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12

Hist

oric

alPe

rspe

ctiv

eH

istor

ical

Per

spec

tive

�Fl

ow

-acc

eler

ated

corr

osi

on (

FAC)

is n

ot

a new

phen

om

enon

�H

isto

rica

llyit

was

calle

der

osi

on

corr

osi

on

�H

isto

rica

lly it

was

cal

led e

rosi

on-c

orr

osi

on

�As

use

d h

isto

rica

lly,

erosi

on-c

orr

osi

on

des

crib

ed t

wo d

iffe

rent

mec

han

ism

s�

A c

hem

ical

dis

solu

tion o

f th

e pro

tect

ive

oxi

de

laye

r in

a

movi

ng s

trea

m o

f w

ater

or

wet

ste

am�

Am

echan

ical

wea

ring

away

ofth

epro

tect

ive

oxi

de

�A m

echan

ical

wea

ring a

way

of th

e pro

tect

ive

oxi

de

laye

r

�E-C

is

iden

tified

as

one

of

the

8 f

orm

s of

corr

osi

on

inFo

nta

na

&G

reen

e’s

clas

sica

lte

xtco

rrosi

on in F

onta

na

& G

reen

es

clas

sica

l te

xt

book

“Corr

osi

on E

ngin

eering”

publis

hed

in 1

967

Eros

ion-

Cor

rosio

n an

d Fl

ow-A

ccel

erat

ed C

orro

sion

Film

Fre

e

Bre

akaw

ay

te

Film

Bre

akdo

wn

Velo

city

rosion Ra

Eros

ion-

Cor

rosi

on

Corr

FAC

Velo

city

Bre

akaw

ay v

eloci

ty for

carb

on s

teel

str

aight

pip

e in

wat

er ~

10 m

/sec

, w

et s

trea

m ~

30 m

/sec

1940

s19

40s

�M

ost

ear

ly r

esea

rcher

s w

ere

conce

rned

about

turb

ines

, hea

t ex

chan

ger

tubes

, an

d f

eedw

ater

i

(FAC

ith

if

fd

ti

)iron (

FAC is

the

prim

ary

sourc

e of

feed

wat

er iro

n)

�Fa

ilure

s of

pow

er p

lant

pip

ing a

ttribute

d t

o F

AC

wer

eid

entified

inth

e1940s

wer

e id

entified

in t

he

1940s

�U

nfo

rtunat

ely

they

wer

e n

ot

wel

l docu

men

ted

�Fo

ssil

and indust

rial

pla

nts

typ

ical

ly r

epla

ced

the

pip

ing a

nd r

esta

rted

1940

s (co

ntin

ued)

�In

the

late

1940s,

Mar

s Fo

nta

na

at O

hio

Sta

te

,U

niv

ersi

ty (

and o

ther

s) b

egan

to inve

stig

ate

E-C

. Stu

die

s w

ere

conduct

ed o

n m

any

diffe

rent

allo

ys

with

diffe

rent

fluid

sw

ith d

iffe

rent

fluid

s�

Stu

die

s in

cluded

car

bon s

teel

and d

istille

d w

ater

.

Found:

�Rat

e f(

velo

city

)�

Rat

e f(

pH

); r

ate

was

neg

ligib

le f

or

pH

> 1

0.0

�Rat

e f(

tem

per

ature

)�

Rat

e f(

allo

y an

d f

luid

)

1950

s

Di

fi

ll

lt

ith

id�

Des

ign o

f co

mm

erci

al n

ucl

ear

pow

er p

lants

in t

he

mid

1950s

nec

essi

tate

d a

hig

her

lev

el o

f sa

fety

and d

esig

n

�Ship

pin

gport

(PW

R)

wen

t oper

atio

nal

12/1

957

�D

resd

en 1

(BW

R)

