fn
parallel parallel 3p tanks
rallel f n 2-stage
between 650 2-500,000/
Aluminum 40,000/
Aluminum
Ferrous Sulphate Nalco Anion c tfon & anion cat. &
Polyme r sins anion beds
Millstone 2 Cft.Y water Organic Dow Resin Dow Resin D Resins -

T.,..
surface and No 160 250,000/ None
reservoir Dow/
HCR-W SBR-P H -w and A240
Charcoal
s -0 TP304
("") Rohm & Haas Rohm & Haas
I
w
Gfnna Cfty-
treated
lake water
Carbon
Resin Resfn Re fns
Between
1st cation
120 - 2-30,000/
epoxy
Rubber
bladded
IRN 78 IRN 79 IR 78, & 1st coated C/S ( fnopera-
2 tanks in series 2 tanks f n serf es anion bed tfve)
Tfhange 1 Well water Sand - - After 1st
cation bed
705 -I 2-66,050/ None
epoxy coated
concrete
Arkansas 1. City
water
3 Anthra-
ffl t f n
parallel
2 trains in
parpallel Doul fte
C20 resfn
2 trains fn
parallel Ouolfte
1 ank
Du lfte C20 &
No 100 - 200,000/
CIS epoxy
Extraction
steam
A1010 Resin & 1010 Resins lined spargf ng
for heating
Rancho Seco Rfver
water
3 parallel
Anthrallte
2 parallel tanks
Duolf te R3si n
2 parallel tanks
Duol f te A10jD
2 arallel
Du lite C20 & 2 stage
vacutJn;
370 - 450,000/
carbon
Nitrogen
over
C20 71 ft Resin 71 ft A1 1D 18 cu. after steel pressure
ft each cation
bed
Main Yankee Brook
water
3 Anthra-
lfte fn
N/A Ion exchanger
uses Dowex llAS
2- anks fn
pa allel gel
After
fon
200 - 143,000/ Floating
cover
parallel an anion re fn Aluminum
exchange
absorbent trap

•llot excluslve of auxHlary feed supply.

tlnformatfon from Doel 1 & 2 and Rfnghals was not available.
 TABLE C-2
MAKEUP WATER PLANT MONITORING AND WATER DEMAND
Species Monitored Water Demand Cleanup of
Plantt Inline* Normal (GPM) Extended Shutdown Secondary Systems
Trojan Specific Conductivity,
Silica, Cation
Conductivity
Salem 1 Specific Conductivity 300
Millstone 2 Specific Conductivity 40-80
Ginna Specific Conductivity, 10 plus 50,000 50,000 gal/polisher 30,000 gal.
('")
I
Silica gal once/twice for C.P. regeneration for F.W. system fill
-!=:> per week
Tihange 1 None 132 2,600- 6,610 gal. Up to 26,420 gal.
over several hours
Arkansas 1 Specific conductivity 75-100 2,000-3,000 gpd 75,000 gal. for polisher
regeneration
Rancho Seco Specific conductivity, 300 1000 gpd 5,000 gpd
S11i ca
Maine Yankee Specific conductivity, 7-20 1,000,000 gal. 1,300,000 gal.
for fill and drain average per startup
of S/G's.

tinformation on DOel 1 and 2 and Ringhals was not available.

*Representative Makeup Water Quality Ranges: pH 5.8-8.2, Spec. Conductivity .1-1.8 umhos, Cl- .
05-.lppm, F-,.lppm, TDS,.lppm, and Silica 2-2 oppb
 TABLE C-3
MAKEUP WATER SYSTEM OPERAriONAL PRACTICES
esponsible Department for Manpower
Plantt Supervision of System Regeneratirn Automation (if necessary)

Trojan Chemistry Partially 1 operator available

though usually not needed.
Salem 1 Performance Partially 1 operator for
1 shift per day
Millstone 2 Chemistry 1 system - fully 1 technician per regeneration
1 system - partially
Ginna Operations - supervises Partially 1 operator 8 hrs per 3 days
('"')
I
(.]1
Tf hange 1 Chemistry - quality Partially 1 operator to start
Operations - quality regeneration
Arkansas 1 Operations supervises Manual stalt/stop 1 operator part-time
partially butomated
sequences
Rancho Seco Operations Partially I 1 operator per shift
plus steam plant
coordinator
Maine Yankee Chemistry recommends Fully aut atic - normal 1 operator per shift
action Partially butomatic -
abnormal

ffnformation on Doel 1 and 2 and Ringhals was not available.

 Appendix D

PLANT SECONDARY SYSTEM LAYUP INFORMATION

(REFER TO PWR PLANTS LISTED IN TABLE 3-2 OF SECTION 3)

INTRODUCTION

The secondary system layup information contained in this Appendix includes a

compilation of layup practices and related data derived from the plant re
sponses to the field survey inquiries. This information supplements the layup
evaluation presented in Section 3 and provides more detail data for the indi
vidual plants. The information presented reflects both the similar and var
iant character of the plant operational styles as applied to secondary systems
during extended outages. In this regard, it is important to note that plant
specific information included herein reflects the usual practice or the views
of plant personnel at the time the survey was conducted (first half of 1980
an oes not necessarily represent prior or future practices or points of view.

The information provided in this Appendix is divided into: preshutdown condi

tions, short duration shutdown conditions and extended shutdown conditions.
The preshutdown and short duration shutdown information briefly summarizes the
normal course of conditions which precede an outage. A knowledge of these
latter conditions is useful in providing a degree of continuity between normal
operation and the extended shutdown layup conditions, the latter being the
subject of this study. In this manner, a better definition of the boundary
conditions at the beginning of the extended outage may be provided. A know
ledge of these boundary conditions furnishes a basis for judging what effect,
if any, prior conditions will have on the extended shutdown behavior.

PRESHUTDOWN CONDITIONS

The preshutdown conditions are usually those associated with normal operation
and are established in accordance with the normal operation requirements. The
preshutdown or normal operation chemistry environment provides the initial
conditions for layup, and may influence the subsequent layup state and cleanup
burden.

D-1
Chemistry Requirements For Normal Oper !io

Main Steam System. The main steam system chemistry requirements are deter
mined by the turbine inlet steam requirements. Typical requirements are list
ed in Table D-1.

Feedwater and Condensate System. The feedwater and condensate chemistry re

quirements are determined by those required to meet steam generator and main
steam specifications. Typical requirements are listed in Table D-2.

Secondary System Sampling. Principal secondary system sampling taps are lo

cated as follows:

Steam Upstream of the turbine control valves

Feedwater Immediately downstream of the high pressure heater
closest to the steam generators and/ or at the feed
pump suction line.
Condensate - Condensate pump discharge; condensate polisher outlet
Drains Heater drain tank(s)
Steam Generator - Blowdown line
Hot well Hot well drain line
The condenser steam space is not sampled.

Sample lines normally go from the tap location to the chemistry laboratory
(cold lab) or the chemistry sampling station. The samples are cooled close to
the sampling location. Normally sampling flow is continuous and ranges from
100-1000 ml per minute. The lines range from 50-200 ft. of 1/4 in. to 3/8
in. diameter stainless steel tubing. Thus, the purge time to reach
equilibrium is estimated to be 10 to 20 minutes.

It should be noted that sampling during shutdown (cold) is limited to grab

samples which represent only the local conditions near the sampling point.
Without system flow and/or pressure sample line flow cannot occur, automatic
sampling cannot function and fluid mixing, necessary to obtain
representative samples, is not available.

Hydrazine. Hydrazine is typically injected into the condensate water to con

trol oxygen. It is not injected into the condenser steam space as a means of
controlling oxygen in any of the plants covered by the field survey. The
in-

D-2
 TABLE 0-
TURBINE INLET STEAM RkQUIREMENTs(l)

l
Trojan Salem 1 Millstone 2 Ginna Tihange 11(2) Doel Arkansas 1 Rancho Maine
1 and 2 Seco Yankee

Sodium, ppb <1.0 <5 DO NOT SAMPLE DO NOT ONLY <3 <10
Ox.ygen, ppb --- <5 SAMPLE AS BUT NO <51.0 SAMPLE AS REQUIREMENTS <10
Silica, ppb <2.0 <10 THERE REQUIRE- <10 THERE ARE ARE VENDOR 10-80 <20
Ammonia, ppm <0.5 --- ARE NO MENTS .05-.15( ) NO FEEDWATER --- 0.5
w Specific Cond.
mmhos/cm-25 •c <4.0 --- REQUIREMENTS --- REQ'MENTS CHEM.SPECS. --- 3-5
pH-25"C 6.0-9.2 9-10 --- --- 9.: :.J --- --- 8.6-9.0 8.8-9.2
Suspended
Solids, ppb --- --- --- --- --- --- 10-75
Chlorides, ppb --- --- --- --- 1 I --- --- 25-50

(1)Plant specified
(2) Also morpholine 3.0-4.0 ppm. Tihange values are a combination Jf requirements and measured values.
 TABLE D-2
STEAM GENERATOR INLET FEEDWATER REQUIREMENTS(l)
Trojan Salem 1 Mfllstone 2 G1nna12) T1hange 1 Doel Arkansas 1 Rancho Maine
1 and 2 Seco Yankee

pH - 25•c 8.8-9.2 8.8-9.2 8.8-9.2 8.5-9.0 8.8-9.2 8.8-9.2 8.5-9.3 9.3-9.5 8-9.5
Cation Cond.
llllllhos/cm-25"C <2 --- <1 0.2-0.4 --- --- <0.5 <0.3
Spedfie Cond.
111111hos/cm-25•c <4.0 <4.0 --- --- <4.0 4.0 --- 5.7-8.4 <10
Sod1WII, ppb <1 --- --- 5-20 --- <1 <5(3) <3
Dissolved
Oxygen, ppb <5 <5 <10 --- <5 <5 <7 <7 <10
Iron.ppb 10 <10 <10 --- --- --- <10 <10 100
0
I
+:>
Copper, ppb
-<5 -<5 <10 --- --- --- <2 <2 50
Amoon1a, ppm <0.5 <0.5 <1.0 --- <0.5 <0.5 .07-.7 0.5-1.5 l.ol4l
Alllf ne, ppm 10 --- --- --- --- --- --- --- 0.2(4)
Chloride, ppb --- --- <60 5-20 --- <15 <100 <3 <50
H,ydrui ne.ppb 10 >5 --- --- --- 20 50-100 20-100 50
Free Hydroxide
ppa oo- --- --- --- <0.15
Total
Solids ppb --- --- --- --- --- --- <50 <40
S1Hca, ppb --- <5 <100 <10 20
Lead, ppb --- - --- --- --- --- --- --- <1

(1) Plant Spec1f1ed as guide to s. g. blowdown requfrements.

(2) Steam generator blowdown requirements, Gfnna does not specify feedwater inlet
requirements. (3) Plant liait others by s. g. vendor.
(4) nia and aorpho11ne at the condensate pump discharge.
jection point is normally at the condensate pump discharge or immediately
downstream of the condensate polishers.

Air and Non-Condensable Gases. Air ejector or vacuum pump vent flow is mea-
sured and recorded, at least periodically, in some plants as an aid to indi
cating air inleakage rates. However, the primary chemistry concern is
conden sate oxygen content which is determined frequently (daily) via inline
and grab sampling or the condensate pump discharge water. The plants at which
vent
flow is measured routinely are Trojan, Salem 1, Ginna, Arkansas 1 and Maine
Yankee.

Dumping of air ejector after condenser drains to control dissolved gases is

not a normal practice, although it was reported by one plant as a means of
reducing carbon dioxide during startup. The usefulness of the practice to
eliminate excess ammonia could not be determined from the field survey infor
mation.

Chemistry Control. The secondary system chemistry for operating, layup and
· · d b the Chemistry Department (also referred to as
Health Physics and Chemistry, Performance Departments) of all the p an s cov
ered by the field survey. These departments are also responsible for
securing and analyzing secondary system water and steam samples, for
monitoring the chemistry performance of the systems and the condensate
polishers. The oper ations or the maintenance departments are responsible for
implementing the chemistry specifications.

Generally during shutdowns, when equipment is in wet layup, steam generators

are monitored initially on a daily basis and later biweekly or weekly, via
samples taken from the blowdown taps. The other systems are not monitored
routinely, if at all, because flow is secured as noted above.

Analytical Equipment. The typical chemistry analytical equipment at the

plants covered by the survey includes:
Atomic adsorption spectroscopy
Spectrophotmeter
pH meters
+
Specific ion electrodes, usually N a , Cl-, NH 3 +
Conductivity

D-5
The pH and conductivity in line measuring equipment is standard in all the
plants surveyed. Oxygen, sodium and chloride in line measurements are also
available in some plants.

SHORT DURATION SHUTDOWN CONDITIONS

The short duration shutdown information, as noted in the Introduction, is of

significance because it provides some degree of continuity between the normal
operating status of the secondary systems and the extended shutdown status.
Thus, the short duration shutdown conditions represent the usual boundary
con ditions for those prevailing during extended shutdown layup and indicates
the initial conditions with which the prescribed layup treatments must contend.
The extent to which these initial conditions may ordinarily affect secondary
system carbon steel corrosion is apt to be small in most instances; however,
the information is worth documenting and may also be useful in answering some
questions which otherwise would remain unanswered.

Short duration shutdown, as noted in Sections 3 and 5 is arbitrarily assumed

to include periods up to ten days. This period is ample for the implementa
tion of prescribed layup treatments and at the same time is too short for sig
nificant general surface corrosion of secondary system internal surfaces to
occur. It is also assumed that ten days will take into account most of these
forced shutdowns when the plant is kept hot for a number of days pending a
decision to shutdown for an extended period or return to power operation.

Main Steam Path Systems and Equipment

The main steam path systems and equipment includes the main steam and reheat,
extraction and drain systems (to the drain tank), the turbines, moisture
sep arator reheaters (MSR's), feedwater heater shells and the condenser
steam
space. (See Tables 33 and 5-3 in Sections 3 and 5 respectively.)

Typical LayPr The main steam path systems (as well as all secondary
actice.
systems) are left in the "as is" condition during short duration shutdowns.
That is, if the plant is hot, a steam blanket condition exists, but if the
plant is cooled down and vacuum is lost, air enters and replaces the steam.
One plant injects 25-50 ppm hydrazine into the condenser just prior to shut
down. The same plant circulates dry air through the shell side of the feed
water heaters.

D-6
Environment. Subsequent to the entrance of air into the systems the equipment
internal surfaces are subject to varying degrees of oxygenated water and dry
ness at temperatures between 200°F and ambient. The condenser hotwell water
oxygen content increase on exposure to air and the condenser steam space is
filled with warm moist air. No effort is made to monitor the steam path en
vironment during shutdown.

Significance. As noted above, the short duration shutdown environment is ty

pical of the initial condition for any subsequent layup.

Feedwater-Condensate Systems

The feedwater-condensate systems includes all the piping between the condenser
hotwell and steam generator feed control valves, as well as recirculation
paths and drain lines from the heater drain tanks. The equipment includes the
condensate and feedwater pumps, the water side of the drain coolers, air ejec
tor condensers and the water side of the feedwater heaters. Deaerators, where
available, are also included; condensate polishers are not included.

Typical Layup Pract1ce. I fie ma1 n feedwater and conde11sate systems are Aor
mally in the ''as is" condition. Feedwater-condensate flow and temperatures
decrease as power generation is reduced and, ultimately, terminated. Water
becomes stagnant when condensate pumps are stopped and, depending on how tight
check valves or closed isolation valves are, the system water drains back to
the condenser over a period of time. Where recirculation lines are available,
a condensate pump may be kept operating and recirculation flow maintained in
order to establish normal chemistry or layup chemistry for long shutdowns.
One plant reports placing the feedwater-condensate system in wet layup for
short duration shutdowns.

Environment. Initially the feedwater is at pH>8.0, cation conductivity2.0,

temperature -200°F. As the system drains over a period of several days or
more, air will enter through the vents (usually from the condenser shell) and
the surfaces will be exposed to wet, oxygenated conditions. Cation conductiv
ity is likely to increase locally because of reverse hideout effects and/or
carbon dioxiqe ingress. Sample preshutdown feedwater chemistries are given in
Table D-3.

D-1
 TABLE 0-3
SAMPLE SHUTDOWN FEEDWATER CHEMISTRIEs(l)

Trojan Salem 1 Millstone 2 Ginna Tihange 1 Doel Arkansas Rancho Maine

1 and 2 Seco Yankee

Condensate polshers
X X X X X X

pH 9.1 8.8-9.5 --- 8.8-9.3 9.0-9.3 8.8-9.5 8.5-9.3 9.5 8.8-9.0

C1
I Cation Cond.
OJ mmhos/cm-25"C .450 .345 <.2 .10 .14 .10 .18 .13
Dissolved
Oxygen, ppb 2 10 3 2 2 3 2 <5 <5
Hydrazi ne, ppb 3-12 33 3-14 5-20 --- 10-30 35-100 30 10-20
Iron, ppb <20 <10 1.4 10-20 --- --- 11 <10 <100
Copper, ppb <10 <5 1.7 5-10 --- --- 2.5 --- <50
Morpho11ne,
ppb --- --- --- --- 2.5-4.0
-
(1) Taken from available chemistry log data. The data may not be representative of typical operation in all cases.
No effort is made to monitor the condensate/feedwater chemistry during short
duration shutdowns unless condensate pumps are operating, in which case, nor
mal sampling is maintained.

Significance. The short duration shutdown environment is generally the ini

tial condition for subsequent feedwater condensate system layup.

EXTENDED SHUTDOWN PRACTICES

The extended shutdown information summarized below is intended to supplement

that reported in Section 3. It includes an abstract of the layup practices
and experiences of the individual plants as reported by the field survey. The
objective in presenting this information is to record the similarities and
variants in practice and experience, particularly those circumstances which
might have a significant influence on prescribed layup treatments.

The extended shutdowns have been previously defined as those longer than ten
days. In actual practice, extended shutdowns usually exceed thirty days.
Also, shutdowns have occurred which initially were expected to last only a few
days but became extended because of unfor·eseen develop111e11ts. Uflder tf:lese cir
cumstances implementation of prescribed layup treatments are delayed. How
ever, these latter circumstances are rare.

In regard to prescribed layup treatments, as noted elsewhere, interruption of

these treatments by the inspection and maintenance demands for secondary
sys tems is a frequent occurrence during an extended outage.

The secondary systems and equipment, for the purposes of recording layup
prac tices, may be grouped into main steam path equipment and feedwater-
condensate system equipment. This grouping reflects that shown in Table 3-2
of Section 3 and Table 5-3 of Section 5, and is the same as that identified
under short duration shutdown discussed above. The information on layup
practices is an elaboration on that reported in Table 3-2 for the individual
plants.