wen

t oper

atio

nal

7/1

960

�In

the

late

1950s,

the

US A

tom

ic E

ner

gy

Com

mis

sion

sponso

red

ase

ries

ofex

per

imen

tson

PWR

type

reac

tors

sponso

red a

ser

ies

of ex

per

imen

ts o

n P

WR-t

ype

reac

tors

�Concl

uded

car

bon s

teel

could

be

use

d in t

he

prim

ary

loop if oxy

gen

was

low

and p

H >

10.5

to 1

1.5

�Als

o in t

he

late

1950s,

Oak

Rid

ge

Nat

ional

Lab

ora

tory

te

sted

car

bon s

teel

at

250°C

, a

wat

er v

eloci

ty o

f 8 m

/s

and v

aryi

ng o

xygen

, an

d n

ote

d v

aria

tions

in o

xide

film

an

d c

orr

osi

on r

ates

as

a fu

nct

ion o

f oxy

gen

1960

s-G

E19

60s

GE

�In

the

late

1950s,

GE

beg

ana

pro

gra

mto

study

corr

osi

on

in�

In t

he

late

1950s,

GE b

egan

a p

rogra

m t

o s

tudy

corr

osi

on in

stea

m,

wet

ste

am,

satu

rate

d w

ater

and s

ubco

ole

d w

ater

co

nditio

ns

�In

cluded

was

the

rele

ase

ofco

rrosi

on

pro

duct

sin

typic

alBW

R�

Incl

uded

was

the

rele

ase

of co

rrosi

on p

roduct

s in

typ

ical

BW

R

feed

wat

er c

onditio

ns

(then

O2

< 1

5 p

pb)

�Pr

ior

dat

a w

as t

aken

at

~25°C

and 2

88°C

, w

ith little

to n

o d

ata

inbet

wee

nin

bet

wee

n�

One

study

use

d a

sid

e st

ream

tes

t lo

op a

t th

e H

um

bold

t Bay

N

ucl

ear

Pow

er P

lant

loca

ted in C

aliforn

ia (

oper

atio

nal

8/1

963)

�Q

uan

tified

the

dep

enden

ceofO

on

FAC

rate

s�

Quan

tified

the

dep

enden

ce o

f O

2on F

AC r

ates

�Als

o c

oncl

uded

that

:�

Car

bon s

teel

can

be

use

d o

nly

if O

2>

15 p

pb

Si

lb

df

lll

lfO

�Sta

inle

ss c

an b

e use

d f

or

all le

vels

of O

2

�Le

ad inve

stig

ators

wer

eBru

sh a

nd P

earl

1974

Kel

ler

Dev

elop

sthe

Firs

tPre

dict

ive

Mod

elK

elle

r D

evel

ops t

he F

irst

Pre

dict

ive

Mod

el

�In

1974,

H.

Kel

ler

of Sie

men

s/KW

U d

evel

oped

the

firs

t pre

dic

tive

model

�Val

idfo

r2-p

has

elin

esw

ith

ast

eam

qual

ity

of70-1

00%

�Val

id for

2-p

has

e lin

es w

ith a

ste

am q

ual

ity

of 70-1

00%

FAC R

ate

= [

f(T)

· f(

X)

· V ·

Kc]

–Ks

(m

m/1

04

hours

)

Wher

ef(

T)

= d

imen

sionle

ss c

oef

fici

ent

f(X)

= d

imen

sionle

ss c

oef

fici

ent

rela

ted t

o s

team

wet

nes

sV =

flu

id v

eloci

ty (

m/s

)Kc

= f

acto

r to

acc

ount

for

loca

l geo

met

ryKs

= a

const

ant

that

must

be

exce

eded

bef

ore

FAC is

obse

rved

1974

Kel

ler

Dev

elop

s the

Fir

st P

redi

ctiv

e M

odel

(

tid)

(con

tinue

d)

1974

Kel

ler

Dev

elop

s the

Fir

st P

redi

ctiv

e M

odel

(c

ontin

ued)

(con

tinue

d)

Kel

ler’s

Geo

met

ryKel

lers

Geo

met

ry

Fact

ors

1970

s –C

EGB

(UK

)(

)

�In

the

late

1970s

and

early

1980s

GBig

nold

I�

In t

he

late

1970s

and e

arly

1980s,

G.

Big

nold

, I.

W

ools

ey a

nd o

ther

s at

the

Cen

tral

Ele

ctrici

ty

Gen

erat

ing B

oar

d (

UK)

wer

e per

form

ing

syst

emat

ic s

tudie

s of

FAC

�Q

uan

tified

wal

l lo

ss a

s f(

tem

per

ature

, pH

, ve

loci

tyal

loy

com

posi

tion)

velo

city

, al

loy

com

posi

tion)

�CEG

B r

esea

rcher

s al

so a

pplie

d t

hin

lay

er s

urf

ace

activa

tion t

o lab

ora

tory

exp

erim

ents

to a

ccura

tely

m

easu

re w

all lo

ss r

ates

in r

eal tim

e�

Dev

eloped

a p

redic

tive

model

FAC

4k3

(Co

)3(H

+)2

/B2

FAC =

4k3

· (C

oeq

)3·

(H+)2

/B2

1970

s –ED

F (F

ranc

e)(

)

�Sta

rtin

g in t

he

early

1970s,

P.

Ber

ge,

M.

gy

,g

,Bouch

acourt

, F.

Rem

y an

d o

ther

s at

Ele

ctrici

te d

e Fr

ance

wer

e al

so p

erfo

rmin

g s

yste

mat

ic s

tudie

s of

FAC

�In

cluded

lab

ora

tory

tes

ts t

o inve

stig

ate

oxi

de

laye

r,

influen

ce o

f st

eam

qual

ify,

surf

ace

roughnes

s, m

ass

tran

sfer

allo

yco

mposi

tion

pH

amin

eet

ctr

ansf

er,

allo

y co

mposi

tion,

pH

, am

ine,

etc

�

ED

F al

so s

tart

ed t

he

dev

elopm

ent

of

a m

echan

istic

model

to p

redic

t th

e ra

te o

f FA

C

FAC =

(

Ceq

-C

�)

(1/2

K +

1/k

)

1982

Duc

reux

Mat

eria

lInv

estig

atio

nsD

ucre

ux M

ater

ial I

nves

tigat

ions

�In

1982,

J.D

ucr

eux

ofED

F(F

rance

)publis

hed

labora

tory

dat

a�

In 1

982,

J. D

ucr

eux

of ED

F (F

rance

) publis

hed

lab

ora

tory

dat

a on t

he

effe

ct o

f al

loy

com

posi

tion o

n F

AC r

ates

. H

is m

odel

:

FAC R

ate/

FAC R

ate m

ax=

1/(

83 ·

Cr%

0.8

9·

Cu%

0.2

5·

Mo%

0.2

0)

�The

Ducr

eux

rela

tionsh

ip is

the

bas

is for

most

of th

e pre

dic

tive

te

chnolo

gy

in u

se t

oday

Earl

y 19

80s –

Siem

ens/

KW

U (G

erm

any)

y(

y)

�Sta

rtin

g in t

he

late

1970s,

H.

Hei

tman

n,

W.

Kas

tner

an

d o

ther

s at

KW

U (

now

Sie

men

s) w

ere

also

(

)per

form

ing s

yste

mat

ic s

tudie

s of

FAC

�In

cluded

wer

e ra

te s

tudie

s ve

rsus

pH

�In

the

mid

1980s,

the

Kel

ler

model

was

furt

her

dev

eloped

FAC =

Kc·

F 1(V

, T,

h)

· F 2

(pH

) ·

F 3(O

2)

· F 4

(t)

· F

5(x

)

1984

Hui

jbre

gtsM

ater

ials

Inve

stig

atio

nsH

uijb

regt

s Mat

eria

ls In

vest

igat

ions

�In

1984,

W.

M.

M.

Huijbre

ghts

of

KEM

A

(Net

her

lands)

publis

hed

la

bora

tory

dat

aon

the

effe

ctla

bora

tory

dat

a on t

he

effe

ct

of

allo

y co

mposi

tion o

n F

AC

rate

s. H

is m

odel

:

�FA

C R

ate/

FAC R

ate m

ax=

1/(

0.6

1 +

2.4

3Cr(

%)

+

1.6

4Cu(%

) +

0.3

Mo(%

))

June

197

8O

yste

rC

reek

(US)

Oys

ter

Cre

ek (U

S)

�G

ener

alEle

ctric

BW

R�

Gen

eral

Ele

ctric

BW

R�

Failu

re o

ccurr

ed in a

200 x

350 m

m r

educe

r dow

nst

ream

of

a fe

edw

ater

pum

p

�Fa

ilure

was

att

ribute

d t

o c

avitat

ion

�Sig

nific

ant

and r

eocc

urr

ing d

amag

e w

as f

ound in

seve

ralfe

edw

ater

contr

olva

lves

seve

ral fe

edw

ater

contr

ol va

lves

�D

amag

e w

as a

ttribute

d t

o f

lash

ing

�Sig

nific

ant

wal

l th

innin

g w

as f

ound in s

ever

al

pip

ing

aea

sm

ost

ldo

nst

eam

of

cont

ol

pip

ing a

reas

, m

ost

ly d

ow

nst

ream

of

contr

ol

valv

es�

Eve

nt

and f

indin

gs

had

little

effe

ct o

n n

ucl

ear

indust

ry

Nov

embe

r 19

82

Nav

ajo

Foss

ilPl

ant(

US)