Main Steam Path Systems Layup Practices

The majority of the plants included in the field survey left the main steam
path systems and equipment in the "as is" condition during extended shut
downs. As noted in Section 3, the difficulty of establishing, and then sub-
D-1
sequently maintaining, a prescribed layup treatment in these systems is a major
deterrent to a positive layup program. During most outages different
pieces of equipment are open for inspection and maintenance, and not necessar
ily at the same time. In regard to the lack of positive layup programs, it is
to be noted that specific layup recommendations from the equipment suppliers,
applicable to typical refueling/maintenance outages, have apparently not been
made available to plant personnel. The condenser steam space is invariably
filled with moisture laden air, and in none of the plants surveyed was any
type of moisture-proof barrier ever used to separate the L.P. turbines from
the condenser for extremely long shutdowns. Steam blanketing was not reported
as ever being used for extended shutdowns.

The methods used for laying up the steam path equipment include air drying and
nitrogen purge, and in some instances, wet layup for the feedwater heater
shells. Returning the systems to operation is accomplished by venting and
draining where appropriate, and then purging with steam in the normal course
of startup. Air and non-condensables are vented to the condenser where they
are removed by the vacuum equipment. Wet layup water in the heater shells is
drained to waste, or to the hotwell, in which case the water is subjected to
the cleanup cycle.

Trojan. The layup method prescribed for the steam side equipment consists of
opening up the condenser top and bottom manways, opening the turbine control
valves and purging with air using compressed air eductors. Air is introduced
upstream of the turbine control valves and exhausted via the condenser man
ways. The main steam system isolation valves are closed and the extraction
steam system is isolated from the feedwater heaters. This evolution takes
four days.

For planned extended outages the air purge begins while the systems and equip
ment are still warm ( 200°F). With the systems and equipment suitably dried,
a favorable layup environment can be maintained in spite of access for main
tenance or repairs. As a general objective, layup is implemented whenever a
shutdown is expected to extend beyond 14 days for turbine equipment and 30
days for feedwater heaters.

Feedwater heater shells have been purged with nitrogen during extended out
ages, although more recently they have been left "as is" because of inspection
and maintenance demands.
The condenser is drained for extended outages, but is never dry because of
residual water in connecting lines which cannot be drained.

Layup conditions are not monitored during shutdown. Trojan experience has
shown that when the systems surfaces were suitably air dried there was no ob
servable change or corrosion of the surfaces after four months.

The condenser shell steel surfaces generally assume a red color but no exten
sive corrosion has been observed.

Salem_!.. The Salem practice is to leave the steam path systems in the "as is"
condition during outages of any duration. The steam path equipment is drained
and subject to varying degrees of moist air. Systems which might retain water
on the turbine deck are drained during winter months to prevent freezing.
Most of the equipment is open at some time during outages for inspection
and/or maintenance.

Salem has not observed any significant corrosion formation during outages.
There is not any information on corros1on product d1str1but1on. As noted
elsewhere, condensate polisher bed pressure differential increased during
startup indicating a higher than normal release of corrosion products at this
time. Also, more cycles of air scrub have been needed to clean the resin un
der these circumstances.

Millstone 2. The Millstone 2 practice is to leave the turbine, MSR's and con-
densers in the "as is" condition and to place the heater shells in wet layup.
In the latter case the heater shells are filled via shell side drains with
demineralized water treated with hydrazine (50-75 ppm) until full; i.e.•
water coming out of the nitrogen connections. It takes 24 hours to put the 14
heat er shells into wet layup. When the feedwater heater shells cannot be put
in wet layup they are inerted with nitrogen at 10 psig.

Millstone experience indicates that the turbines and MSR's have sufficient
residual heat to dry them out. They have observed no significant corrosion of
steam path equipment surfaces, nor has any malfunction attributed to corrosion
been noted. The condenser shell structural steel exhibits general surface
rust. The turbine and MSR's surfaces are coated with a tight magnetite film.
Inspection of the heater drain tanks has shown them to be clean.

0-ll
The steam path equipment is returned to operation by returning heater shell
valve line ups to normal, allowing them to drain, and allowing steam to purge
the system during startup.

There are no known equipment layup requirements for the normally encountered
down times.

Ginna. The main steam path piping and equipment are left in the "as is" con
dition during all outages. Thus, the steam path equipment is drained and the
internal surfaces are exposed to varying degrees of moist air. Most feedwater
heaters are open during extended outages, and other equipment is frequently
opened for inspection and maintenance.

The Ginna Plant has experienced no malfunctions of steam path equipment attri
butable to corrosion. Numerous inspections have shown that nothing but a
light dust is on the normal oxide film surface coating. Also, the condensate
polishers have not exhibited much sludge buildup during startup.

The main steam path piping and equipment is purged by steam during normal
startup operations.

Tihange 1. The practice at Tihange 1 is to leave the steam path piping and
equipment in the "as is" condition but with the turbine, MSR's, feedwater
heater shells, and condenser shells open to the atmosphere to facilitate
dry ing.

Tihange has experienced corrosion in the steam piping, MSR's, and heater shell
side tubing. However, this is attributed to a low pH condition during normal
operation because of low volatility of the ammonia. Consequently, a change to
the use of morpholine in feedwater chemistry was made to maintain pH. Erosion
and pitting problems have also been noted, but no specific evidence of in
creased general corrosion as the result of layup practices has been observed.

The steam path piping and equipment are returned to normal operation by purg
ing with steam during startup.

Doel 1 and 2. The Doel practice is to leave the steam path piping and equip
ment in the "as is" condition during extended outages. Specific layup proce-
dures are not used and there are no provisions for monitoring. The equipment
is exposed to varying degrees of moist air. Occasional visual inspections are
made but there is no established inspection schedule.

Doel has not observed any unusual conditions attributed to layup conditions.
However, there have been no attempts to investigate such effects.

Arkansas 1. The Arkansas 1 main steam path piping and equipment downstream of
the isolation valves are left in the "as is" condition during extended outages
and, therefore, the internal surfaces are exposed to varying degrees of moist
air. A nitrogen pressure (_ 1-10 psig) is maintained in the steam lines
upstream of the isolation valves in conjunction with the wet layup of the
steam generators.

The Arkansas 1 plant has experienced no problems attributable to layup corro

sion in the steam path piping and equipment. There have been no specific in
spections except for the condenser shell where a coating of red oxide is ob
served on the internal steel surfaces.

The steam path equipment is purged in the normal manner by steam during start
up operations.

Rancho Seco. The main steam path piping downstream of the throttle valves and
the turbine are left in the "as is" condition during extended outages. The
MSR's and feedwater heater shells are maintained with a nitrogen blanket. The
condenser shells are retained in the "as is" condition. Other components and
systems are drained as soon as possible after shutdown to facilitate drying of
the internal surfaces. Where nitrogen blanket is used in MSR's and heater
shells, the nitrogen is injected directly using temporary hoses.

The mainstream lines upstream of the turbine throttle valves are maintained in
wet layup with a nitrogen over pressure(- 2 psi). This part of the system is
allowed to cool for at least 48 hours to avoid contact of cold water with the
throttle valves while they are hot.

Steam system and equipment problems attributable to secondary system corrosion

have not been observed subsequent to retubing feedwater heaters with stainless
steel tubes (formerly carbon steel).

D-1
There has been no monitoring of the nitrogen blanket and there has been no
measure of its effectiveness.

Maine Yankee. The main steam path piping, turbines, MSR's and extraction
sys tems of the Maine Yankee plant remain in the "as is" condition during
shut downs of any duration. In general the systems and equipment drain to
the heater drain tank, or directly to the condenser, and air enters as steam
pres sure drops and when vaccum is lost. There are no specific environment
checks made of these regions, although the equipment is frequently open for
inspec tion, particularly the MSR's. The turbine is also usually open for
inspec tion. The use of a nitrogen purge to layup the steam system is not
considered practical, principally because of inspection demands during extended
outages. Improvements in layup are considered necessary and air drying may be
the most practical.

There have not been any observations regarding corrosion product transporta
tion. Deposition has been observed to be uniform, except that deposits of
magnetite and possibly copper which stripped off easily, have been noticed on
the shell side of the feedwater heaters. Cracking and thinning corrosion has
occurred in the copper alloy feedwater heater tubes, and as a result, the No.
1 and 2 feedwater heaters have been retubed with stainless steel. These con
ditions are not attributed to layup conditions.

The steam systems and related equipment are returned to operation by purging
with steam during startup procedures.

Ringhals · The main steam path piping and equipment in the Ringhals plant is
placed in dry layup using a dry air purge, usually within a few days of shut
down for planned outages. Dehumidified air, supplied by an installed system,
is utilized to continuously purge the main steam piping, MSR's, turbines and
extraction systems. The high and low pressure heater shells are also subjec
ted to the continuous dry air purge. During extended outages the hot well is
drained and the condenser shell is forced air dried, using plant air which was
at a low humidity, and subsequently maintained in a dry condition. Where dry
layup is used, humidity levels are checked frequently.

The Ringhals plant experience indicates that the regions of highest suscepti
bility to corrosion is the crossover piping between the high pressure turbine
and the MSR's.
The main steam system and equipment are returned to operation using normal
procedures of initiating steam flow, and at this time air is purged from
the system in the normal manner.

Feedwater and Condensate System L yup Practices

Similar to the main steam path practices, the majority of the plants surveyed
leave the feedwater-condensate piping and equipment in the "as is" condition
during extended outages. Thus, the internal surfaces are initially exposed to
demineralized, deoxygenated water typical of operating conditions, but at re
duced temperatures. After the condensate pumps are secured, this water is
stagnant. If, and when, the water drains back to the hotwell (which may take
from days to weeks, depending on the tightness of the isolation or check val
ves), the internal surfaces are exposed to moist air. With respect to the
absence of positive layup practices, as was also noted for the steam path
equipment, the equipment suppliers apparently have not provided specific layup
recommendations for typical refueling, maintenance, or repair outages. This
is in marked contrast with those provided for the steam generators.

The layup treatments used for the feedwater condensate systems include wet
layup, nitrogen blanket and forced air circulation. It is preferable that the
latter be performed while the equipment is still warm. However, similar to
the steam plant layup experience, maintaining the continuity of the layup is
difficult because of inspection and maintenance demands typical of extended
outages.

In general, returning the systems to operation consists of first draining, if

in wet layup, then filling the drained system with demineralized water which
may or may not be deaerated depending on the capability of the storage facil
ity to exclude oxygen and the degree of makeup water deaeration. Systems in
wet layup are usually drained to waste or in some plants to the hot well.
Feedwater-condensate system fill is accomplished according to the standard
filling procedures and is followed by vacuum deaeration and cleanup process
which vary from plant to plant.

Trojan. The feedwater and condensate systems are drained for extended shut
downs. Air is blown in near the condensate pump and exits near the feedwater
flow nozzles. The procedure is initiated when the system equipment is still
warm to facilitate drying. No dehumidification is employed, the ambient air
is pumped into the system using eductors supplied with compressed air.

Where the shutdown is expected to be less than a month {> 2 weeks) wet layup
of the feedwater and condensate systems may be established. Hydrazine (10-
20 ppm) and ammonia {_ 10ppm) are injected to establish a layup chemistry
fol lowing shutdown using the recirculation cleanup loop and a condensate
pump. After this has been accomplished the flow is secured and the water
becomes stagnant. The chemicals are injected downstream of the condensate
pump. The system is monitored by grab samples taken at condenser and
condensate pump. Hydrazine, conductivity, and pH are measured weekly. Wet
layup is frequently hindered by inspection and maintenance demands.

Trojan has not observed significant corrosion in their feedwater and conden
sate systems attributable to layup or other conditions. Systems which are air
dried when warm show no visual evidence of corrosion during extended outages.
The only monitoring performed is visual inspection when equipment is open.

The condenser hotwell contains water when the feedwater/condensate systems are
in wet layup and having a similar initial chemistry. Otherwise the hotwell is
drained.

The system is returned to operation by filling with demineralized water and

recirculating through cleanup loop, hotwell, and condensate polishers until
chemistry is within specifications.

Salem. The Salem practice is to leave the feedwater and condensate systems
in the "as is" condition. Thus, the system equipment internal surfaces are
ex posed to feedwater conditions similar to those of normal operation. After
vacuum is lost, and the system drains back to the condenser hotwell, the sur
faces are exposed to moist air.

Salem has experienced no adverse corrosion of the feedwater or condensate sys

tems. However, condensate pump strainers have been plugged, on occasion, by
corrosion products during startup.

Visual inspection of equipment is performed during the outage when the equip
ment is open. Systems are simply drained when inspection or repairs are

0-17
scheduled. During outages about 20 percent of the water side heater tubes are
inspected by probalog.

The systems are returned to operation by filling with demineralized water,

which has been deaerated to 200-300 ppb oxygen, and which is recirculated
through the hot well for further deaeration by hotwell spargers and condenser
vacuum, then through condensate polishers until chemistry is within specifica
tions.

Mills! - · The Millstone practice is to place the feedwater and condensate

systems in wet layup. After shutdown the feedwater condensate system is
placed in a long recirculation path mode (i.e. clean up loop path) and
hydra
zine is added until 50-75 ppm residual is achieved. The hydrazine is injected
into the condensate pump suction. Once this has been accomplished the conden
sate pump is secured and the systems become stagnant. Back drainage to the
hotwell over several days, through leaking isolation valves, results in sub
stantial sections of the system being subsequently exposed to moist air. How
ever, undrained parts of the systems retain treated water. No further moni-
tor1ng of the teedwater condensate stagnant water is performed during the out
age. If the systems or equipment are open for repairs or inspection the water
is drained out and the systems are left in the drained condition. Thus, the
internal surfaces are exposed to moist air during any such period.

Millstone 2 experience has not included observations of feed and condensate

system corrosion directly attributable to layup conditions. High condensate
polisher bP has been observed at high flows following extended outages and
necessitating more frequent regeneration. On inspection during outages, hot
well condensate and feedwater train internal surfaces showed general surface
corrosion. Also, feedwater heater venturis are hydrolased during every outage
of sufficient duration with the result that subsequent power operation showed
an increase of 1-3 MWe.

Until recently, corrosion product accumulation has not been significant in the
secondary systems. However, corrosion product accumulation has been observed
in the feedwater heaters. Corrosion films in the No. 4 heaters (low temper
ature end) were bright orange, and those in No. 2 heater (high temperature
end) were dark red at inlet and black at the outlet. Pipe downstream of the
No. 2 heater showed deposit plateout with subsequent peeling off of flakes
1/32 inch thick. The No. 1 heater (HP) had tube inlet deposits which reduced
the flow area significantly. The tube outlets were clean. While these obser
vations are not attributed to layup conditions, they do suggest a corrosion
product distribution which could affect subsequent startup transport levels.

The Millstone 2 feed and condensate systems are returned to operation by

fil ling with hotwell water and recirculating through the condensate
polishers until chemistry is within specification.

Ginna. The feedwater and condensate systems at the Ginna plant are initially
left in the "as is" condition which is filled with water with air intrusion.
Subsequently, for extended shutdowns, the systems are frequently drained
shortly after the shutdown, particularly when equipment is open for inspec
tion. The draining of system low points is made possible by the availability
of low point drains throughout the system. Since there is not any special
layup treatment, there is no monitoring program. However, the feedwater heat
ers are frequently inspected visually and the tubes are subjected to eddy
cur rent examinations.

The Ginna plant has experienced tube side fouling in No. 3, and somewhat less
in No.'s 4 and 5, feedwater heaters. Shell side fouling in No. 4 feedwater
heater has occurred. U bend tube cracking also occurred in No. 3 feedwater
heater, necessitating 10 percent of the tubes being plugged. However, these
conditions are attributed to corrosion occurring during normal operation, not
to corrosion resulting from extended outages. There have been numerous oppor
tunities to visually examine the heaters and other equipment in the feed
water/condensate system. These inspections have revealed no significant
changes, other than those noted above, indicating that oxidation during shut
downs appears to be minimal. In addition, there has not been any evidence of
significant corrosion product concentrations during startup, as shown by the
low level during the first hour of feedwater recirculation, and relatively low
6P increase across the condensate polisher beds. Steam generator sludge has
been estimated to have been reduced by one half since the installation of the
condensate polishers.

The procedure for returning the condensate/feedwater systems to operation con

sists of filling and venting to eliminate the air, establishing recirculation
flow through the condensate system and polisher, then routing the feedwater
flow back through the recirculation loop to the hotwell. This mode is main-
tained, making chemistry adjustments as required, until the feedwater meets
chemistry requirements.

Tihan _l. The feedwater/condensate system is normally placed in wet layup

except when precluded by inspection or maintenance requirements. While the
condensate pumps are available, hydrazine and morpholine (to pH of 9.0-9.5)
are injected, as required, in the discharge of the condensate pump. Conden
sate is recirculated through the feedwater system and back to the buffer tank
via a recirculation line downstream of the R-6 HP heaters. Once layup chem
istry is established, the system is left stagnant and the water chemistry is
no longer monitored, since flow is not available. There is no requirement
to reestablish wet layup should it be interrupted for any reason. Also,
system sample lines are isolated during shutdown to prevent the fouling of
sensing cells. After having installed the dehumidified air system for layup
of the
turbine group equipment, consideration is being given to the installation of a
similar system for the condensate-feedwater equipment.

Tihange has not experienced condensate-feedwater problems to date. Inspection

of the condensate/feedwater train equipment is not normally performed. An
ob Qrv tion of corrosion products transported in the feedwater du1 i119 star tap
indicated that the amount transported was a small fraction of the quantity
removed from the steam generators by sludge lancing. Also, an estimate of the
relative amounts of corrosion product transported to the steam generator was
reported which indicated that 65 percent of the iron oxides originated in the
steam and feedwater-condensate piping, while 35 percent originated in the con
denser feedwater heaters and turbine. An increase above normal values in the
feedwater suspended solids content was observed in the weekly measurements
made during operation immediately following cold shutdowns. The carbon steel
turbine of the No. 3 (LP)feedwater heater experienced service pitting corro
sion but this experience was not considered to be related to layup conditions.

The Tihange condensate-feedwater systems are returned to operation following

normal procedures.

Doel 1 and 2. The practice is to drain the feedwater/condensate systems for

extended shutdowns and allow them to dry. If to be left filled with water,
some additional hydrazine is added via the normal chemical injection system.
There is no periodic sampling requirement or an established wet layup specifi
cation. When the systems are drained, the draindown is performed when the

D-1
equipment is still warm in order to promote drying. There is occasional vis
ual inspection of equipment, but no specific inspection program. The judgment
is that a high degree of general surface corrosion would be known either by
the random visual inspections, or a noticeable increase in the corrosion pro
duct accumulation on the filters.