(con

tinue

d)N

avaj

o Fo

ssil

Plan

t (U

S) (co

ntin

ued)

�Fe

edw

ater

just

dow

nst

ream

of fe

ed p

um

p�

Origin

al t

hic

knes

s =

9.3

mm

�Thic

knes

s @

fai

lure

= 0

.7 m

m�

Ther

e w

as a

bac

king r

ing a

t th

e upst

ream

wel

dL

Hi

hd

it

hi

t�

Low

pH

am

monia

+ h

ydra

zine

wat

er c

hem

istr

y�

Unusu

al b

ecau

se it

was

a foss

il fa

ilure

that

was

public

ized

and

anal

yzed

public

ized

and a

nal

yzed

�Li

ttle

chan

ge

in t

he

way

foss

il an

d n

ucl

ear

pla

nts

appro

ached

FAC.

Nov

embe

r 19

82

Nav

ajo

Foss

ilPl

ant(

US)

Nav

ajo

Foss

il Pl

ant (

US)

Note

direc

tion o

f flow

Dec

embe

r 19

86Su

rry

Uni

t2(U

S)Su

rry

Uni

t 2 (U

S)

Flow

Conden

sate

sys

tem

just

bef

ore

the

feed

pum

p

Dec

embe

r 19

86Su

rry

Uni

t2(U

S)(

id)

Surr

y U

nit 2

(US)

(con

tinue

d)

�W

estinghouse

PWR

�W

estinghouse

PW

R�

Four

work

men

wer

e ki

lled.

Four

oth

ers

wer

e in

jure

d�

Am

monia

wat

er c

hem

istr

y w

ith a

low

pH

y

p�

Man

y re

pla

cem

ents

(~

190)

wer

e m

ade

in b

oth

units

�Sim

ilar

conditio

ns

as N

avaj

o�

This

fai

lure

show

ed:

�Ser

iousn

ess

of

FAC

Sib

ilif

il

hC

�Susc

eptibili

ty o

f si

ngle

-phas

e sy

stem

s to

FAC

�N

eed f

or

an insp

ection p

rogra

m�

Max

imum

dam

age

may

not

be

atex

trad

os

of

�M

axim

um

dam

age

may

not

be

at e

xtra

dos

of

elbow

s

1987

US

Indu

stry

Res

pond

sto

Surr

yU

S In

dust

ry R

espo

nds t

o Su

rry

�N

UM

ARC a

ssem

ble

d a

work

ing g

roup a

nd iss

ued

guid

elin

es f

or

utilit

ies

to im

ple

men

t an

insp

ection

pro

gra

m f

or

single

-phas

e sy

stem

s

NRC

dIN

POb

it

td

ith

i�

NRC a

nd I

NPO

bec

ame

inte

rest

ed in t

he

issu

e

�U

S n

ucl

ear

pla

nts

sta

rt t

o im

ple

men

t in

spec

tion

pro

gra

ms

of

single

phas

epip

ing

pro

gra

ms

of

single

-phas

e pip

ing

1987

C

urre

ntIn

dust

ry Im

prov

es it

s Pre

dict

ive

Tec

hnol

ogy

Tec

hnol

ogy

�EPR

Idev

elops

apre

dic

tive

model

and

soft

war

efo

r�

EPR

I dev

elops

a pre

dic

tive

model

and s

oft

war

e fo

r utilit

y use

�Bes

t es

tim

ate

model

dev

eloped

by

Bin

di Chex

al a

nd J

eff

Horo

witz

usi

ng a

reg

ress

ion a

nal

ysis

of la

bora

tory

dat

a�

Rel

ease

d C

HEC in 1

987:

1-p

has

e lin

es o

nly

�Rel

ease

dCH

ECM

ATE

in1989:

1an

d2-p

has

elin

es�

Rel

ease

d C

HECM

ATE in 1

989:

1 a

nd 2

-phas

e lin

es�

Rel

ease

d C

HECW

ORKS in 1

993 (

curr

ent

vers

ion is

2.2

)�

Com

ponen

t-by-

com

ponen

t pre

dic

tions

of ra

te o

f w

all

thin

nin

g,

tota

l w

all lo

ss t

o d

ate,

rem

ainin

g s

ervi

ce life

�W

ater

chem

istr

y an

d n

etw

ork

flo

w a

nal

ysis

�Sto

rage

and e

valu

atio

n o

f co

mponen

t in

spec

tion d

ata

g�

Man

agem

ent

of

rela

ted o

uta

ge

activi

ties

1987

-C

urre

ntIn

dust

ry Im

prov

es it

s Pre

dict

ive

Tec

hnol

ogy

(con

tinue

d)(c

ontin

ued)

�ED

Fdev

elops

the

BRT-C

ICERO

soft

war

ebas

edon

�ED

F dev

elops

the

BRT-C

ICERO

soft

war

e bas

ed o

n

the

Big

nold

/Ber

ge/

Bouch

acourt

model

:

FAC =

f(C

r) ·

f(�

) ·

(Ceq

-C�

)[0

.5 ·

(1

/k +

�/D

)]

�Res

ults

incl

ude:

�W

ear

and w

ear

rate

�Res

idual

thic

knes

s �

Ran

ge

of

valid

ity

of

thic

knes

s ta

king u

nce

rtai

nties

in

toac

count

into

acc

ount

1987

-C

urre

ntIn

dust

ry Im

prov

es it

s Pre

dict

ive

Tec

hnol

ogy

(i

d)(c

ontin

ued)

�Sie

men

s/KW

U d

evel

ops

the

WATH

EC a

nd D

ASY p

rogra

ms:

FAC =

Kc·

F 1(V

, T,

h)

· F 2

(pH

) ·

F 3(O

2)

· F 4

(t)

· F

5(x

)

�Res

ults

incl

ude:

�W

all th

innin

g a

nd r

emai

nin

g life

�D

esig

ned

topro

vide

conse

rvat

ive

pre

dic

tions

of

�D

esig

ned

to p

rovi

de

conse

rvat

ive

pre

dic

tions

of

max

imum

pro

bab

le t

hin

nin

g�

Curr

ent

vers

ion is

calle

d C

OM

SYS

Inl

des

oth

em

ehan

ism

ss

has

stai

nin

ded

�In

cludes

oth

er m

echan

ism

s su

ch a

s st

rain

-induce

d

crac

king,

mat

eria

l fa

tigue,

cav

itat

ion,

dro

ple

t im

pin

gem

ent

For

Mor

e In

form

atio

n

�D

etai

ls o

f th

e va

rious

model

s, a

theo

retica

l tr

eatm

ent

and lab

ora

tory

dat

a ar

e pro

vided

in

yp

EPR

I re

port

TR-1

06611-R

1.

Prim

ary

auth

ors

:�

Bin

di Chex

al a

nd J

eff

Horo

witz

–EPR

I�

Mic

hel

Bouch

acourt

and F

ranco

is R

emy

–ED

F�

Wolfgan

g K

astn

er –

KW

U/S

iem

ens

Apr

il 19

89A

rkan

sasN

ucle

arO

ne(U

S)A

rkan

sas N

ucle

ar O

ne (U

S)

Apr

il 19

89k

l(

)A

rkan

sas N

ucle

ar O

ne (U

S) (c

ontin

ued)

�Com

bust

ion E

ngin

eering P

WR

�Tw

o-p

has

e co

nditio

ns

Lti

dt

fhi

h�

Loca

tion w

as d

ow

nst

ream

of

hig

h-p

ress

ure

ex

trac

tion n

ozz

le�

This

failu

resh

ow

ed:

�This

fai

lure

show

ed:

�Aggre

ssiv

e nat

ure

of

FAC in 2

-phas

e lin

es a

nd

nee

d t

o incl

ude

them

in t

he

insp

ection

pro

gra

m

May

198

9U

SN

RC

Issu

esG

ener

icLe

tter

89-0

8U

S N

RC

Issu

es G

ener

ic L

ette

r 89

-08

�Req

uired

the

US u

tilit

ies

to:

�Im

ple

men

t a

long-t

erm

FAC m

onitoring

pro

gra

m�

Incl

ude

all su

scep

tible

hig

h-e

ner

gy

carb

on

stee

lpip

ing

syst

ems

stee

l pip

ing s

yste

ms

�In

clude

both

sin

gle

-an

d t

wo-p

has

e lin

es�

Utiliz

e th

e N

UM

ARC/E

PRI

or

equal

ly e

ffec

tive

U

te

te

UC/

oeq

ua

ye

ect

em

ethod

Dec

embe

r 19

89

Sant

aM

aria

deG

aron

a(S

pain

)Sa

nta

Mar

ia d

e G

aron

a (S

pain

)

�G

E B

WR

�A s

mal

l pie

ce o

f th

e fe

edw

ater

lin

e w

as b

low

n

pout

�Fa

ilure

was

just

dow

nst

ream

of

a flow

met

er.