The only corrosion related events in the condensate/feedwater system have been
feedwater heater carbon steel tube leaks, none of which are related to general
surface corrosion or extended shutdown environmental conditions. There have
been no observations or measurements of corrosion during layup.

The condensate/feedwater systems are returned to operation according to normal

fill and venting procedures, followed by recirculation through the condensate
polisher until the feedwater chemistry complies with the specified require
ments.

Arkan _l. The feedwater-condensate system is placed in wet layup by injec

ting hydrazine and ammonia, as required, into the suction line of the conden
sate pump while recirculating the feedwater via the cleanup loop through the
system and back to the hotwell. The chemical addition is sufficient to main
tain pH at 9.8-10 and a residual hydrazine level of 200 ppm (approximately
110
gallons of 35 percent N2H4 is required). Once the layup chemistry is es
tablished, circulation is stopped and the systems are isolated from the hot
well. The isolation valves are replacement valves specifically installed to
prevent significant drainage back to the hotwell during the layup. Subsequent
to establishing the initial chemistry conditions sampling (by grab samples),is
discontinued. The wet layup of the systems takes 8-10 hours. If circum
stances indicated that adequate layup chemistry was not being maintained,
draining and refilling of the systems would be considered. More frequently,
if the systems are drained for maintenance, they are left drained. There is
no dry layup procedure for the condensate-feedwater train. The conflict of
wet layup with opening for inspection and maintenance occurs frequently. The
condenser is drained during most outages.

There have been no unusual conditions observed during, or in connection with,

layup of the feedwater-condensate systems. There have been no equipment fail
ures attributable to corrosion products. On occasion, a half wheel barrow of
sediment has been removed from the bottom of the hotwell.
The system is returned from wet layup to operation by filling the hotwell to
normal level, opening the isolation valves and establishing recirculation
through condensate polishers, feed train, and a recirculation path (long or
short), until water chemistry is within normal specifications. If the system
has been drained, normal fill procedures precede the above operation.

ano Seco. The condensate-feedwater systems are placed in dry layup using a
nitrogen purge during extended shutdowns. The systems are drained to the hot
well and then nitrogen jumper hoses are connected from the heater shells,
which are also under a nitrogen blanket. All the extraction lines to the
heater shells have nitrogen connections. The nitrogen regulator bleeds off at
> 2 psig. Monitoring of the layup condition consists simply of periodically
checking the nitrogen pressure maintained downstream of the regulator. A
liquid nitrogen shipment once per week fulfills the needs for all plant uses,
including layup requirements.

The use of the nitrogen blanket method of layup was instituted because of the
difficulty in maintaining wet layup conditions and preventing ingress of oxy
gen over a period oF time, a11d tile corrcer n tlrat i11adequate wet .layup contr i
buted to the failure of carbon steel heater tubes. The heaters were retubed
with stainless steel and nitrogen blanket layup practice was established. The
quantity of iron corrosion products observable as the result of layup has de
creased, since the proportion of steel to stainless steel has been reduced and
the nitrogen blanket layup has been used.

The condensate/feedwater systems are returned to operation by filling the hot

well to the normal level, establishing a vacuum using auxiliary steam, and
feeding and bleeding the feedwater/condensate system or adding chemicals as
required, according to normal procedures. Once these are filled, the pre
startup recirculation cleanup procedure is implemented until the feedwater
chemistry is within operating specifications.

Maine Yankee

The feedwater and condensate system and equipment are normally drained during
extended shutdowns in anticipation of inspections. On occasion they may be in
the "as is" condition if the system will remain full, and where the initial
chemistry of the feedwater would correspond to that at normal operation.
There is no check on system conditions in either form of layup. The pumps,
the feedwater heaters, and feed flow nozzles are usually inspected during ex
tended shutdowns.

There have been no observations of corrosion product distribution or the ex

tent of corrosion in the feedwater-condensate systems. The examination of the
tube side of No. 1 and 2 (HP) feedwater heaters has shown the absence of sig
nificant deposits, although as noted above, deposits were found on the shell
side.

To return the condensate-feedwater system to operation following an extended

shutdown, the hotwell is filled from the demineralized water storage tank.
The condensate pumps are started, and the condensate system is put on recircu
lation through the condensate filters. During this time the feedwater
heaters are vented. When condensate meets specification requirements startup
can pro ceed.

Ringh · The condensate feedwater systems are placed in wet layup by in

jecting hydrazine to achieve a level of 20-150 ppm while the condensate pumps
are still operating. When flow is secured the water remains stagnant through
out the layup period. In the event of drainage for inspection or maintenance,
a low circulation flow is available to aid restoration of the wet layup condi
tion with adequate levels of hydrazine.

Ringhals has not experienced any feedwater-condensate corrosion attributable

to layup conditions.

The condensate feedwater systems are returned to operation by bleeding and

feeding using large quantities of water. A few ppm of hydrazine are added to
the feedwater to facilitate cleaning (the hydrazine functions as a wetting
agent). Millipore filter samples are taken periodically during the bleed/
flush operation to determine corrosion product level. The operation takes
about two days. Deaeration of the secondary system fluids occurs in the
con denser. There is no separate deaerating device.

D-22
 Appendix E

CONDENSER WATER SIDE AND COOLING SYSTEM

SHUTDOWN PRACTICES

The condenser water side and cooling system shutdown practices are summarized
in this Appendix. They are included in the study because the information was
obtained during the field survey and is likely to be of interest to the util
ity industry. In addition, the shutdown practices furnish comparative infor
mation for a major balance of plant fluid system which interfaces with the
turbine cycle systems and equipment. The condenser water side and cooling
system includes circulating pumps, piping to the condenser, the condenser
in let water boxes, tubes and outlet water boxes and the effluent piping. It
also includes the tower sump for plants having towers, and suction conduits to
the pumps.

The shutdown condition of the condenser water side and cooling water system do
not normally affect secondary system layup corrosion nor the transport of lay
up corrosion products during subsequent startups. The only conceivable link
would be the ingress of cooling water contaminants due to condenser leakage.
However, the condenser leaks are, with few exceptions, repaired either at
pow er, or during short duration shutdowns, and any contaminant ingress
associated with such leaks is predominantly an operating consideration, not an
extended shutdown consideration. Any condenser leaks present during shutdown
would be somewhat reduced due to the absence of a vacuum in the shell side of
the con denser and because of reduced water side pressure associated with the
partial cooling water flow condition with lower water side head. In any event,
such leakage would collect in the hotwell with little opportunity to migrate
to the other secondary systems during the shutdown, because these systems are
either drained or left in a nonflowing condition.

In regard to the condenser water side chemistry, the practice usually

consists of simply adding chlorine for algae control. In a few plants,
ferrous sulfate is injected to reduce the potential for copper alloy tube
corrosion, particu larly where brackish or sea water is used for cooling.
Plants which utilize cooling towers routinely monitor pH, specific
conductivity and sulfates.
Where cooling water flow is maintained during shutdowns, the chemistry addi-

E-1
tions and/or controls are continued, but on a reduced schedule in some
plants. Table E-1 lists typical cooling water chemistry requirements for the
plants surveyed.

The results of the survey on condenser water side and cooling system shutdown
practices are summarized in Table E-2. The table shows that these systems,
in the majority of the plants, are maintained wet with water circulating,
usually at reduced flow. Three of the plants simply drain the condenser and
cooling water system without further attention. One plant attempts to dry
out the condenser water boxes by flowing air through them subsequent to
draining. All plants have the capability of isolating the individual
condenser water boxes
so that they can be drained, cleaned and flushed out. This operation may be
performed periodically at power as well as during an extended outage. In at
least three plants, cooling water circulation is maintained during outages as
much to provide dilution capability for certain types of liquid wastes as for
other purposes. Power levels at which an individual water box can be drained
for leak repair or other maintenance are:

Trojan 60 percent Doe] 1 and 2

Salem 1 100 percent Arkansas 1 100 percent
Millstone 2 100 percent Rancho Seco 50 percent
Ginna 50 percent Maine Yankee 75 percent
Tihange 1 50 percent

Maintenance requirements which require draining of the cooling water piping

are minimal. The usual maintenance activities are pump impeller inspections,
which may be performed with the system flooded by using a diver, pipe protec
tive coating repairs, and cleaning. The cooling water pipes are made of con
crete in many plants and not subject to corrosion, or requiring special layup
treatments. In a number of plants where circulating pump suction is taken
directly from fresh or sea water sources, the system drains automatically when
flow is secured. Refill of the system requires prior vacuum priming in order
to avoid water hammer problems. This situation provides some incentive for
avoiding drainage of the system.

The representative cleanup methods identified in Table E-1 for the condenser
water side and cooling water system are referred to three typical system modes
as shown below. As shown in Table E-2 these cleanup methods may or may not be
used in a specific plant.

E-1
 TABLE q-1
CONDENSER COOLING WATER CHkMISTRY REQUIREMENTs(l)
Trojan Salem 1 Mfllstone 2 Ginna Tihange Doel Arkansas Rancho Maine Rfnghals 2
1 and 2 Seco Yankee

Cooling Brackish Sea Water Fresh Fresh(4 Brackish Fresh Tower Sea Water Sea Water
Heat Sink Tower River Lake River River Lake
pH 7.5 7.4-7.8
Specific Cond.
nunhos/cm-25"C <1000 1050 Max

Chlorl Y
fTl
I
ppm --- 0.2 0.2 0.2 0.5 I None (3) <0.2
w
Sulfates, ppm <1000
Ferrous
Sulfate, ppm --- --- --- --- --- I 2 i njecti ons
per day
( 5)

Silica, ppm 150

Total Of s.
Solids, ppm BOO Max

(1) Plant specified.

(2) Chlorination for algae control, residual at
outlet. (3) Chlorination periodically.
(4) River water normal sink, supplemented by cooling towers when iiver temperature is above normal range.
(5) Ferrous sulfate daily treatment during operation consists of .5 ppm for 16 hours followed by 0.1 to 0.2 ppm for 2 hours.
Installation of Titanium Condenser Tube will make ferrour sul ate treatment unnecessa .
 Condenser Water
Side Mode Cleanup Methods

1. Condenser full, water Clean tubes by means of

circulating at full or rubber or plastic ball
reduced flow, plant at systems (Taprogge,
normal or reduced Amertap).
power, or shutdown.

2. Same as 1 except one

condenser water boxes Clean tubes with brushes
and tube section and/or water lancing, flush
drained. with water. Reverse flush
tubes with hot water to remove mussels
(sea water plants). Clean water boxes
manually (shovels) to remove debris,
flush internal water box surfaces and
tube sheet with fresh water using hoses.

3. C
Circulat le
ing an
cooling sa
water me
system as
secured ab
and ov
piping, e
condense wi
r water th
boxes f
and l
tube u
section s
s
h
drained
. i
n
g
o
f

E-1
t after
h p draining is done frequently, but the
e i plant is just as likely to be at
p power as shutdown when this type of
c i cleanup is performed. Circulation of
o n cooling water is maintained through
o g the remaining condenser section(s)
l when one section is drained. The
i w insides of the condenser tubes may
n i also be cleaned by use of brushes
g t and water lancing when access via a
h drained water box is provided.
s The cooling water piping system is
y f seldom drained.
s r
t e
e s
m h
water.

In summary, the
predominant practice in
regard to the condenser
water side and cooling
water system is to
maintain cooling water
circulation at reduced
flow throughout both
short duration and
extended shutdowns.
However, three plants
drain the systems and
air dry the condenser
water side. Another
utility is considering
this latter practice
for a future unit.
Cleanup of condenser
water boxes by manually
removing debris and
flushing with fresh water
E-2
 TABLE IE-2
CONDENSER WATER SIDE AND COQLING SYSTEM SHUTDOWN
Practices
Plant Cooling Water Normal AlternHe Remarks
(See Remarks) During power reduction, acid feed
Ory-r<JO days) flow is secured and blowdown continued
Trojan Tower air through water until river water quality is
boxes. achieved. During any given outage,
system may be exposed to any or all
ndenser conditions;
water boxes are i.e., drained, stagnant or circulating.
drained, water boxes When circulating, chlorination is per
are cleaned and tubes formed at 0.2 ppm, for 1 hour. There
are water lanced. is no time limit on stagnant conditions.
Salem 1 Rf ver Water (See Re..arks)
Brackish As==TS; wet with During an outage, the condensers may
rr1 circulation, be drained for inspection. If the
I
(]1 one pump entire system is drained, refill
operating. requires evacuation prior to starting
Elednup pumps to avoid water hammer.
e er water boxes, Chlorination normally used to control
tube sheets and tubes algae growth.
are cleaned
periodically using hoes,
shovels and tube probes
and flushed with fresh
Millstone 2 Sea Water water. (See R arks)
System has not been shut down to date.
As"'"Ts, wet; one pump Cooling system pipe is concrete. Condenser
operating to maintain water boxes can be isolated, and they are
flow (1/2 flow) drained for inspection or maintenance about
fl anup every two months. Daily chlorination fs
u es are cleaned provided except when sea water temperature
as required by blowing is 45"F-55"F when chlorination is continuous.
brushes through them.
Reverse flow to heat.
Tube water is used to
remove mussels. Piping
would be cleaned by
flushing with fresh
water.(No use yet.)
 TABLE E-2 (CONT.)
Layup-Cleanup Practices
Plant Cooling Water Norma1 Alternate Remarks
Ginna Lake, None Water boxes can be isolated for inspection
or maintenance. Circulation maintained for
.

Fresh As=TS; cf
rculatf on waste dilution. Circulation may be secure
maintained, one for a few hours to permit diver to inspect
of two pumps. impellers. No chemical treatment.
oxes
normally cleaned and
Tfhange 1 River, hosed. (See Remarks) System is drained only for repairs. Indi
Fresh vidual water boxes can be isolated and
drained for inspection. Circulation is
As=TS; circulation maintained to provide waste dilution.
maintained. Chlorination (use hypochlorite) to D.S ppm
at outlet once per week. (3x/week during
!"T1 ball summer) For Tihange 2, water sided to
I tube cleaning be forced afr dried.
0" system
Taprogge)fn
operation 24 hrs.
a day. Brush
Doel 1 & 2 Estuary, method considered 6 Days - Whenever circulation fs maintained, FeS04
Brackish for future. Circulati on is metered in twice a day at high tide
Maintained when oxygen level is highest. No chlorine
required.
JJraTiled - no air
drying.
rft:lraTned, high
pressure water hosing.
If circulating, con
Arkansas 1 Lake, tinue rubber ball • None The condenser water side is rarely secured.
Fresh cleaning. (Taprogge) It has not been shutdown in 3 years.
Condenser water boxes can be isolated for
inspection and/or maintaining. Chlorination 2-
As=TS; circulation 3 per
maintained; one week for 15 minutes.
of two pumps.
COnaenser water boxes
drained, debris
shovelled out.
 TABLE E-2 ( ONT.)

Practices
Plant Coolinq Water Nonnal Altema11e Remarks
Rancho Tower h!r "COililenser Full of Tube sheet of condenser fs 304SS, tubes are
Seco and systern Water - 304SS. Carbon steel water boxes coated with
drained. Stagnant epoxy preparation. No specific layup require
ment. The condenser and cooling water system
Ti.iDeSCleaned by fs drained for inspection and maintaining; e.g.
water 1anci ng, cleaning and repair epoxy coating. If filled
brushes or rubber and circulating, the water fs
balls. Tube sheets chlorinated periodically
cleaned each shutdown.
Pipe epoxy coating
repaired.
Maine Sea Water, Drained Condenser sections can be isolated for
Yankee Brackf sh s.:.-rs: one or inspec tions or maintainence. Circulation
two punps maintained for waste dilutions. No chemical
rn
I operating. fl treatment.
-....J ball (Amertap)
cleaning for tubes
operated three times
per week. Tubes are
back flushed with hot
water to remove mussels.
Rfnghals 2 Sea Water Circulat for
Drilied short sh t The condenser is drained and flushed with
down at St. fresh water to remove residual salt. Plastic
C01fdenser water boxes, flow. R bber covers placed fn cooling water channel to
tube sheets and tubes ball (Ta rogge) prevent sulfate gases from reduction of
are flushed with tube cle residual sulfates which might attack tube
fresh water. ning system k materials. FeS04 used during operation.
pt These may be discontinued since installing
in opera ion. Titanium condenser tubes.
 Appendix F

SECONDARY SYSTEM CLEANUP EQUIPMENT AND METHODS

The plant specific equipment and methods used for the prestartup and startup
phases of secondary system cleanup following extended outages are outlined in
Tables F-1 through F-9 of this appendix. The information was obtained from the
field survey of representative PWR plants selected as described in Section 2.
The cleanup practices, as indicated by the information presented in the tables,
are, to a large extent, determined by the installed equipment and resources
available which facilitate implementation of cleanup procedures. For example,
the installation of condensate polishers (usually for the purpose of
controlling feedwater chemistry during operation) invariably includes a
recirculation line from the feedwater system back to the condenser. This
arrangement provides an
effective prestartup feedwater cleanup path through the condensate polisher with
the result that the high demineralized water usage associated with blowdown or
bleed and feed methods is avoided. Similarly, the installation of lines connec-
Ling the high pressure ara1ns wltn the condenser perm1t the flushing of the main
steam system, MSR's, HP extraction system and heater shell particulates back to
the condenser during the power startup ramps. When this drain water is subse
quently passed through the condensate polishers, the particulates are removed.
These and other cleanup features are discussed in Section 4.

It should be noted that the information presented in this appendix is intended

to indicate the industry trends at the time of the survey. It is not intended
to reflect a relationship between specific plant practices and any other plant's
needs.

F-1
 TABLE F-1
TROJAN PLANT

Condensate Powder polisher- backfitted prior to initial

Polisher or Filters: operation.
Feedwater Condensate 10 inch diameter line from the feedwater header downstream
Prestartup Cleanup of the HP heaters back to the hotwell of condenser C.
Loop: Also feedwater recirculation is available from the feed
pump discharge to the hotwell and from the condensate
pump discharge to the condenser shell.
Recirculation Flow: Prestartup cleanup loop flow - 3000 gpm (9 percent of
MCR*. All recirculation paths - 6000 gpm.
HP Drain Path HP drains are pumped back to the condenser during
During Startup: startup.
Prestartup Open manual valves in cleanup loops and recirculate
Cleanup Procedure: hotwell water using one condensate pump until feedwater
meets Cl, Na, conductivity, and suspended solids
startup requirements (SS 10ppb)
Prestartup Less than 24 hours. Never limiting on plant startup.
Cleanup Time:
Deaeration During Condenser, only after vacuum has been established.
Startup:
Remarks: Recirculation flows are limited by line sizes and re
strictions on feedwater pump windmilling.
Feedwater iron and copper concentration may exceed normal
limits during power startup ramps (>10 percent). These
are adjusted by steam generator blowdown.