�Li

ne

oper

ated

with v

ery

low

oxy

gen

(~

6 p

pb)

�Fa

ilure

dem

onst

rate

d:

�N

eed

for

FAC

pro

gra

mfo

rBW

Rs

�N

eed f

or

FAC p

rogra

m f

or

BW

Rs

�D

anger

s of

oper

atin

g w

ith low

oxy

gen

in

neu

tral

wat

er

July

198

9EP

RIf

orm

sCH

UG

EPR

I for

ms C

HU

G

Th

en

(1

98

9)

No

w (

20

08

)�

Purp

ose

was

to s

upport

the

CH

EC a

nd C

HECM

ATE c

om

pute

r co

des

�FA

Conly

�Is

sue

gro

up t

o d

eal w

ith

deg

radat

ion in F

AC s

usc

eptible

sy

stem

s�

FAC

erosi

on

wel

ddeg

radat

ion

�FA

C o

nly

�2 m

eetings/

year

�Tra

inin

g�

10 m

ember

s re

pre

senting ~

30

�FA

C,

erosi

on,

wel

d d

egra

dat

ion

�2 m

eetings/

year

�W

eb s

ite

�Tec

hnic

al inve

stig

atio

ns

pg

nucl

ear

pla

nts

(U

S o

nly

)g

�Tra

inin

g�

46 m

ember

s re

pre

senting >

160 n

ucl

ear

pla

nts

l•B

elgiu

m•C

anad

a (a

ll)•C

zech

Rep

ublic

•Fra

nce

(CO

•Rom

ania

•Slo

vaki

a•S

outh

Kore

a•S

pai

n (

all)

i•J

apan

(TEPCO

only

)•M

exic

o

•Ta i

wan

•US (

all)

May

199

0 Lo

viisa

Uni

t1(F

inla

nd)

Lovi

isa U

nit 1

(Fin

land

)

Not

eor

ifice

Not

e or

ifice

.

Dow

nstre

am P

ipe

Ups

tream

Fla

nge

May

199

0 Lo

viisa

Uni

t1(F

inla

nd)(

cont

inue

d)Lo

viisa

Uni

t 1 (F

inla

nd) (

cont

inue

d)

�Russ

ian

built

PWR

�Russ

ian b

uilt

PW

R�

Failu

re just

dow

nst

ream

of orifice

in fee

dw

ater

lin

e�

Wat

er c

hem

istr

y w

as n

eutr

al w

ater

with low

O2

�Fa

ilure

thro

ugh o

rifice

fla

nge.

Ther

e w

as little

wea

r in

pup

pie

ce a

nd d

ow

nst

ream

pip

e�

11

of12

sist

erlo

cations

wer

e<

min

imum

thic

knes

s.�

11 o

f 12 s

iste

r lo

cations

wer

e <

min

imum

thic

knes

s.�

This

fai

lure

show

ed:

�The

signific

ance

of Cr

(ther

e w

as >

0.1

% C

r in

d

ti

d0

Ci

thfl

)dow

nst

ream

pip

e an

d ~

0 C

r in

the

flan

ge)

�Im

port

ance

of hig

h o

xygen

if usi

ng n

eutr

al w

ater

�H

igh

risk

atorifice

sH

igh r

isk

at o

rifice

s�

All

types

of

nucl

ear

pla

nt

des

igns

are

at r

isk

�N

ote

: U

nit 2

had

a s

imila

r fa

ilure

in 1

993

Dec

embe

r 19

90

Mill

ston

e3

(US)

Mill

ston

e 3

(US)

Dec

embe

r 19

90

Mill

ston

e3

(US)

(con

tinue

d)M

illst

one

3 (U

S) (c

ontin

ued)

�W

estinghouse

PWR

�W

estinghouse

PW

R�

Sim

ultan

eous

failu

res

of tw

o (

of fo

ur)

par

alle

l lin

es

dow

nst

ream

of

leve

l co

ntr

ol va

lves

and d

ow

nst

ream

of

mois

ture

separ

ator

dra

inta

nk

mois

ture

sep

arat

or

dra

in t

ank

�The

lines

wer

e om

itte

d fro

m t

he

CH

EC

©an

alys

is.