*MCR = Maximum continuous rate.

F-1
 TABLE F-2
SALEM UNIT 1

Condensate Polisher Deep bed polisher - backfitted 1979. One startup

or Filters: operation with polisher had been performed prior to
field survey.
Feedwater Condensate A 16 inch dia. recirculation line connects the main
Prestartup Cleanup feedwater header upstream of the steam generator
Loop: feed lines to the shell of condenser 2 through a spray
nozzle. A remote operated valve is provided in the re
circulation line near the feedline connection.
Recirculation Flow: Recirculation flow is 8000 gpm (-25 percent MCR). 8
inch dia. bypass lines are provided around the feedwater
pumps to minimize the possibility of pump windmilling at
high recirculation flows.
HP Drain Path HP drains are pumped back to the condenser during
Startup: startup.
Prestartup Cleanup Recirculation through the condensate polisher, feedwater
Procedure: train and back to the condenser shell is maintained un
til the HP heater discharge water meets the chemistry
requirements- oxygen, <5ppb; cation cond., <0.1 s/cm;
suspended solids, <100ppb.
Prestartup Cleanup 24 to 36 hours.
Time:
Deaeration During With condenser under vacuum, steam sparging of the
Startup: hotwell water to raise temperature, and the spray of the
recirculated water into the condenser shell, oxygen and
noncondensibles can be removed.
Remarks: Chemistry log data during startup power ramps and subse
quent power operation indicate high suspended solids
levels for several days.
Salem installs 20 mesh (0.030") condensate and feed
pump suction strainers for a period of approximately one
week following long outages
Prior to installation of condensate polishers, the feed
water was cleaned up by a bleed and feed process.

F-3
 TABLE F-3
MILLSTONE UNIT 2

Condensate Polisher Deep bed polisher- backfitted 1977.

or Filters:
Feed water-Condensate A recirculation cleanup line connects the feedwater
Prestartup Cleanup header downstream of the HP heaters to the hotwell.
Loop:
Recirculation Flow: Recirculation flow is 2800-3000 gpm (-10 percent of
MCR), can be as high as 4000 gpm.
HP Drain Path During HP drains are not pumped back to the condenser during
Startup: startup.
Prestartup Cleanup Recirculate for periods of up to 3 days prior to startup.
Procedure: One hour prior to drawing vacuum, initiate cleanup flow
through condensate polishers until feedwater from HP
heater has <100 ppb suspended solids.
Prestartup Cleanup Cleanup can be achieved within 24 hours.
Time:
Deaeration During Deaeration is accomplished in the condenser in the normal
Startup: manner. There are no special features.
Remarks: Cleanup recirculation flushes feedwater train corrosion
products and contaminants to the hotwell. Excessively
contaminated water is dumped and replaced with clean
water. When subsequent flushing of feedwater train .indi
cates additional dumping is not necessary, flow is initi
ated through the condensate polishers for final cleanup
prior to initiating flow to the steam generators.

F-1
 TABLE F-4
GINNA PLANT

Condensate Polisher Deep bed polisher- backfitted 1977.

or Filters:
Feedwater-Condensate A cleanup line permits feedwater to recirculate from
Prestartup Cleanup downstream of the HP heaters back to the condenser
Loop: hotwell.
Recirculation Flow: Recirculation flow is 3200 gpm (-22 percent of MCR)
HP Drain Path HP and LP heater drains are pumped back to the condenser
During Startup: up to 40 percent power during startup.
Prestartup Cleanup The feedwater-condensate system is filled with demineral
Procedure: ized water, hydrazine is added until 50 ppb residual is
measured. The water is recirculated and cleaned up by
the condensate polisher until the chemistry is approxi
mately that achievable during normal operation.
Prestartup Cleanup Cleanup is accomplished within 24 hours.
Time:
Deaeration During Deareation only available subsequent to establishing a
Startup: vacuum in the condenser.
Remarks: During recirculation at 3200 gpm the feedwater pumps
may windmill.
 TABLE F-5

DOEL UNIT 1 a 2

Condensate Polisher Deep bed polishers backfitted prior to initial commercial

or Filters: operations.
Feedwater-Condensate Two 8" lines are available connecting the two feedwater
Prestartup Cleanup pump discharge lines with the condenser hotwell through
Loop: which recirculation of feedwater can be accomplished.
Also,one 12" line connects the condensate line down
stream of the condensate polisher with the condenser
hotwell through which the condensate can be recirculated
during cleanup operations.
Recirculation Flow: Not available.
HP Drain Path The drain tanks have 10 inch lines connecting them to
During Startup: the condenser.
Prestartup Cleanup Recirculation is maintained through condensate polishers
Procedure: until sodium is< 1ppb and oxygen is< 200-300 ppb.
Prestartup Cleanup Not avail able.
Time:
Deaeration During Deareation only available via the condenser after a
Startup: vacuum is established.
Remarks: Condensate polisher was installed primarily to cope with
potential condenser leakage system; cleanup was a minor
consideration.
 TABLE F-6
ARKANSAS ONE

Condensate Polisher Deep bed polisher - polisher included in plant design

or Filters: in accordance with OTSG requirement.
Feedwater-Condensate A 10 inch recirculation cleanup loop connects the feed
Prestartup Cleanup water header downstream of HP heaters with the condenser
Loop: shell. An 8 inch line connects the feedwater pump dis
charge line with the condenser hotwell.
Recirculation Flow; Cleanup recirculation flow is 2800-3000 gpm (-12 per
cent of MCR) limited by feedwater pump windmilling.
HP Drain Path HP drains are pumped back to the condenser up to 50
During Startup: percent power.
Prestartup Fill condenser hotwell and condensate-feedwater
Cleanup Procedure: systems and recirculate until feedwater chemistry meets
specifications - i e. condnctivity < 10 1.s/cm, oxygen
<7 ppb. Then secure recirculation and fill steam gener
ators.
Deaeration During Condenser vacuum is established by vacuum pumps early
Startup: in the recirculation procedure, steam sparges in hotwell
water assist by raising the water temperature. Recircu
lating the water to the condenser shell aids deaeration.
Remarks: OTSG are not blown down at power, so that the MSR drains
are a collection point for solids carried through the
system during normal power operation.
 TABLE F-7
RANCHO SECO

Condensate Polisher Deep bed polisher installed during plant con

or Filters: struction. A polisher is a requirement for OTSG's.
Feedwater-Condensate One path connects each of the two 20 inch feed- water
Prestartup Cleanup lines to the stam generators at a location upstream of
Loop: the manual stop valves via 12 inch lines to
a common header, then into four 8 inch lines back to
the
condenser shell. Another path consists of two 6 inch
lines which connect respective ends of the main feed
water header downstream of the HP heaters with the con
denser hotwell.
Recirculation Flow:
The flow capacity of the 12 and 8 inch system is
6000 gpm (-23 percent of MCR).
HP Drain Path
During Startup: HP heater drains pumped back to the condenser
automatically at power levels below 35 percent. MSR
drains flow back to the condenser at all power levels.
Prestartup Cleanup
Procedure; After the condensate-feedwater systems are filled
the recirculation cleanup is initiated through the 12
inch lines; the condenser is placed under vacuum and the
feedwater is heated by means of auxiliary steam to a4
heaters. During plant startup recirculation, a lower
flow is maintained through the 6 inch lines.
Prestartup Cleanup
Time: Not available.
Deaeration During
Startup: Deareation is accomplished in the condenser by
establishing a vacuum using auxiliary steam and heating
the recirculating feedwater by means of auxiliary steam
in the a4 heaters.
Remarks:
The chemistry requirements for cleanup are: oxygen <10
ppb, iron (Fe) <100 ppb initially and <7 ppb and <10
ppb respectively 8 hours after feeding the S.G.s,
cation conductivity <1 s/cm and <15 percent power,
<0.5 at
15=50 percent <0.3 > 50 percent.
The OTSG's are not blowndown at power so that the MSR
drains are a collecting point for solids carried through
the system during normal power operation. 6 inch lines
provide a cleanup function during plant startup.
The cleanup system provides extensive cleanup coverage
of all secondary systems during startup.
F-9
 TABLE F-8
MAINE YANKEE

Condensate Polisher Condensate filter system installed; backfitted in

or Filters: 1977.
Feedwater-Condensate Condensate recirculation is provided from down
Prestartup Cleanup stream of the gland seal condensers (upstream of
Loop: the 6th point heater) back to the condenser shell. The
cleanup loop consists of 4 Cuno Filter Units (each with
80-3 foot long cartridges), 2 in service at one
time connected to the system with 8 inch lines.
Recirculation Flow: Cleanup flow is 1000 gpm through two filter units.
HP Drain Path During During startup, HP heater drain tank automatic
Startup: ally dumps to the condenser until the drain pump is
turned on at about 25 psig (-15-20 percent power).
Prestartup Cleanup Condensate is recirculated from hotwell through
Ptocedute. filters and back to the condenser shell qntjl condensate
suspended solids is < 5 ppm in hotwell and < .5 ppm in
condensate. Hold power level in the 2-4 percent range
until solids are less than limit. Makeup to steam gen
erators provided by auxiliary feedwater system.
Prestartup Cleanup After a 30 day outage cleanup time is less than
Time: one day. Prior to filter installation, cleanup by se
quentially filling and dumping condensate after 17
days shutdown took a week to accomplish.
Deaeration During Condenser only means of deaeration. Deaeration
Startup: effectiveness low below 10 percent power.
Remarks: During perstartup condensate cleanup 50 micron car
tridges are installed until differential pressure sta
bilizes. Then 3 micron cartridges are installed to com
plete the cleanup. During the March 1980 cleanup the
cartridges were changed four times. With the 3 micron
cartridges the differential pressure changes from about
8 psi clean to 25 psi for replacement.
 TABLE F-9
RINGHALS UNIT 2

Feedwater-Condensae Cleanup
Initial step is to bleed and feed using large quantities of water. A few ppm of
hydrazine are added to the feedwater as this has a proven cleaning effect on the
system. The bleed stream can either be rejected to the condenser cooling water
discharge stream or routed back to the condenser if desired.
Millipore filter samples are taken during the flushing period which usually
lasts 2 days. There is no separate deaerating device installed in the circuit,
the condenser itself being used for this purpose.
Condenser vacuum is initially pulled with a vacuum pump, the air ejectors being
brought into operation after 0.7 bar has been reached. At steady state opera
tion oxygen at the condensate pump discharge is less than 5 ppb. The 4 LP
feed heater drains are always cascaded back to the condenser.
The 2 HP feedwater drains route to the Heater Drains Tank and then back to
the condenser under low load (25 percent) but at higher power levels this
water is pumped forward to join the main feed stream.
All steam trap drains are rejected to waste for the first week after starup to
minimize carbon dioxide levels. One of the two air ejectors is always dumped to
waste to remove C02 and the decomposition products from organics. Tests have
shown that when this is not done low pH values result. There are no installed
filters for start-up cleaning.
 Appendix G

CORRELATION OF OPERATING PLANT IRON AND COPPER TRANSPORT DATA

(NWT Studies)

Operating plant iron and copper transport data was obtained from the EPRI
sponsored "PWR Secondary Water Chemistry Studies" being performed by the NWT
Corporation. The data was obtained from the quarterly reports for EPRI pro
grams RP404-1 and RP704-1 in NWT reports Nos. 116-3 to 116-9 and 133-4. The
corrosion product data abstracted from these reports consisted of iron and
copper transport rates derived from sampling during selected periods of oper
ation of six PWR plants. The derived transport data is tabulated in Table G-1
and represent average rates over many hours of sampling the feedwater, the
condensate pump discharge, the high pressure drains and the condensate polish
er effluent (where applicable).

The data correlation consisted of rearranging the transport data from Table
G-1 according to the regional grouping shown in Tables 5-4 and 5-5 in Section
5 and determining average values for each plant. From these, the percent
transport was determined for each regional group and an average percent of all
the plant data for each group was calculated. These correlations are pre
sented in Table G-2. The tabulated average percents for each regional group
from G-2 is also listed in Table 5-5 in Section 5 in order to provide a com
parison between the relative transport obtained from the plant data and that
derived from the internal surface area model described in Section 5.

It should be noted that the correlation of the plant data shown in Table G-2
included the Prairie Island 1 and 2 information. Since these plants have all
ferrous systems, a somewhat higher iron corrosion product distribution is to
be expected in the B-E-F regions of the plant data than in that based on in
ternal surface areas shown in Table 5-5.

G-1
 TABLE G-1
IRON AND COPPER TRANSPORT DERIVED FROM EPRI PWR SECONDARY
WATER AND CHEMISTRY STUDIES
(ALL VALUES ARE IN GRAMS/HOUR)

PRAIRIE

SPECIES SAIIPLE( 2 l ARI<ANSAS 11 3 )( 5)

PRAIRIE
ISLAND 1( 4 ) ISLAND 2( 4 )
SURRY 2(ti)
i\(6) i lJ)(7)

133-4/ 116
Data Source NIIT Report (I)
SAl 9/5.13 882 9/5.12 682 682 8C3 5C5 7CI 7C2 9C2 6C1 702 BA1 BA2
Vol/Page p. 6.14
2/2- 10/21- 3/1- 9/13- 10/29- 2/17- 3/15- 1/3- 10/7- 2/27- 10/21- 6/2-
Dates of Saaples
Z/16/76 11/18/76 3/22/76 9/21/76 12/22/75 3/1/76 3/29/76 213/77 11111/75 3/31/76 12/27/76 6/14/77

37.9 44 46 39 56 56 38 37 56
Iron Feedwater
22.4 16 19 4 16
HP Ora1ns

23 44 31 28 18 30
"' Condensate 21.6 28
I
Cond. Polish 3.9
N Effluent

Copper feedwater .70

HP Oratns .41 .1
Condensate 4.11 4
Cond. Polish .21
Effluent

NOTES:

1. Date taken fr0111 NWT reports as follows: Akransus One ... NWT 133-4; Prairie Island 1 & z. Surry 2, Turkey Point 4,
Calvert Cliffs ... NWT116-3 to 116-9. Saq>le values are averages over time period indicated. Values in parenthesis are
esthaated.
2. Saaple Pofnts: Condensate-Condensate Pump discharge header
Condensate Po11sher- Effluent ltne
High Pressure Drains .. Heater drain tank or drafn punp discharge (Except Arkansas 1 where lP heater
discharge on Train 8 and feed ptll'llp suction on Tra1n A are sampled and difference
recorded.
Feedwater .. HP heater discharge (except Arkansas 1 where feed puup sucUon h sampled - thus excluding
the HP heaters).
3. Arkansas 1 and Calvert Cltffs had condensate polishers fnstalled prior to date when samples were taken. Other plants dfd
not have po11 sher operable at that ttme.
4. Pra1rte Island 1 & 2 do not have copper alloy heat transfer surfaces tn major equipment.
5. Arkansa1! has copper alloy condenser and MSR tubes.
6. Surry l: and Turkey Pofnt 4 had copper alloy heat transfer surfaces at the time the samples were taken.
7. Cahert'Cltffs had copper alloy condenser and MSR tubes, stainless steel and carbon steel heater tubes at the ttme
samples were taken.
 TABLE G-2
CORRELATION OF NWT IRON AND COPPER TRANSPORT
ACCORDING TO MAJOR REGIONS(a)
CAl.VERi AVERAGE
TURKEY
CLiffS
TRA!ISPORTI b)
TRAHSPORT( b)
REG!D!IS AAK. 1 PR. IS. 1 PR. IS. 2 SURRY 2 !.!.:..!
PATHS
IRON (GRAMS/HR.)
48.8 51 (8S.9)!dl
t A-F(c) 43.0 46.8
55.6
1. Total

5.0 16.6
22.4 17.5
A
2. HP Drat n to
FW System 30.0 27 31
25.5 30.0
B+E+F 21.6
3. LP Extract!on & Oral ns
to Condenser to Cond.
Pump Discharge
C+ll 11.6
4. Condensate and Feedwater
System to SG
!RON !PERCENT)
32
11 31
40 41
5. See z. _A_

I A-F
53 (36) 52
64 61
39 59
6. See 3.
I A-
F

tA-F COPPER (GRA.'IS/HR.)

5 (4.lld
Prairie Island 10.3
t A-F 4.6
8. Total Syst<ms - do not
contain copper alloys
4.2
A .41
9. HP Drain to
FW Sstem
2.3
4.0
B +E +F 4.11
10. LP Extraction &
Orai ns to Condenser
to Cond. Pump
Discharge
COPPER (PERCENT)
25
41
9
ll. See 9. _.!._
tA-F 56 66
39 80
8 + E +F 89
12. See 10. z----
tA-F

NOTES:
(al Transport data from hble G-1. Averages are listed when more than one value ls recorded ln Table G-1.
(bc)) TP.r-aFnisspotratkepnathtos abned threeGaiovnesragase doef fitnheed feinedsweactteironsam5.ple data from Table G-1 for
plants without condensate polisher (i.e., Prairie Island l & 2, Surry 2 and Turkey Point 4). For plants with condensate
polisher (i.e •• Arkansas 1 and Calvert Cliffs) A-F is the average of the Table G-1 feedwater values plus the condensate
less the condensate poll sher effluent
(d)
V alue f or Calvert Cliffs in parentheses() are estimates assuming a condensate polisher effluent value of 5.6
v a es .
(e)
grams/hour iron oxide and 1.2 grams of copper oxide.
Single data point insufficient to determin e an average for all plants.

G-3
 Appendix H

FEEDWATER CORROSION PRODUCT VARIATION WITH PLANT OPERATING MODES

As part of the evaluation of corrosion product transport associated with plant

outages and subsequent startup, a review of the NWT "PWR Secondary Water
Chem istry Study" data (Reference H-1) has been made. This data represents
the primary source of inplant quantitative data available on this phase of
corro sion transport for PWR nuclear plants. The NWT study has reported
significant differences between feedwater iron and copper transport rates
associated with normal operation and those associated with startup. For the
purposes of layup and cleanup evaluations an examination of the data in
relation to the length
of the preceding shutdown was made in order to separate out iron and copper
transport associated with normal operation, short duration shutdowns and ex
tended shutdowns. The results of the examination are tabulated in Table H-1
for all the plant data obtainable from the NWT quarterly reports listed under
Reference H-1.

The information in Table H-1 was arrived at by taking the feedwa er

copper concentrations reported in the appropriate appendices of the NWT quar
terly reports and correlating them with the corresponding power histories in
the NRC Gray Books. By assuming that the feedwater flow is proportional to
power, the quantity of iron or copper transported can be determined as follows:

Weight of iron or copper = Concentration x Feedwater Flow x Time of

Sampling

For steady operation, the concentrations reported for a large number of

samp ling periods were averaged and converted into a monthly transport rate
using an average feedwater flow rate. Since the transient periods were
relatively short (most frequently1 day and not exceeding 5 days) and
because they oc
cur randomly, the quantity of corrosion product is reported for each transient
vent. The power level during steady operation was usually between 80
percent and 100 percent. The power level during transients was usually less
than 40 percent but greater than 10 percent. The method of data reporting
in Table
H-1 provides a useful comparison between the normal transport rate and the
impact of the individual transient events; e.g., one transient event causes a
release of corrosion products in the range of 0.5 to 1.5 times the
quantity

H-1
 TABLE H-1
IRON AND COPPER FEEDWATER TRANSPORT ASSOCIATED WITH STARTUP
AND/OR RAMP POWER-FLOW TRANSIENTS

Column 2 3 4 5 6 7 8 9
Average Transport for
Plant Plant Characteristics Steady Oeeratlon Quantity Transeorted Ouring Transient Events
1) tlllt Transient Events For Startup Transients
2) Condensate Polisher Short Duration Shutdown Following
3) Ht. Ex. Mat. and Power Variations Extended Shutdown
4) FW Flow lbs./hr.
5) Prestartup Cleanup loop Fe Cu Oays Fe Cu Days Fe Cu
6) Oeaerator Shutdown Shutdown
ppb/kg/mol a l ppb/kg/mol a l kg kg kg kg

Turl<ey Pt. ll 2200 14.1/42.2 1.8/5.3 <1 25.8 5.3 85(f) 50 6.9
Unit 4 2) No (b) 7.0 1.1 (Startup B/3/77, prior
3} Cond. AlBr <1 36.0 4.0 extended shutdown ended
HP Monel (c) 30.7 0.4 12/6/76}
:X: LP ADM (b) 6.9 0.6
I MSR 90-10 <1 27.8 4.0
N 4) 9.6 X 106 (b) 6.9 1.9
5} No 1 11.2 4.0
6) No {b) 10.6 1.4
4(f) 21.2 4.6
Ave. N:<T n
Surry 1) 2241 8.5/27.4 1. 6/5.2 <1 24.7 2.9 48(f) 63 31
Unit 2 2) tlo <1 16.7 2.7 (Startup 6/10/76, prior
3) Cond. ABM (b) 9.5 2.0 extended shutdown ended
HP/LP 90-10 3(f} 20.3 6.0 6/16/ 75}
MSR 80-20 2 37 .o 6.6
4) 10.6 X 106 (b) 3.4 1.2
5} No Ave !J.b D
6} No

Prafrfe Island
Unit 1
1J 1650
2) No (e)
13.7/29.3 --- <l(f) 20.41 --- 47(f) 27.1
(Startup 5/5/77, prior
3) Cond, HP /LP 304SS extended shutdown ended
MSR CS 5/10/76)
4) 7.04 X 106
5) No
6) No
Pra1 rl e Island
Unit 2
Same 13.0/26.0 --- (c) 11.7 --- 34(f) 58.7 (Startup
l/20/76, prior extended
shutdown 6/2/75)
 TABLE H-1 .)

8 9
5 6
4
3
2 _Quantity Transported During Transient Events
1\verage Transport for
Column _steady Operation _
Pl nt Characteristic2_ 20.3 .33
o. 53/2.0 (cl • 70
16.6/64.5 1( f) 16.3
32.8 2.0
1) 2560 (d)
Calvert Cliffs 2) Yes
Unit 1 3) Con d. 70-30
HP/LP 304SS
MSR 90-106
4) 11.7 X 10
5) Yes
1( f) 3.9 o.l3
6) No .10/0.3
17.6/53
Crystal River 1) 2552
2) Yes
Unit 3 3) Cond. 70-30
HP/LP 304SS
:c
I
MSR 90-10
4) 10.6 X 106
w 5) Yes
6) Yes duration shutdowns and power variations which actually release

\al steady operation data excludes that input due to transient events for
oxides that accumulated during prior normal operation.
(b) Power shutdown ramp- not included in the average.
(c) No plant transient, no explanation for high value - not included in the

(de)l F o u r d ay p o w e r r e d u c io n to 8 6 , ;.
P r a ir ie I s la n d o p e ra te d co nd e ns a te polishers subseqUent to this data.
(f) Data which is pertinent to information in Table 4-2 in Section 4.
released monthly. The arrangement also permits separating out the corrosion
product transport associated with short duration shutdowns (periods of negli
gible corrosion due to noncontrolled chemistries)from the transport associ
ated with extended outages. Because the data available for the extended out
ages is limited, any conclusions based upon this data must necessarily be ten
tative. Table H-1 also lists related parameters of interest for each plant
which will facilitate the interpretation of the data.

The following comments apply to the data presented in Table H-1:

• The data in Table H-1 provides additional evidence of continuous low level
general corrosion of the carbon steel and heat transfer surfaces under
operating chemistry conditions, and the release of the resulting corrosion
products into the fluid streams.

e Transient flow and, possibly, temperature variations cause a temporary

increase in corrosion product release rates. Both increasing and decreas
ing flow transients are accompanied by increasing release rates of corro
sion products.

• There is evidence in the NWT data reported in Reference H-1, as indicated

by Note C of Table H-1, that during prolonged operation, in the absence of
significant flow transients, high corrosion product release comparable to
starting transients will periodically occur for a short period of time.
It should also be noted that the transport rates shown for steady opera
tion represent an average of variable measurements within a factor of two
of the values presented.

• There is evidence in the NWT data reported in Reference H-1, not shown
by Table H-1, that where a startup or shutdown transient has recently
been preceeded by another transient, the corrosion product release rates
are near normal. This suggests that the scrubbing action of the first
tran sient removed the available loose oxide.

• Flow transients, whether decreasing or increasing, result in the

release of oxides which were accumulated during the prior steady
operation. By inference, this means that:

H-1
 1. The steady operation transport must be combined in a suitable
manner with short duration transient in order to more accurately
represent the ongoing corrosion produce release. For example,
assuming one transient a month for Turkey Point 4, the monthly
iron release is 42 plus 24, or 66, kg/mo.

2. The values for the extended shutdowns indirectly include the corrosion
product release increments which accumulated during the prior steady
power operation and would have been released during the startup tran
sient, even if the extended shutdown had not occurred. Thus, the ex
tended shutdown values should be adjusted downward to more accurately
reflect any corrosion which occurred only during the outage.

t The large transport values identified for extended shutdowns not only in
clude the startup transient contribution attributable to prior operation,
but conceivably also inlcude a greater percentage of prior accumulated
oxide than the short shutdown/startup transient values listed in Table H-1
would indicate. The reason for this is that the cold startup operations
are normally relatively more severe than those as-
sociated with short duration shutdowns. Speci 1ca re
apt to include cycling of the feed and condensate pump several times, as
well as additional heatup and cooldown transients not usually part of re
covery from reactor trips or shutdowns of only a few days. The expected
result of these more severe transients is a more thorough scrubbing of the
surfaces and greater release of loose oxides.

t The corrosion product transport data was obtained, for the most part, when
power was above 10 percent and, therefore, substantial fluid movement
throughout all the major secondary systems was occurring during the samp
ling period.

• In general the copper transported during transients increased when the

iron transport increased, but not necessarily in proportion. It would
appear that the condensate polishers in the Calvert Cliffs and Crystal
River Plants reduce the copper transport in feedwater significantly.

e While the steady operation and transient transport appear in the same
range for several plants, the significant differences between the
heat

H-5
 transfer surface materials of the plants listed make a plant to plant com
parison difficult.

The data presented in Table H-1 provide possible insights into the potential
relative release/transport of carbon steel corrosion products which occur on
startup, and are attributable to the immediately preceeding extended shutdown;
i.e., the period to which a special layup treatment would be applicable. For
example, if the iron transport data in Table H-1 are reorganized to reflect a
yearly release, a comparison between that attributable to extended shutdown
corrosion and that due to normal operation can be obained. Such a comparison
is shown in Table H-2.

The assumptions underlying the normalized iron release data presented in Table
H-2 are as follows:

1. The period of operation is sufficiently long to exclude the release of

corrosion products generated during previous extended shutdowns. As indi
cated in Table H-1, the previous extended shutdowns were six to twelve
months prior to the ones for which the data is shown.

2. The iron corrosion products formed during the extended shutdown, and re
leased during the subsequent startup are due entirely to carbon steel cor
rosion and not to stainless steel corrosion. Stainless steel is not sub
ject to significant general surface corrosion when exposed to typical site
atmospheric conditions.

3. The iron corrosion products released during startup are comprised of both
those generated sometime during the preceeding six to twelve months oper
ation and those generated as the result of general surface corrosion dur
ing the extended shutdown period. The release data in Table H-1 was ob
tained on startups following shutdowns during which there was no special
layup treatment of the secondary systems. (Exclusive of the steam gener
ators.)

4. The iron corrosion product release attributable only to that resulting

from general surface corrosion occurring during the extended shutdown
can be approximated by subtracting the average transient value (column
5) from the total iron transport (column 8)in Table H-1. The data on
transient corrosion product release demonstrates that startup transients
which are

H-1
 TABLE H-2
NORMALIZED YEARLY IRON (Fe) RELEASE
FOR TURKEY PT 4, SURRY 2 AND PRAIRIE ISLAND 1 & 2 (a)

Iron Release, (kg)

Steady Operation Transient Operation Extended Shutdown

Turkey Pt 4 420 240 18

Surry 2 274 260 49

Prairie Is. 1 a 2 277 160 45

NOTES:
(q) The basis for the normalization is:
1. The corrosion product transport, as determined by feedwater concentrations,
is equivalent to the corrosion product release.
2. The year is comprised of ten months operation with an average of one transient
per month plus a two month scheduled outage. Thus, the steady transport
values recorded in Table H-1 are multiplied by ten and the transient values are
also multiplied by ten to give the release presented above. Because of the
limited transient data for Prairie Island the data for both plants are
arthimetically averaged.
3. The extended outage release shown above is adjusted by substracting the trans
ient transport in Table H-1 from the transport shown for extended outages.
Then the resulting value is divided by the number of shutdown days to obtain a
release attributed only to each day of the shutdown period, and not attribu
table to the normal operation prior to the shutdown. The resulting daily shut
down value is then multiplied by 60 to reflect two months assumed shutdown.
For Prairie Island the same procedure is used except that the release attribu
table to each day of the shutdown period for the individual plants is first
determined and these values are then averaged before calculating the composite
total average release attributable to 60 days.
 not associated with extended shutdowns will result in substantially great
er corrosion product release than normal. A major part of this release
must be due to corrosion products generated during prior steady state op
eration. On this basis, it is concluded that a comparable release due to
prior steady state operation will also accompany any release which may be
due to corrosion generated during the extended shutdowns. Therefore, the
adjustment of the latter is considered appropriate.

5. The number of transient shutdowns in a typical year, consisting of ten

months operation, is about one per month, or a total of ten per year. A
review of Turkey Pt. 4, Surry 2, and Prairie Island 1 operating
histories over a three to five year period showed that the average
number of tran sients per year were 10, 12 and 9 respectively, or an
overall average of about 10 per year.

Using these assumptions, the data in Table H-1 for Turkey Pt. 4, Surry 2,
and Prairie Island 1 and 2 were reorganized into a normalized iron (Fe)
release for a one year period as shown in Table H-2. The extended shutdown
data was not available for Crystal River 3 and Calvert Cliffs 2. The
apparent conclu sion indicated by the normalized iron release values shown in
Table H-2 is
that the release attributable to the two month extended shutdowns is relative
ly low compared to that resulting from steady state and transient operations;
i.e., 3 percent of the total for all plant modes for Turkey Point 4; 8
percent of Surry 2; and 9 percent for Prairie Island 1 and 2; with an overall
average of 7 percent for the two month period. If one were to assume a six
month rather than a two month shutdown, the relative release attributable to
the extended shutdowns would be about 21 percent of a typical yearly total
release due to all plant modes.

A practical application of the iron transport values in Table H-2 might be in

determining the level and/or scope of layup treatments appropriate for a par
ticular plant shutdown condition; e.g., a two month shutdown may not warrant
extensive layup treatment. While the data base upon which the iron transport
values shown in Table H-2 is admittedly limited, for most plant outages it is
judged that a 50 percent increase in the Extended Shutdown values would not
appreciably alter a prescribed layup treatment decision. Should future needs
indicate the desirability of a more accurate determination, the data base
could be expanded, or plant specific data could be obtained.

H-1
Another interesting use for the corrosion product release data shown in Table
H-2 is the estimation of secondary system carbon steel corrosion over long
operating periods. Specifically, if it is assumed that the iron (Fe) release
in a given year is reasonably representative of the corrosion rate, and the
carbon steel surface area is known then an estimate of the general surface
corrosion rate may be calculated. For example, using an average of the sum of
the steady plus transient release data for Turkey Pt. 4
and Surry 2 results 1.n a yearly release rate of 600 kg (1..e.- 660 + 534
2 ).
2
Then, assuming a carbon steel surface area of 89,000 Ft as typical of
plants of this size, the general surface corrosion is calculated to be about
0.36 mils per year (mpy). Such an estimate is useful as an indicator of the
amount of iron corrosion product potentially generated during normal operation
as derived from plant data. The open literature was reviewed for information
regarding carbon steel corrosion under both normal operating and shutdown con
ditions as part of the literature search reported in Section 2. This effort
did not produce quantitative data considered applicable to either condition.

In addition to the data from the NWT studies, other indicators of interest
regarding corrosion product transport were inferred from responses to in
quiries obtained during the field survey. These are presented in Table H-3
which consists of a compilation of corrosion related events and comments as to
their significance in regard to corrosion product transport. For example, the
presence of considerable amounts of sediment in the hot well of a drained con
denser is indicative of corrosion products, which, if not removed, might be
flushed into the condensate line during the subsequent startup. Under these
circumstances, this accumulation would show up as a high concentration of iron
and copper in the feedwater. This might very well be attributed to outage
corrosion, where in reality it came from plant operation prior to the outage.
Similarly, the accumulations found in the Trojan and illstone high pressure
feedwater heaters in all likelihood, came down through the high pressure
drains (Region A defined in Section 5), because both the Trojan and
Millstone plants have condensate polishers, and the low pressure heater
tubes were not fouled. The presence of black sludge reported in the Salem
and Rancho Seco condensers are other indications that corrosion proqucts
observed following extended outages likely originated during prior operation.
 TABLE H-3
CORROSION PRODUCT TRANSPORT OBSERVATIONS FROM THE FIELD SURVEY

PLANT OBSERVATION/EVENT COMMENT

TROJAN A 1/8" sludged buildup observed in It is probable that this sludge
(Condensate No. 6 high pressure heater inlet was not generated during the out
Polisher tubes, restricting flow (sludge age when it was observed. Most
Operative) 30 of it probably accumulated during
w/o iron oxide, 60 w/o copper prior to normal operation.
oxide). Release of this type of sludge
May come from drain tank. The accumulation is likely during
feed water heaters and flow startups, particularly those asso
venturies was subsequently ciated with the flow transients of
hydrolased. cold startups following extending
shutdowns. Since the plant has
condensate polishers and since
Condenser hotwell sludge removed the low pressure heaters were
(by shovel)prior to startup. clear, the HP drains are
consid ered a likely source.
Hotwell sludge accumulation at
tributed primarily to prior oper
ation.
MILLSTONE 2 See above
(Condensate
Polisher
Operative) Piping down stream of 2nd point
heater had plate out deposit such
that 1/32" flakes peeled off. HP
heater (1st point) showed deposit
at tube inlet which reduced flow.
Content Fe203 and metallic copper.
Practice is to hydrolase flow ven See above
turies during outages.
SALEM 1 Condenser hotwell cleaned with broom Black sludge most likely formed
at first refueling outage. during prior operation. Layup
cor rosion would be red.
Follow extended outages, 20
mesh startup strainers installed
for about 1 week in condensate
and
feed pump suction lines. Condensate
pump strainers have been plugged by
corrosion products on startup. Black
sludge accumulates on polishers
during cleanup following outages.
 TABLE H-3 (CONT)
CORROSION PRODUCT TRANSPORT OBSERVATIONS FROM THE FIELD SURVEY
PLANT OBSERVATION/EVENT
GINNA Fouling of water side of No.4 heater
(immediately upstream of feed pump)
resulted in loss of efficiency. Foul
ing on shell side also occured. No. 3
heater tube side also fouled.
MAIN Deposits of magnetite and possibly
YANKEE copper have been noticed in shell
side of feedwater heaters. No
deposits observed on tube side.
Study of suspended solids by site
chemists after 42 day shutdown shows
high spikes (- 5000 ppb) in
particu lates during startup ramps.
ARKANSAS On occasion 1/2 wheel barrow of
ONE sedi ment removed from bottom of the
hot· well.
RANCHO Loss of heat transfer efficiency in
SECO MSR's caused by iron fouling.
Condenser shell inspection after
draining has shown heave magnetite
particulates which subsequently
oxidized to red rust.
TIHANGE 1 A change to morpholine pH control was
made to reduce corrosion in the MSR's
and steam system which resulted in
reduced oxide transport to the
S.G.'s.
COMMENT
Condensate system is the assumed
source of corrosion products in
heater water side. Main steam and
reheater lines are assumed source
of shell side fouling.
Magnetite indicates that release
of corrosion products from steam
and extraction system piping and
reheater tubing during normal
operation is the source of shell
side fouling.
This indicates the release of
corrosion products into the
secondary fluids during power
ramps and corresponding flow
increases which occurred subse
quent to prestartup cleanup.
See Trojan and Millstone above.
Secondary system corrosion pro
ducts in the feedwater tend to
pass through the OTSG's and ac
cumulate in the MSR's. Subse
quent release would be to the
drain tank.
The presence of magnetite indi
cates the corrosion products
were formed during prior
operation and not during an
outage.
The MSR's and adjacent steam
paths are a significant source of
corro sion products.
REFERENCES

H-1. EPRI Program RP404-1 and RP704-1, NWT Corp., PWR Secondary Water
Chemistry Study- Quarterly Reports No. 116-3 to 9 and No. 133-1 to 6.
 Unit Number
l)
2.0 TECHNICAL DATA

2.1 GENERAL

a. Date of commercial operation (Month/Year}

b. Unit capacity (Net MWe)

c. Turbine and MSR supplier

d. Condenser supplier

e. Feedwater heater suppliers

f. Condensate polisher suppliers

g. Use of steam generator wet layup (Yes/No)

h. Type of system or method used to augment

wet layup (circulation, gas sparging, thermal
mixing)

i. Use of deaerators (Yes/No)

j. Deaerator supplier

k. Use of post outage-prestartup feedwater system

cleanup system or method (Yes/No)

I. Use of extensive layup procedures for secondary

system (non-steam generator! components (Yes/No)

I-4
 Unit Number
r>
2.2 TECHNICAL

a. Condenser

- Present tube material(s) (SS, Ti, Cu alloy -

Please name alloy)

Main bundle

Air removal

- Tube sheet material

- Condenser type (e.g., single pass, single

or multi shell, multi pressure, parallel or
perpendicular to turbine)

b. Feedwater heater tube material - LP

HP

c. MSR tube material

d. Type of condenser cooling cycle

(e.g., open, tower)

e. Type of condenser cooling water (name of body

of water - fresh, salt, brackish)

f. Condenser cooling water treatment, if any

 Appendix I

STEAM GENERATOR OWNERS GROUP SECONDARY SYSTEM

LAYUP AND CLEANUP EVALUATION MAIL
QUESTIONNAIRE

The purpose of this questionnaire is to obtain preliminary information for an

investigation of utility secondary system layup practices during extended out
ages, cleanup methods used following such outages, and the effects of
condensate polisher operation. The overall aim of the investigation is to
determine the relationship between these practices, sludge transport into the
secondary side
of the steam generators, and steam generator corrosion.