�This

fai

lure

show

ed:

�N

eed for

a co

mpre

hen

sive

susc

eptibili

ty a

nal

ysis

�H

igh r

isk

dow

nst

ream

of

contr

ol va

lves

Ct

dl

ti

ld

lltibl

t�

Com

pute

r m

odel

s m

ust

incl

ude

all su

scep

tible

sys

tem

s�

Import

ance

of

good c

om

munic

atio

ns

bet

wee

n c

entr

al

engin

eering a

nd t

he

pla

nt

gg

p�

Para

llel lin

es m

ay w

ear

diffe

rently

Nov

embe

r 19

91

Mill

ston

e2

(US)

Mill

ston

e 2

(US)

Nov

embe

r 19

91

Mill

ston

e2

(US)

(d)

Mill

ston

e 2

(US)

(con

tinue

d)

�Com

bust

ion

Engin

eering

PW

R�

Com

bust

ion E

ngin

eering P

WR

�Fa

ilure

dow

nst

ream

of

leve

l co

ntr

ol va

lve

in t

he

rehea

ter

dra

in lin

e.�

Loca

tion h

ad n

ot

bee

n p

revi

ousl

y in

spec

ted.

�In

both

of

the

Mill

stone

acci

den

ts,

per

sonnel

wer

e i

thi

iit

fth

bk

lti

htl

bf

in t

he

vici

nity

of

the

bre

ak loca

tions

short

ly b

efore

th

e co

mponen

ts f

aile

d,

but

wer

e not

inju

red

�This

fai

lure

show

ed:

�A lar

ge

effo

rt w

as n

eeded

to im

pro

ve t

he

FAC

pro

gra

m a

t al

l of

the

ow

ner

s units.

This

re

quired

asi

gnific

ant

rest

art

effo

rtre

quired

a s

ignific

ant

rest

art

effo

rt.

Mar

ch 1

993

Sequ

oyah

Uni

t2(U

S)Se

quoy

ah U

nit 2

(US)

�W

estinghouse

PWR

�W

estinghouse

PW

R�

Failu

re o

f a

275 m

m O

D p

ipe

dow

nst

ream

of

a te

e in

a h

igh-p

ress

ure

ext

ract

ion lin

e �

150 x

75 m

m “

fish

-mouth

” fa

ilure

�Po

st-a

ccid

ent

inve

stig

atio

n indic

ated

num

erous

pro

gra

mm

atic

def

icie

nci

espro

gra

mm

atic

def

icie

nci

es�

Length

y sh

utd

ow

n f

or

both

Seq

uoya

h u

nits

was

re

quired

�This

fai

lure

show

ed:

�N

eed f

or

per

sonnel

tra

inin

g

�N

eed

toid

entify

apro

gra

mow

ner

�N

eed t

o iden

tify

a p

rogra

m o

wner

�D

anger

s of

exce

ssiv

e per

sonnel

turn

ove

r

Nov

embe

r 19

93EP

RII

ssue

sNSA

C-2

02L

EPR

I Iss

ues N

SAC

-202

L

�In

res

ponse

to c

ontinuin

g lea

ks a

nd fai

lure

s, in 1

992

EPR

I beg

an a

ser

ies

of pla

nt

visi

ts t

o u

nder

stan

d h

ow

FA

C k

now

ledge

and t

echnolo

gy

wer

e bei

ng im

ple

men

ted

ggy

gp

�Vis

its

found a

wid

e ra

nge

of im

ple

men

tation d

etai

ls

�In

1993 E

PRI

and C

HU

G d

evel

oped

NSAC-2

02L

“Rd

tif

Eff

tiFl

Al

td

“Rec

om

men

dat

ions

for

an E

ffec

tive

Flo

w-A

ccel

erat

ed

Corr

osi

on P

rogra

m”