Experience over the years has shown that sludge accumulations can build up in
steam generators. Generally these sludges consist mainly of magnetite. How
ever, in plants with copper containing material in the feed train it is not un
common to find sludges containing large amounts of copper. In addition, sludge
transported into the steam generators has been observed to be significantly
higher than normal following an o!ltage

Laboratory test program have shown that copper species contribute to the type of
accelerated corrosion of carbon steel associated with denting. Also, in vir
tually all cases, plants that have undergone extensive denting have high copper
containing sludges. Furthermore, field experience has shown that other corro
sive conditions (tube cracking or thinning)can be produced in the vicinity of
sludge deposits, evidently as the result of contaminant concentrations which
occur in these deposits.

The information obtained from this questionnaire will be used as a guide in the
selection of a number of representative plants for a subsequent, more detailed
field survey to be accomplished by means of site visits.

I-1
 SECONDARY SYSTEM LAYUP AND CLEANUP EVALUATION
MAIL QUESTIONNAIRE
(A Steam Generator Owners' Group Project)

Station Name and Address: Utility Name and Address (Main Office)·

Station Superintendent's Name: Person to Contact

(Re: Secondary System Evaluation):

Position:

1.0 STATION INFORMATION/RECORDS

1.1 For each item (a through j) please indicate "C" for complete and "P" for partial records available
over the unit life.

Unit Number
r>
a. Utility's inhouse studies and publications related to (1) secondary system layup,
(2) steam generator wet layup, (3) secondary system cleanup and (4) condensate
polishing

b. Power operating histories and dates and duration of outages

c. Design information on turbine cycle systems and equipment, including

condensate polishers, such as system arrangements, system descriptions,
operating and maintenance instructions and procedures

d. Operational and maintenance histories and records for turbine cycle systems
and equipment, including condensate polishers

e. Secondary system and steam generator layup procedures

f. Secondary system clean up procedures

g. Auxiliary secondary fluid system arrangement and system descriptions,

including auxiliary feedwater system, condensate purification system, and
cleanup systems

h. Feedwater, condensate and steam generator chemistry sampling procedures and

sampling locations

i. Feedwater, condensate, steam generator and condensate storage chemistry records

j. Records of corrosion product transport on startup, sludge accumulation and

sludge properties

Note: NA indicates not applicable

1-5
 Unit Number I)
g. Steam generator secondary water chemistry
(Provide inclusive dates: Month/Year)

- AVT from Unit initial operation

- Phosphate initially followed by AVT

- Phosphate from Unit initial operation

h. Steam generator secondary side corrosion

information (as of Month/Year)*

- Approximate percent of tubes dented

- Known tube support plate ligament cracks

(Many/Few/None)

- Number of tubes plugged due to denting/

SG (exclude tubes plugged due to preventative
plugging)

- Number of tubes experiencing thinning/SG

- Number of tubes experiencing cracking/SG

- Number of tubes plugged due to thinning or

cracking/SG

- Total number tubes/SG

• Please provide estimates only for the firu six items under h. Data will be used only for comparison purposes.
 Unit Number
(>
i. The number of times the steam generator tube
sheets have been cleaned of sludge accumulations.

j. The method of sludge removal

k. Approximate total sludge removed per unit

(lbs or gals)

I. Predominant elements in sludge (e.g., approximate w/o

of Fe, Cu, Ni, Zn, Cr, P)

m. Approximate frequency of feedwater heater tube

leaks during the last two years

n. Frequency of sludge removed from feedwater

heaters (Frequently/Infrequent)

o. Blow down information following extended outages.

- Duration (Hours Max/Avg)

- Corresponding rate

- Conductivity standard for startup

p. Condensate polishers
- Installed and operating (type)

- Planned (Month/Year)

- Operating mode (startup, continuous)

- Any observed-high t:,.p (Yes/Not

Low exchange capacity (Yes/No)

I-7
 Unit Number

q. High pressure drains

- Pumped forward or back to condenser

During startup (Yes/No)

During operation (Yes/No)

- Filtered (Yes/No)

r. Inspection of turbine cycle piping and equipment

surfaces at the beginning or end of extended
outages (Yes/No -- please comment)

3.0 COMMENTARY

3.1 Would you make your station records relating to the secondary system design, operation and maintenance
available to an EPRI/Westinghouse survey team visiting your station?

Yes _ No _

3.2 The EPRI/Westinghouse survey team visits are scheduled to take place between July 15 and October 15, 1979.
Please indicate the first and second choice periods most convenient for you. Visits will be limited to no more
than two days at any one station plus one day at utility headquarters.

From To

First choice

Second choice

3.3 Please comment on operating and maintenance experience which have a bearing on corrosion product
formation in the turbine cycle piping and equipment and transport into the steam generators, including
time and methods involved for cleanup, where applicable. Use back of sheet if more writing space
is needed.
 Appendix J

STEAM GENERATOR OWNER'S GROUP SECONDARY

SYSTEM LAYUP AND CLEANUP EVALUATION FIELD
SURVEY DATA FORM
September 1979

The Field Survey Data Form is provided as an aide in the gathering of informa
tion during plant site visits by the EPRI survey team. The form is forwarded in
advance of the visits to provide a basis for planning the visit with cognizant
utility representatives and, where appropriate, to facilitate information re
trieval.

The information obtained is to be used in support of three EPRI projects con

cerning secondary system layup, condensate polishing, and steam generator lay
up. The intent of these projects is to utilize industry experience to identify
possible improvements in secondary system layup and cleanup practice, condensate
polishing utilization and steam generator layup methods in order to minimize
steam generator corrosion and the transport of secondary system corrosion pro-
ducts and contaminants into the steam generator. The ultimate objective is to
minimize the ingress of substances which may be directly or indirectly conducive
to secondary side steam generator corrosion.

The Field Survey Data Form is organized into four major categories reflecting
the general physical organization of the systems of interest in a nuclear
gener ating plant and the specific projects covered by the survey; namely
Secondary System Layup and Cleanup (Sections 3 and 6), Makeup Water System
(Section 7), Condensate Polishing (Section 8), and Steam Generator Layup
(Section 9). Within
these broad categories, the form is divided into design information, chemistry
information, and operation and maintenance information in order to more readily
separate out sections according to specific departments within the utility.
Items of information which may be available from the recent mail questionnaire
and/or sources outside the utility are included for the sake of completeness and
to assure that their inclusions in the data is visible.

J-4
 TABLE OF CONTENTS

Section

1.0 GENERAL SURVEY INFORMATION J-4

1.1 Station/Unit Information J-4
1.2 UtiIity/Station Contacts J-4
1.3 Survey Team J-4
1.4 General Survey Comments J-4

2.0 DOCUMENT REQUEST LIST J-5

3.0 GENERAL TECHNICAL DATA J-6

3.1 Secondary System Operating Parameters J-6
3.2 Steam Generator Information J-6
3.3 Special Secondary System Features J-6
3.4 Steam Generator Corrosion Information J-7

4.0 SECONDARY SYSTEM DESIGN DATA J-8

4.1 Main Steam System J-8
4.2 Main Feedwater and Condensate Systems J-10
4.3 Condenser and Cooling Water System J-11
4.4 Heater Drain System and Deaerator System J-13
4.5 Cleanup System for Feedwater and Condensate J-14

5.0 CHEMISTRY INFORMATION J-15

5.1 Chemistry Requirements for Normal Operation J-15
5.2 Short Duration Shutdown Conditions J-17
5.3 Extended Shutdown Conditions - Chemistry Information J-21
5.4 Analytical Facilities J-26
5.5 Chemistry and Corrosion Effects J-27
5.6 Interfacing Systems and/or Conditions J-28
5.7 Cleanup System Chemistry Requirements J-30
 TABLE OF CONTENTS (CONT.)

Section

6.0 OPERATION AND MAINTENANCE INFORMATION 7-31

6.1 Secondary System Layup History and Practice J-31

6.2 Main Steam System J-34
6.3 Feedwater and Condensate Systems J-36
6.4 Cleanup System for the Feedwater/Condensate System J-37
6.5 Condenser Water Side and Cooling System J-39

7.0 M/l.KEUP WATER PLANT J-41

7.1 Makeup Water System Design J-41

7.2 Makeup Water Chemistry Information J-42
7.3 Makeup Water Plant Operation J-44

8.0 CONDENSATE POLISHING SYSTEM J-45

8.1 Polisher Design J-45

8.2 Condensate Polishing Chemistry Information J-49
8.3 Cendensate Polishing Operation and Maintenance . J-52

9.0 STEAM GENERATOR LAYUP J-55

9.1 General
9.2 Steam Generator Wet Layup J-55
9.3 Steam GenBrator Dry Layup J-60
9.4 Steam Generator Layup Corrosion J-61

10.0 UTILITY RECOMMENDATIONS J-63

11.0 ADDITIONAL INFORMATION J-64

J-3
1.0 GENERAL SURVEY INFORMATION

1.1 Station/Unit

Name/ Address Utility Name

Phone --------------
Unit Rating----------- Date of Commercial Operation -----
NSSS Supplier ------- A/E Turbine Gen --------

1.2 Utility/Station Contacts

Name Position Location/Phone

1. --------------------
2. -----------------
3. --------------------
4. ------------------
5. --------------------

1.3 Survey Team

Name Dates of Survey

1. ----------------------------
2. ----------------------------
3. --------------------------------
4. ----------------------------

1.4 General Survey Comments

J-1
2.0 DOCUMENT REQUEST LIST

2.1 Design Documents

Literature, articles, in-house studies or evaluations on: main steam, feedwater, and condensate
system layup and/or cleanup and layup chemistry; secondary system corrosion and corrosion
control; corrosion product transport into the steam generators; and steam generator corrosion.

Flow diagrams and descriptions for:

Main steam system

Main feedwater and condensate systems
Auxiliary feedwater system
Turbine cycle makeup water system
Condensate polishing system
Air removal system
Drain system
Secondary system cleanup and/or recirculation systems
Steam generator wet layup system
Steam generator blowdown system
Chemical waste system

Turbine cycle heat balance.

mation

Chemistry logs of analyses for all samples taken from the feedwater an con en
two days prior to until five days subsequent to all startups and shutdowns longer than four
days during the past two years.

Steam generator blowdown chemistry logs (same periods as above).

Makeup water chemistry logs for all of the periods for which feedwater chemistry logs are
requested.

Raw makeup water chemistry logs for periods corresponding to those for the makeup water.

Sludge lancing reports and evaluations.

Secondary systems layup chemistry requirements including component manufacturer's

recommendations.

2.3 Operation and Maintenance

Turbine cycle component layup procedures.

Secondary system cleanup procedures.

Secondary system startup and shutdown procedures.

Power operating history.

J-5
3.0 GENERAL TECHNICAL DATA

3.1 Secondary System Operating Parameters (Normal/Rated)

Steam pressure, psig Feedwater temp, ° F -----------

Steam flow, lbs/hr ------ Condenser vacuum, in. Hg
Condensate flow, lbs/hr ---- Slowdown rate, % ------------
Condenser cooling water flow, gpm

3.2 Steam Generator Information

Supplier/Type ------- Model Overall dimensions ------

-------
Secondary volume, tt 3 (total) _ Below top of primary separators------
Below top of tube bundle------- Wet layup liquid volume ----------

Secondary Side Penetrations Size, in. Use Location

(exclusive of instruments 12.
and manways):
.-
----_ -
3. _
4. _
5. _

Wet layup mixing features

Sludge removal features -----------------------------

3.3 Special Secondary System Features

Identify the function/service, capacities, pipe size connections, location, significant operating
characteristics.

Deaerator ----------------------------------------------

Condensate polisher, type/supplier ----------------------------

Steam generator heatup system----------------------------

Feedwater recirculation system---------------------------

Feedwater, condensate, or drain filters------------------------

Drains pumped back to the condenser---------------------------

Dual turbines (if any) ----------------------------

J-6
3.40 Steam Generator Corrosion Information

3.41 List the following information for each steam generator (information available from the
Mail Survey indicated by *).
Steam Generator
2 3 4
a) Estimated percent of intersections 1
dented for each support plate (indicate 2
the number of support plates by 3
circling the number, e.g., 5 ) 4
5
6
7

b) Average dent depth/support plate - 1

mils radial 2
3
4
5
6
7

c) Total number of tube cracks

-Due to dents**
-Other

d) Average crack depth (mils)

e) Number of tube locations thinned (>20%)

f) Average wastage due to thinning (mils -

*g) Number of tubes plugged - Denting

- Cracking
-Thinning

*h) Total number of tubes - Dented

- With cracks
-Thinned

*i) Total amount of sludge/year of opera-

tion (identify years)

*j) Total number of tubes

k) Total number of tube-tube support

plate intersections.

•• Assume one crack associated with each dent region.

J-7
4.0 SECONDARY SYSTEM DESIGN DATA

4.10 Main Steam System

4.11 Main Turbine

Manufacturer ---------- Model ------------
Rating: Steam flow, lbs/hr ;.... Pressure, psig ------
3
Internal volume, tt : HP -----
LP-1) _ 2) 3)

Low temperature constraints-----------

Rotation requirements when idle---------
Extraction points:
Turbine To Size Isolation Valve
Type Location*

LP-1
-2
-3

Drain connections:
Turbine To Size Isolation Valve
Type Location*

LP-1
-2
-3

Access ports: Size -------- Location

---------

4.12 Moisture Separators/Reheaters

Number of units --------
Manufacturer--------- Model --------------
Rating: Shell flow, lbs/hr _ Pressure, psig -------
Tube flow, lbs/hr -----
Tube information: Material Dia., in. Number _
Surface area, tt2 _
Shell side: Shell material ----- Tube sheet material _
Separator material --------- Type(s) _

•Adjacent to turbine, close or not close

J-1
 Overall dimensions (external, exclusive of mountings):
Length, ft Diameter, ft

Connections Function Size Number

(include instrument Dia., inches
taps): 1
2. .----- _-
3. _
4. _
5. _

Isolation points ---------------------------

Access ports: Location _ Size, in.------- Number _

4.13 Main Steam Pipe/Valves

Pipe Size, dia., in/Sch. Material Function Length, ft
(>6 in.): (Rough est. ±30')

Pipe material _

Identify the kinds and general function (e.g., isolation, control) of valves (>6 in.) in the
main steam system, including the body and internal materials.

4.14 Turbines for Main Feed Pumps

Model _
Manufacturer ---------
Connections: Sizes, in. Steam flow, lbs/hr Pressure, psig -----
Describe the disposition of the exhaust steam, including air removal and routing of
condensate features:

4.15 Auxiliary Steam System

Rating------------ Heat source---------
Source of feedwater ----------------------
Feedwater processing------------------
Source of makeup water--------------------
Makeup rate, gpm ------------------- Equipment
serviced ----------------------
Normal availability

J-9
4.20 Main Feedwater and Condensate Systems

4.21 Feedwater Heaters

HP LP
8 7 6 5 4 3 2
Manufacturer
Model
Steam flow (rated), lbs/hr

Steam pressure (normal), psig

Tube material
Tube diameter, in.
No. of tubes
Tube surface area, tt2
Shell volume, ft3
Channel head volume, tt3
Channel head material
Tube sheet material
Overall diameter, ft
Connections
Function
Size, in.
Number

Describe the location of feedwater heater isolation valves on both the steam and water
side. Note the type of isolation valve.

list the size, number, and function of instrumentation taps.

Describe how the heaters are vented and whether they are vented separately to the
condenser or cascaded to the next heater.

J-1
4.22 Feedwater/Condensate Pumps

Feedwater Condensate Booster

Number
Manufacturer
Model
Flow, gpm
Head, ft
Casing material
lmpellet material
Fluid volume, ft3
Drive
Connection
Size

4.23 Main Feedwater/Condensate Pipe and Valves

Pipe Size/Sch. Material Function Length

(>6 in.): (Rough est ±30')

Pipe material

Identify the kinds and §eReral function (e.g., isolation, control) of valves (>6 in.) in the
main feedwater and condensate systems, including the body and internal materials.

4.24 List the auxiliary feedwater system pipe sizes and estimated length (±20 ft).

Identify the source of auxiliary feedwater.

4.30 Condenser and Cooling Water System

4.31 Condenser

Manufacturer _
Rating----------
Type _
Cooling water: Flow, gpm --- Temp, a F
(e.g., twin shell, etc.)
Tube Bundle Surface Area
Material Number of Tubes Tube Dia. ft2 % of
Main bundle
Air removal

J-11
Water box: Volume ------ Material ------------
Tube sheet material ------ Type (single/double)--------
Shell volume, ft3(net) ----- Material -------------
Hot well volume/shell, gal--------------------
Type of construction ------ Field erected-----------

Access Ports:
Size Location Number
(e.g., top, side, water box)

Penetrations Size Range Location Number

Identify if connections are available to recirculate from one hot well to another through
the condensate polisher.

Air Removal Equipment and Systems/Location (Describe)

J-1
 Isolation points: Steam side-------------------------

Water side-------------------------

4.32 Cooling Water System

Pipe size, in. Length, ft. (estimate ±10 ft) _

Number of parallel connections to condenser _
Pumps: Number Flow/head, gpm/ft ------
Casing material ------ Impeller material
-----
System isolation-------------------

Drain points--------------------

Type of cooling water _

· e the chemical control system for chemical addition.

4.40 Heater Drain System, Deaerator System

4.41 Drain System

Drain Tanks: Number Size Material

Pipe size, in. Material
Isolation points Valve types (typical)
Vent method
Filters
Drains discharge to

4.42 Deaerators

Number Type Mfg. Rating

Isolation points/valve types
4.50 Cleanup System for Feedwater and Condensate

4.51 Describe the design basis and motivations for the cleanup system. Include whether or not
the system provides for deaeration of the feedwater and condensate before power opera
tion is achieved; the limits before power operation is permitted.

4.52 Sketch system flow diagram including interfaces with other systems.

4.53 Provide the system flow capacity and design operating time. Describe any filters or
similar equipment and how they are used. (NOTE: See Section 5.8 for chemistry
requirements).

J-1
5.0 CHEMISTRY INFORMATION FOR SECONDARY SYSTEM LAYUP

5.10 Chemistry Requirements for Normal Operation

5.11 Main Steam System

a) Main steam system normal operation requirements:

Turbine MSRs Gland Seals Auxiliary Turbine Drains

Moisture, %
Sodium, ppb
Oxygen, ppb
TDS, ppb
Suspended
solids, ppb
Silica, ppb
Ammonia, ppm
Chlorides, ppb
C02 , ppb
Specific cond.
J.Lmhos/cm @ 25°C
pH @ 25°C..

b) Describe the methods of sampling the steam, including the location of sample taps,
sampliflg frequency, and vvhic:h department is responsible for taking the samples.

c) Record and state the reasons for any differences between the requirements in the
above table and those for the condenser steam space. Record whether or not
hydrazine is injected into the condenser steam space and in what quantities.

d) Describe the method for monitoring the chemistry in the condenser steam space,
the frequency of the monitoring, and which department is responsible.
 e) Briefly describe the technique for monitoring air inleakage into the condenser,
including whether or not vent flow is measured.

f) State whether or not dumping air condenser drains are used for controlling
ammonia or C02 concentrations in the condenser.

5.12 Feedwater and Condensate Systems

a) Feedwater and condensate system requirements:

Steam Steam Condensate Condensate
Generator Generator Polisher Pump
Inlet Slowdown Outlet Discharge

pH @ 25°C
Cation conductivity
mhos/em @ 25°C
Specific conductivity
mhos/em @ 25°C
Free hydroxide ppm OH-
1
Sodium, ppb
Dissolved 02, ppb
Iron, ppb
Copper, ppb
TSD, ppb
Suspended solids, ppb

Ammonia, ppm
Amine, ppm
Silica, ppb
Chloride, ppb
Hydrazine, ppb
Other
 b) Describe the method of sampling, locations of sample taps, the proximity of the
cooling coil to the sample tap, length of sample lines, time and rate of purge,
sampling frequency, and which department is responsible for taking the samples.

5.13 Condenser Water Side and Cooling Water System

a) List the water side chemistry requirements during normal operation.

5.14 Check the availability of the operating chemical analyses logs requested in Section 2.2.

5.20 Short Duration Shutdown* Conditions

5.21 Main Steam System, Turbine, MSRs, Feedwater Heater Shells, Condenser Shells

a) Describe the usual environmental conditions which exist in the main steam
system equipment and condenser steam space following shutdown and cooldown.
Particular note should be made of the collection of moisture, ingress of air,
ingress or presence of other contaminants conducive to corrosion.

• Short duration shutdowns are arbitrarily defined 8$ those ,;;;; 10 days for unanticipated or scheduled maintenance where a return
to operation is expected as soon as possible. Extended shutdowns are defined as those > 10 days where the
shutdowns are expected to last several weeks or more.

J-17
 b) Briefly describe any changes which may normally occur in the turbine cycle steam
environment, including the condenser steam space during the first four to ten days
after shutdown for a typical short duration shutdown.

c) Identify those regions/surfaces most susceptible to corrosion in the turbine, MSRs,

feedwater heater shells, condenser shell, gland seal steam system, heater drains,
and auxiliary turbines.

d) Describe briefly, the methods used to determine the environment in the steam
system equipment and spaces normally exposed to steam.

5.22 Feedwater/Condensate Systems, Condenser Hot Well

a) Provide chemical analyses for tour representative short duration shutdowns during
the past two years (use table).

Feed water Condensate

System System Hotwell
Shutdown 1 2 3 4 1 2 3 4 1 2 3 4
Dates-from-to
Sampling
location
pH @ 25°C
Cation cond.
pmhos- 25° C
Specific cond.
pmhos-25°C
Dissolved o2 ppb
Ammonia, ppm
Amine, ppm
Chlorides, ppm
Hydrazine, ppm
,.
TDS, ppb
C02, ppb
Iron, ppb
Copper, ppb
Suspended
solids, ppb

J-18
 b) Briefly describe the sampling method and state when the samples were taken
relative to the shutdown.

c) Comment on the effect of purge (rate and time) on sample accuracy. Comment
also, on restraints imposed by available sample locations. Note, also, the feedwater
system flow status and where the heater drains are directed.

d) Compare the analyses results (5.22-a) with the makeup water analyses provided
in Section 7.21 and record and explain any differences.

e) Describe any experiences or observations which would indicate the degree of

corrosion occurring during short duration shutdowns.

5.23 State which department is responsible for establishing the short duration shutdown
requirements for main steam feedwater condensate and condenser systems, and for
providing instructions to the operating personnel.

J-19
5.24 Describe the extent of chemistry control exercised during the shutdown and indicate
which department is responsible for establishing and maintaining control.

5.25 Report on the sources and amount of air ingress into the main steam and feedwater/
condensate systems during and after shutdown is complete. Report, also, on the ingress
of other contaminants from polishers or condenser inleakage, and/or corrosion product
rei ease.

5.26 Describe the likely changes in the condenser water side and cooling water system
conditions and/or environment during short duration shutdowns (exclusive of draining
to fix tube or tubesheet leaks).

J-20
5.30 Extended Shutdown Conditions - Chemistry Information

5.31 Extended Layup of Main Steam System and Related Equipment

a) Identify the typical extended shutdown layup condition for each of the
following components·
Forced Steam
As Is N2 Blanket* Air Dry* Dehumidify Blanket
Turbine
MSRs
Condenser shell F.W.
heater shell Gland
steam system Drains
Auxiliary turbine

•Note the quality of nitrogen or air.

b) Comment on how the typical conditions correspond with the layup chemistry objective
for each component.

c) Record the frequency and dates where the typtcal condtttons were not matntatned, and
briefly describe the environmental conditions which did exist and reasons for the
non-typical conditions (e.g., repairs). Include all abnormal layup events and state
whether or not significant corrosion was observed or investigated.

d) Where a nitrogen blanket is used, record the typical quantities initially required and
those quantities needed to maintain the required condition. Identify the locations
where the nitrogen is injected.

J-1
e) Where forced dry air or dehumidification is used, describe the requirements and
system capabilities including temperatures, dew point of inlet air and flow rates,
and where access is attained.

f) Where steam is used to exclude oxygen, determine the compatibility of the steam
sources with the secondary system chemistry requirements.

g) Identify the maintenance or layup circumstances, if any, where the turbine is

separated from the condenser by inserting a solid partition between them.

h) Monitoring Techniques for Layup Conditions

Describe the method for checking the layup environment of the main steam
system, turbine, MSRs, feedwater heater shell, and condensers. Include frequency
of checks and locations.

i) Effectiveness of Layup Methods

Report on the effectiveness of the layup methods used for the main steam system
and related components. Identify the measurements used to make such determinations.
 j) Determine if internal surfaces are inspected for surface corrosion during the layup
period. Identify the locations of such inspections and frequency.

k) Describe any experiences or observations which would indicate the degree of corrosion
occurring during shutdowns.

I) Main Steam System Environment during Equipment Repairs

Describe environment conditions during extended equipment repairs. Note equipment

exposed to non-typical layup conditions, nature of exposure, and frequency over the
life of the system.

5.32 Extended Layup of the Feedwater and Condensate Systems

5.321 Describe the circumstance when the main feedwater, condensate system, and condenser
hot well are placed in wet layup or dry layup.

5.322 Wet Layup of Feedwater, Condensate Systems, and Hot Well

a) Chemistry requirements

b) Flow or circulation requirements

c) Locations and methods tor chemical injection

d) Method of monitoring

e) Sampling locations/frequency of sampling and analyses

f) Representative analyses for four representative extended layup periods during the
last two year referencing the samples reported to the respective sampling locations
in (e) above (see Section 2.2, chemistry data log).

g) Compare the analyses results with the makeup water analyses for the corresponding
periods provided in Section 2.2 and record and explain any difference.

h) Describe method for re-establishing wet layup chemistry in the event it is out of
specification.
5.323 Dry Layup of Feedwater and Condensate Systems

a) Conditions of layup
As is N2 Forced air Dehumidity Other

b) Method of implementation, describe

c) Monitoring technique and frequency

d) Surface inspection for corrosion - describe method, surfaces inspected, and

e) Experience - comment on experience using dry layup, noting differences in the

extent of surface corrosion.

5.33 Extended Layup of Condenser Water Side and Cooling System Layup

a) Describe the condenser water side extended shutdown layup environment.

b) If wet layup is used, identify the chemistry requirements. State whether fresh,
sea water, or tower is normally used for the cooling water heat sink.

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 c) If the condenser water side is drained for any length of time, identify any
measures taken to minimize corrosion of the tubes and tubesheets.

d) State whether or not the water side of the condenser is cleaned before returning to
power. Identify the cleaning method. Also, state whether or not reverse flow using
heated water from another shell is employed to kill marine growth.

5.34 Determine the extent of chemistry control exercised for each system and major component
in the main steam, feedwater/condensate, and condenser during extended shutdowns. Also,
determine which department is responsible for establishing and maintaining such control
in each case.

5.40 Analytical Facilities

5.41 Describe the analytical facilities available for establishing and maintammg chemical control
of layup environments. Include consideration of staffing as well as equipment.
5.50 Chemistry and Corrosion Effects

5.51 Chemistry Upsets

a) During operation - comment on possible effect of chemistry upsets during operation

on subsequent layup or outage conditions (e.g., a condenser leak may require shutdown
such that chloride or oxygen in the feed system remain high for considerable periods)
and state what the appropriate corrective actions would be.

b) During layup - comment on real or potential chemistry upsets during layup, their
likely duration, and their corrosion effects on the feedwater or condensate system
(e.g., high oxygen in makeup water).

c) Identify the events, dates, and circumstances of main steam system and feedwater/
condensate equipment malfunction or failure attributed to corrosion, abnormal
chemistry, or corrosion product transport (e.g., deposition of sludge on flow
venturi's).
5.52 Corrosion Processes and Distribution

a) Identify principle corrosion processes occurring during secondary system layup.

b) Record secondary equipment repair history due to corrosion.

c) Determine, to the extent possible, the secondary system corrosion product

distribution, physical state, and composition during layup, following system cleanup,
and during operation.

d) Identify the principle corrosion product transport routes.

e) Identify the principle modes of corrosion product deposition and removal in the
secondary system:;.

f) Determine, to the extent possible, the quantity of the secondary plant corrosion .
product inventory pumped forward into the steam generators following a layup
period.

5.60 Interfacing Systems and/or Conditions

5.61 Heater Drain System

a) Comment on the effect the drain system has on layup chemistry and method of
layup of drain system.
 b) Note if drains are filtered during startup following extended shutdowns.

c) State whether or not the drains are pumped forward or back to the condenser
during startup.

5.62 Air Removal System

Comment on the effect of the air removal system on feedwater/condensate system

layup (e.g., efficiency at low power on condensate oxygen levels).

5.63 Equipment Repairs

Briefly describe the degree of interference feedwater/condensate equipment repairs have on layup
chemistry objectives or procedures. Comment on actual experience, time involved, and potential
system corrosion effects.

5.64 Main Feedwater and Condensate System Chemical, Hydraulic, or Mechanical Cleaning

Event 1 2 3

Purposes

Solvent(s)

Method

Subsequent layup
(wet/dry)

General effectiveness

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5.70 Cleanup System Chemistry Requirements

5.71 List the chemistry objectives and/or requirements of the cleanup system. Include whether
or not deaeration is provided and, if so, state the oxygen limits which must be met
before power operation is permitted.

5.72 Indicate the interface of the cleanup system prior to or during startup with:

a) Condensate polisher

b) Drain system flow back to condenser

c) Specially installed filters

5.73 Describe the method for monitoring the cleanup system, including the locations from which
samples are taken. State which department is responsible for sampling and analyses.

5.74 Provide chemistry data during cleanup for startups during the past two years. Include
specific evaluations used to measure the status of cleanup during each operation.
6.0 OPERATION AND MAINTENANCE INFORMATION

6.10 Secondary System Layup History and Practice

6.11 Summarize on Table 6.11 (page 6.3) the secondary system layup history for the past five
years. For very short shutdowns of four days or less, layup will be assumed to be "As Is"
and is not pertinent to this study. For this reason, layup conditions for shutdowns less
than or equal to four days are not to be included.

6.12 Secondary System Layup and Cleanup Practice

a) Identify which department is responsible for the implementation and surveillance

of layup for main steam systems, main feedwater/condensate systems, the condenser,
and cooling water system.

b) State which department is responsible for cleanup operations.

c) State whether or not a time limit is established for allowing each secondary system to
remain in the "As Is" condition before implementing layup procedures.

Main steam system, turbine,

MSRs, F.W. heQter, and
condensate shells
Feedwater/condensate system

Condenser water side and

cooling water system
d) State what, if any, recommendations for layup have been provided by the suppliers
of turbine cycle equipment. Refer to Section 2.3.
Turbine
MSRs
Feedwater heaters
Condenser
Pump
e) Identify the specific roles, if any, the following systems or equipment fulfill during
layup of cleanup:

Makeup water

Drain system

Air removal

Deaerator

S/G blowdown

Auxiliary feedwater

Auxiliary boiler

f) Identify the events, dates, and circumstances of secondary system equipment malfunction
or failure attributed to corrosion, abnormal chemistry, or corrosion product transport
(e.g., deposition of sludge on flow venturi's) not reported in Section: 5.51.c.

g) Report on the corrosion product distribution in the secondary system observed during
layup. Comment on the cause of the corrosion and the distribution observed. Indicate how
the distribution was determined.

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 6.11 Summary of Seconda y System Layup History

Prior Operations Type of Layup (Sl

Dates 111 Feed-Cond.
From- Type 131 '
Heat Exc. System and Cond.
To Purpose(2l Shutdown Days Mode(4) Turbine MSRs Shell Hot Well Shell S/G Comment

c...
I
w
w

1. Only shutdowns > 4 days. 5. Types: AI - As Is

2. e.g., refuel, maintenance, repair SB Steam Bla ket
NB - Nitrogen lanket
3. SO - short duration, 4-10 days Wl- Wet layu
E - extended, > 10 days
DA - DehumidiI ed Air
4. Mode - Normal = Power ;;. 50%; or Other FA -· Forced A i Circulation
6.20 Main Steam System

6.21 Main Steam System Layup

a) Describe the procedures for implementing layup of the main steam system, turbine,
MSRs, feedwater heater, and condenser shells. Include the points where the system
section or component is isolated from interfacing systems and the type of valves used.
Include, also, the times required to achieve layup.

b) Identify the need for and extent of surveillance practiced regarding layup conditions
in the condenser shell.

c) Describe the differences in the layup procedures used when one or more components
in the steam side systems and equipment are being repaired.

d) Report on other non-normal experience during layup (e.g., cleaning operations and
extended periods open to the atmosphere).

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 e) Describe the procedure used to return the system to operation and purge the system
and components of layup chemicals. Include the time required to complete the purging
process.

f) Describe the procedures used to return the system to operation where no special layup
environment is provided and the system/components are filled with air.

g) Describe the procedure(s) for returning the condenser steam side to operation. Note
particularly the methods, effectiveness, and time required to remove air and gas in both
the steam side and hot well water.

6.22 Main Steam System Cleanup

a) Describe any methods used for cleanup of steam system piping, components, or related
systems.

b) Provide the time required to cleanup the major components, e.g., turbine, MSRs, shell
side of the feedwater heaters.

c) Indicate the typical provisions for access to the turbines and MSRs for cleaning or repair.
 d) Elaborate on significant problems or difficulties encountered during cleanup of the major
main steam system components.

e) Report on the extent the drain system is used to cleanup the main steam system.

6.30 Feedwater and Condensate Systems

6.31 Feedwater and Condensate Systems Wet Layup

a) Describe the procedures for implementing wet layup of the feedwater and condensate
systems. Identify the valves (and type) by which the systems/components are isolated
from interfacing systems.

b) Record the typical times required to achieve layup.

c) Elaborate on where the layup chemicals are injected, why these points were selected,
and the methods used to ensure mixing of the chemicals. Include whether batch or
continuous methods are used and the means of control.

d) Describe how the feedwater and condensate systems are returned to the layup specifications
if, during the outage, out-of-specification conditions develop.

e) Describe the procedure used to return the systems to operation and purge the system
of layup chemicals. Include the time required to complete purging process.
 f) Describe the procedure used to return the system to operation where no special layup
environment is used and the systems are filled with oxygenated water or filled with air,
and/or contaminants in excess of specification limits.

g) Describe the differences in the layup procedures used when one or more components
in the feedwater and condensate systems are being repaired.

6.32 Feedwater and Condensate Systems Dry Layup

a) Describe the procedures for implementing dry layup of the feedwater and condensate
systems. Include the points of isolation from interfacing systems and/or components.
Include, also, typical times required to complete layup operations.

b) Describe the procedure used to return the system to operation.

c) Describe the differences in the procedures used when one or more components in the
feedwater and condensate systems are being repaired.

6.40 Cleanup System for the Feedwater/Condensate Systems

6.41 Cleanup Systems and Practice

a) Describe methods used for cleanup of the condensate feedwater train prior to returning
to operation.

b) Note whether or not a cleanup circulating line(s), bypassing the steam generator, is used.

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 c) Specify whether or not condensate polishers are utilized in the cleanup process.

d) Specify whether or not filters, centrifuges, or other devices are employed for cleanup in
recirculating lines, drain system, and condensate system.

e) List the circumstances where cleanup is accomplished by steam generator blowdown.

f) Identify if, and under what circumstances, the drains are pumped back to the condenser
in order to clean up the feedwater.

6.42 Cleanup Experience

a) For outages of ten davs or more during the past two years, report the actual cleanup
experience associated with the subsequerrt startup and return-to-power operation.
(Cleanup time = time to bring feedwater chemistry within specification limits.)

Date Time, Comment

From-To- Method of Cleanup hours Effectiveness (abnormal events)

b) Elaborate on significant problems, difficulties, and/or improvements experienced during

feedwater cleanup operation.
6.50 Condenser Water Side and the Cooling Water System

6.51 Layup Practice

a) Describe the procedures for securing the condenser water side and the cooling water
system. Include the circumstances when the condenser is isolated from the cooling
system and drained.

b) Describe any circumstances when circulation of the cooling water is maintained during a
shutdown period and note the circulation rate. Also, indicate if a time limit is established
for stagnant water conditions in the condenser water side and/or the cooling water system.

c) Describe the methods used to control algae and other organic growths. Also, indicate
how ferrous sulfate is added, if it is used.

d) Briefly describe the method used to clean out the water side of the condenser and the
cooling water system. Include reference to reverse flow thermal treatments for marine
growth removal.

e) Note the circumstances where a condenser tube leak can be repaired while at power.
6.52 Layup History

Summarize the layup history of the past five years for the condenser water side and cooling
water system. Exclude brief shutdowns for leak detection and tube plugging of four days
or less.

Date Type of Layup

From-To- Condenser - Water Side Cooling - Water System

Legend: A·l = As Is
D = Drained
S = Stagnant
C = Circulating
T = Treated (specify)
0 = Other
7.0 MAKEUP WATER PLANT

7.10 Makeup Water System Design

7.11 Process Equipment

a) Sketch process equipment flow diagram. Indicate type, manufacturer, and model
size/capacity.

parameters, and

c) Describe process used for makeup water for the secondary systems. Include the chemistry
requirement, including the quality limits and particularly the oxygen limits; also include
the typical source water chemistries. Check the availability of representative raw source
water chemistry data in Section 2.2.

d) Identify the sources of raw water.

e) Record the in-line instrumentation setpoints.

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7.12 Water Storage Facilities
a) Identify the water storage facilities available at the station/unit site.

b) Secondary System Storage Tank -Size----- Material---------

Oxygen Exclusion Method - Describe--------------------

Used for Auxiliary Feed (yes/no)------ Volume ------------

c) Pipe Supply Lines from Tank

Size _
Material ----- Estimated Length ------------
Isolation Points Type-----------------

7.20 Makeup Water Chemistry Information

7.21 Makeup Water Chemistry Data

a) Provide makeup water analyses data corresponding to the four representative shutdowns
selected in Section 5.22-a (use table).

Shutdown 1 2 3 4
Dates, From - to -
Sampling location,
pH @ 25°C
Cation conductivity, pmhos -
25°C
Specific conductivity,
11mhos - 25°C
Dissolved 02 , ppb
Ammonia, ppm
Amline, ppm
Chlorides, ppm
Hydrazine, ppm
TDS, ppb
C02, ppb
Iron, ppb
Copper, ppb
Suspended solids, ppb

b) Check the availability of the chemical analyses log data requested in Section 2.2.

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7.22 Makeup Water Control
a) Describe the methods, if any, for deaerating the makeup water.

b) Briefly describe the method for monitoring makeup water chemistry, frequency, and
location of sampling.

c) Makeup water demand; record typical quantities.

Quantity (gallons) Dates
1) Normal operations
2) Extended shutdown
3) Cleanup of secondary systems

d) State how makeup water is introduced into the secondary systems during shutdown:

2) During cleanup

3) Auxiliary feedwater usage

e) Makeup water upsets

Describe the course of action taken when the makeup water is out of specification:

1) During operation

2) At or during shutdown

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7.30 Makeup Water Plant Operation

7.31 Operation

a) Identify which department is responsible for the supervision of makeup water

plant operations.

Chemistry department

Operations department

Other

b) Note how regeneration is accomplished

Manually

Fully automatically

Partially automatically

c) Indicate how many operators are required.

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8.0 CONDENSATE POLISHING SYSTEM

8.10 Polisher Design

8.11 Polisher Supplier(s) ----------------------------

Type Model

Date installed------------------- Operation: From-------- to-------

Installed by Capacity

8.1.2 Describe the design basis for installing polishers, include the primary motivation and
secondary reasons (e.g., to counteract condenser leakage, reduce startup time, to filter
particulate). Indicate whether polishers are planned, installed, operating.

8.13 Prior Utility Use of Condensate Polishers

List other units (nuclear or fossil) where polishers have been used; if none, so state.

Unit Type (Deep Bea or Piltei) Performance Experience

8.14 General Design Information

a) Bid specification: Prepared by Evaluated by _

b) Performance Requirements: Inlet Outlet

Dissolved solids ----------

ParticuIates

Silica
Specific conductivity

c) Basis for regeneration----------------------------------

d) Special requirements added to suppliers standard specification-------------

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8.15 Deep Bed Design Parameters

a) Service vessels: Number Dia./height, ft.-----

Bed depth, ft ---------- Pressure, psig
------- Temperature, °F Flow rate, gpm _
Resin ratio Vessel material _

b) Sketch a flow diagram showing major equipment and interfaces with related systems.

c) Equipment
Dia. Height Capacity Material of Construction
Cation tank
Anion tank
Resin storage tank
Acid tank
Alkali tank
Pumps: Flowrate (gpm) - Acid Water Heaters (for Alkali)
Alkali Flowrate, gpm Outlet temp, °F
Other Air blower (resin mixing)-capacity, CFM

Filters/Strainers - Type Size Location

1. ---------------------------
2. -------------

3.------------------------
4.

5.----------- ------------------
d) Identify tanks, pumps, and related equipment used for recovery and re-use of
partially spent acid, alkali, and/or rinse water.
8.16 Filter Type Polishers - Design Parameters

a) Service vessels, number--------------

b) Vessel Parameters:

Diameter, ft --------- Filter Elements:

Height, ft. ---------- Number vessel-----------
Materials of construction ------ Types of seals-----------
Diameter, in. _

Height, ft ------------
Material _

Construction------------
Spacing (min. betw. elements) _

c) Design Parameters:

Flow direction: Up Down-----

Flow rate (gpm): Holding _
Operation _

Pressure, psig
Temperature, oF _
Resin coating thickness, in.: Minimum Maximum _
Number of different precoat formulations used-----------------
Holding pumps: Flow capacity, gpm _
Head, psi, temp _
Horsepower _

Materials of construction------------
Slurry tanks - Dia., ft Height, ft ---------
Materials of construction _

d) Identify tanks, pumps, filters used for resin separation, resin disposal, and water
recovery.

8.17 Instrumentation (deep bed or filter):

Type Number location in System Normal Set Point

(Refer to Sketch)
Automatic regeneration control
Sodium analysis
Chloride analysis

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Type Number Location in System Normal Set Point
(Refer to Sketch) S
p
e
c
i
f
i
c

c
o
n
d
u
c
t
i
v
i
t
y

m
e
t
e
r
s

C
a
t
i
o
n
 e
c n
o s
n o
d r
u s
c
t P
i r
v e
i s
t s

y u
r

m e

e
t s

e e

r n

s s
o

p r

H s

m F

e l

t o

e w

r
8.18 Interface
s Considerations
Silica a)
Temperature sensors
Det
6 er
mi
P ne
if
spe
s cial
 bypass lines are installed from each polisher vessel outlet
to the suction side of the condensate pump and the
design flow capacity of these lines.

b) Identify whether or not cleanup system lines are

installed from the final feedwater heater discharge
back to the hot well and the flow capacity of these
lines.

c) Identify special additional equipment such as

ultrasonic resin cleaner, cation beds, or special filters.

d) Describe waste liquid treatment and disposal systems.

e) Describe briefly, the methods and equipment for spent resin

disposal.

f) Identify facilities for handling radioactivity (such

as shielding, remote handling, special disposal
equipment).
 g) Identify any design modifications made since the original installation of the condensate
polishing system. State reasons and results obtained.

h) Determine if the condenser is designed to permit tube leak repairs during operation.

8.20 Condensate Polishing Chemistry Information

8.21 Chemistry Function of Polisher

a) Cleanup after shutdown period

b) Continuous 100 percent polishing
c) Continuous < 100 percent polishing
d) Operation during periods of condenser leakage

a) Type of resin currently in use

Gel
Macroporous
Ratio of cation to anion resin
Supplier
b) Polishers are operated in

H - OH form
NH4- OH form
Other

c) Resin makeup rate per fuel cycle Cation

Anion
d) Age of resin

e) Number of regeneration cycles per batch

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8.23 Resin Regeneration

a) Indicate how regenerated chemicals are specified.

b) Regenerant chemical dosages, lbs/ft3

Acid---------
Alkali---------
Other _

c) Describe how the resins are cleaned.

d) State what type of tests are used to determine resin capacity and physical condition.

e) Quantity of condensate normally used for:

Regeneration deep bed polishers-----------------

Back washing and recoating filter type _

f) Report whether or not the rinse requirements increase with each regeneration
cycle of deep bed polishers and list the initial and present amount of rinse
water currently required. State the conductivity requirement that is used to
indicate that rinsing is complete.
8.24 Waste Disposal

Describe the methods for waste treatment neutralization and settling - and disposal.
Indicate whether direct release, shipped by bulk or drum, or other.

8.25 Chemistry Operation Information

a) List the condensate polisher operating data routinely recorded.

b) Describe how the data is evaluated.

c) Indicate the schedule for obtaining polisher in-out samples.

d) Describe the analytical methods used on these samples.

e) Typical data for polisher operation

Average Above Average Below Avera ge

Run Run Run

Percent of condensate
polished

Condenser leakage, gpm

Polisher water analysis

Inlet

Outlet

Run time to breakthrough

or high llP

Resin consumption
(filter type)
 f) Transient Experience

Describe the frequency and effect on polisher performance of the following transients:

Condenser leakage

Load change

Startup after shutdown

g) Describe the effects of any modifications to the polisher system or components on

polisher performances.

8.30 Condensate Polishing Operation and Maintenance

8.31 Opetation

a) Identify which department is responsible for the supervision of condensate polishing

operations.

Chemistry department
Operations department
Other

b) Note how regeneration is accomplished

Manually
Fully automatically
Partially automatically

c) Indicate how many operators are required.

d) Describe how operators are trained. Indicate whether or not training is by a formal
program, on-the-job, or other.

e) Provide copies of condensate polishing procedures.

f) Check the availability of plant operating data requested in Section 2.2 and 2.3,
particularly chemistry logs, makeup water logs, and power operating history.
8.32 Maintenance

a) Note the items and schedule subject to routine maintenance:

Items Inspection Resin Test Filter Calibration/Replacement

and Change
Replacement

Polisher

1.

2.

3.

4.
5.

Regeneration
Equipment -

2.

3. NA

4.
5.

I & C
- -
1.

2.

3. NA NA

4.

5.

b) Note the cleaning practice. Include: criteria, method used, and effectiveness.

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c) Report on the failure and repair history for condensate polishing system and related
equipment. Include the following:

Description of failure

Reason ior iailure

Repair procedure

Effect on polisher availability

9.0 STEAM GENERATOR LAYUP

9.10 General

9.11 Extended (long-term) Layup

a) Preferred mode (wet/dry)-------- Circumstances-----------

b) Alternate mode (wet/dry) Circumstances-----------

9.12 Obtain copies of the wet and dry layup procedures.

9.13 Check the availability of chemistry and operating information requested in Section 2.2
and 2.3 and the steam generator information in Section 3.2.

9.20 Steam Generator Wet Layup

9.21 System or concept to ensure mixing of layup chemicals with the bulk water within the
steam generator.
a) Pump recirculation (yes/no)
b) Nitrogen injection or gas lift
c) Thermal mixing
d) Fill and drain
e) Other
f) None

a) Sketch the flow diagram for the recirculation system. Indicate major equipment and
instrumentation, inlet and outlet connections, flow rate, pipe sizes, and interfaces
with other systems.

b) List the functional requirements for the system. Note the duration of mixing required.

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 c) Note whether or not the system includes other features such as ion exchange
facilities, heat exchange capacity, ability to transfer water from one steam generator
to the other. Describe the purpose and effectiveness of each feature.

9.23 Nitrogen Injection System

Where nitrogen is used to induce mixing, provide the following:

a) Point of injection
b) Flow rate (SCFM)
c) Method of injection
d) Duration of injection (hrs)
e) Nitrogen purity
f) Describe the means used for determining the end of the mixing process.

g) Identify the criteria used for determining the need for repeated applications during
prolonged shutdowns.

h) Describe how nitrogen over pressure is implemented and maintained.

i) Identify the circumstances where low pressure steam or auxiliary steam could
be used as a cover gas.

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9.24 Layup Chemical Injection

a) Steam generator shell-side injection points

,.
2·----·
34.·----------------------------------_-
b)
5·--------------------------------
Describe the way the layup chemicals are delivered to the steam generator
1. Direct metering pump discharge into the feedline
2. Slugging in by way of the auxiliary feedwater system
3. Blending into a recirculation loop
4. Other (describe)

9.25 Steam Generator Water Level during Wet Layup

Identify the water level requirement during wet layup.

9.26 Steam Generator Wet Layup Chemistry

a) Record the time period required to establish unifor

erator.

b) List the wet layup chemistry requirements - indicate limits used for control
(including those of contaminante, e.g., oxygen).

c) Record the freouency the layup chemistry is sampled in each steam generator.
Note if only one is sampled and used as an indication of the condition of the
others.

d) Identify the location(s) from which samples are taken from the steam generators.

e) State whether or not samples have shown significant stratification or lack of

mixing of layup chemicals, or contaminants (e.g., oxygen). Describe the
circumstances.

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f) Record any recommendations for preferred sampling locations. Describe the basis.

g) Describe the chemical analyses of steam generator liquid samples during the layup
period. Note whether or not analysis for contaminants are made such as for chlorides,
sulfates, or oxygen.

h) State which department is responsible for maintaining the steam generator wet
layup conditions.

i) Describe the actions, if any, prescribed for returning the bulk water layup chemistry
within specification upon noting a contaminant level above specification.

j) State whether or not deaerated makeup water is used for filling or adjusting the steam
generator water level during layup (refer to Section 7).

k) State how the oxygen level of the makeup water is monitored while adding water to
the steam generator during wet layup (refer to Section 7}.

I) Indicate the oxygen level typically maintained in the makeup water (refer to
Section 7).

m) Where deaerated makeup water is not used, describe how oxygen is scavenged.

n) Where hydrazine is used, indicate whether or not it is catalyzed.

o) State whether or not a nitrogen blanket is maintained above the water level in the
steam generator.

p) Note the magnitude of nitrogen overpressure maintained, including how it is maintained

and how and where it is monitored.

q) Where a nitrogen blanket is not maintained, state what provision, if any, are prescribed
to prevent oxygen ingress into the steam generator.

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9.27 Steam Generator Wet Layup System Operation and Maintenance

a) Identify which department is responsible for monitoring the steam generator shell-side
layup conditions.
b) Indicate the method for establishing an oxygen-free wet layup chemistry after returning
from a period when the shell-side has been open for maintenance. Note one of the
following:
Pull vacuum prior to fill with deaerated water _
Nitrogen purge to fill with deaerated water _
Treat fill water with oxygen scavenging chemicals----------
Other (describe)-----------------------

c) Describe the procedure for treating wet layup fill water with oxygen scavenging
chemicals. Indicate what temperature limits are observed.

d) Identify the time period experience has established as required to establish uniform wet
layup chemistry conditions within the steam generator.

g) Describe the procedures used for returning the steam generator shell-side water chemistry
to that specified for normal operation. Particularly, note the following:

The manner by which the ammonia level is reduced to within normal operating limits.

Describe the methods used to cleanup non-volatile contaminants both dissolved and
particulate (e.g., drain and fill, blowdown, other).

Identify the prov1s1ons made to achieve effective blowdown cleanup prior to a return
to normal operation. Note whether or not:

Slowdown flow is purified or discarded.

Slowdown flow is limited by plant makeup water capacity.

The feedwater system is cleaned up independently via recirculation or by

flushing and draining or is pumped forward into the steam generator.

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9.30 Dry Layup

9.31 Dry Layup Atmosphere

a) Type:
Ambient air _
Circulated ambient air------------
Dehumidifed air _
Filtered ambient air _
Other (specify)--------------
b) Record the temperature, pressure, flow, and humidity conditions used as control limits
for the selected atmosphere.

c) Where a controlled atmosphere is maintained, describe the process or procedures used

to attain the intended conditions.
1) When the steam generator is opened to the ambient atmosphere for maintenance.

2) At the beginning of an extended shutdown.

d) Note the criterion used to establish that the steam generator has been acceptably dried.

9.32 Dry Layup Instrumentation

a) Identify the parameters sampled and the instrumentation used to monitor the layup
process.

b) Layup Control
1) Parametric control limits
2) Frequency of monitoring
3) Sampling cr sensor locations

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9.33 Steam Generator Dry Layup Operation and Maintenance
a) State whether or not there are provisions to maintain a controlled atmosphere or low
humidity air when the shell-side of the steam generator is open for maintenance
or inspection.

b) Where there are no provisions for a controlled atmosphere during periods when the
shell-side is open for maintenance, indicate whether or not there is a time limit placed
on exposure to moist or humid air.

c) Report on the time period needed to obtain an adequate degree of dryness in the
steam generator shell-side atmosphere

Immediately following cooldown

Following a period of access for maintenance.

d) Where nitrogen is used for layup protection, indicate how much is used

During initial establishment of layup following shutdown

To purge the shell volume of oxygen on resuming dry layup after opening the
shell for maintenance.

9.40 Steam Generator Layup Corrosion

9.41 Record any observations. of steam generator corrosion which has occurred during layup
periods.

9.42 Record any quantitative measurements of steam generator corrosion made covering the
layup period.
9.43 Where corrosion has been observed and/or measured, report:

a) The nature and location of the corrosion

b) Related layup history, including:

Dates of layup chemistry

Abnormalities (e.g., oxygen exposure, moist air, or other contaminants)

Sampling and degree of certainty of composition of the bulk water chemistry

Present steam generator status, Preoperational/maintenance.

10.0 UTILITY RECOMMENDAT!ONS

10.10 What recommendations can the station/utility make in the following areas to minimize the
corrosion of the secondary systems during extended outages and to reduce the corrosion
product transport into the steam generators during subsequent startups?

a) Secondary system layup requirements.

b) The use of dry versus wet layup for the feedwater condensate train.

c) The use of dehumidified air during layup for the turbine, MSR's, and feedwater
heater shells.

d) Recirculation cleanup systems for the feed train.

e) Pumping heater drains back to the condenser during startup.

f) Techniques for monitoring feedwater train layup chemistry.

g) Use of condensate polishing for cleanup.

h) Secondary system layup chemistry program development.

11.0 ADDITIONAL INFORMATION

The following space is provided for notations regarding additional information, statements,
or conclusions pertinent to the survey and not covered by it.

11.10 Secondary System Layup and Cleanup

11.20 Condensate Polishing

11.30 Steam Generator Layup

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