�H

as b

een a

ccep

ted b

y IN

PO,

the

US N

RC,

and r

egula

tors

p

y,

,g

in m

any

oth

er c

ountr

ies

as t

he

stan

dar

d for

FAC c

ontr

ol

�Consi

der

ed a

liv

ing d

ocu

men

t, t

he

late

st v

ersi

on is

revi

sion

3is

sued

in2006

(EPR

Ire

port

1011838)

revi

sion 3

iss

ued

in 2

006 (

EPR

I re

port

1011838)

Con

tent

ofN

SAC

-202

L-R

3C

onte

nt o

f NSA

C20

2LR

3

�O

verv

iew

of an

effec

tive

pro

gra

m�

Proce

dure

s an

d d

ocu

men

tation

�Rec

om

men

dat

ions

for

FAC t

asks

�Pe

rform

ing

asu

scep

tibili

tyan

alys

is�

Perf

orm

ing a

susc

eptibili

ty a

nal

ysis

�Pe

rform

ing a

FAC a

nal

ysis

�Sel

ection o

f in

spec

tion loca

tions

Pf

ii

ti�

Per

form

ing insp

ections

�Eva

luat

ing insp

ection d

ata

�Eva

luat

ing w

orn

com

ponen

ts�

Rep

lace

men

ts a

nd r

epai

rs�

Dev

elopin

g a

long-t

erm

str

ateg

y�

Rec

om

men

ded

pro

gra

mfo

rsm

all-

bore

pip

ing

�Rec

om

men

ded

pro

gra

m f

or

smal

lbore

pip

ing

�Rec

om

men

ded

pro

gra

m f

or

vess

els

and e

quip

men

t

Nov

embe

r 19

94

Sh

Uit

1(U

S)Se

quoy

ah U

nit 1

(US)

�W

estinghouse

PW

R�

Cra

ckca

use

da

leak

inth

eco

nden

sate

syst

em�

Cra

ck c

ause

d a

lea

k in

the

conden

sate

sys

tem

.�

Flow

str

aighte

ner

use

d d

uring c

onst

ruct

ion w

as

inad

vert

ently

left

inpla

cedes

pite

dra

win

gs

inad

vert

ently

left

in p

lace

des

pite

dra

win

gs

indic

atin

g t

hat

it

was

rem

ove

d.

�This

fai

lure

show

ed:

�Im

port

ance

of kn

ow

ing a

s-built

conditio

n o

f th

e pla

nt

and insp

ecting “

new

” lo

cations

Febr

uary

199

5 Pl

easa

ntPr

airi

eFo

ssil

Plan

t(U

S)Pl

easa

nt P

rair

ie F

ossil

Pla

nt (U

S)

Febr

uary

199

5 Pl

easa

nt P

rair

ie F

ossil

Pla

nt (U

S) (c

ontin

ued)

()(

)

�Cat

astr

ophic

failu

reof

ast

raig

ht,

seam

less

pip

e�

Cat

astr

ophic

fai

lure

of

a st

raig

ht,

sea

mle

sspip

e dow

nst

ream

of

a te

e in

fee

dw

ater

sys

tem

�Tw

o p

lant

emplo

yees

wer

e ki

lled

�Lo

w p

H a

mm

onia

and h

ydra

zine

wat

er c

hem

istr

y�

The

pip

e had

a m

easu

red C

r of

0.0

3%

and t

he

tee

had

am

easu

red

Cr

of

012%

had

a m

easu

red C

r of

0.1

2%

.�

This

fai

lure

show

ed:

�Im

port

ance

of

chro

miu

m�

Import

ance

of

chro

miu

m�

Nee

d f

or

foss

il pla

nts

to im

ple

men

t a

FAC

insp

ection p

rogra

m�

Import

ance

of

wat

er c

hem

istr

y fo

r fo

ssil

pla

nts

Aug

ust 1

995

Mill

ston

e2

(US)

Mill

ston

e 2

(US)

Gat

e Va

lve

Aug

ust 1

995

Mill

t2

(US)

Mill

ston

e 2

(US)

(con

tinue

d)

�Fa

ilure

dow

nst

ream

of

gat

e va

lve

in h

eate

r dra

in

tank

byp

ass

line

�Po

stac

ciden

tan

alys

isin

dic

ated

that

wat

er�

Post

acc

iden

t an

alys

is indic

ated

that

wat

er

ham

mer

cau

sed t

his

ruptu

re a

lthough t

he

pip

e w

as t

hin

ned

by

FAC.

�

Failu

re o

ccurr

ed e

ven t

hough t

he

pip

e w

as

above

min

imum

wal

l th

ickn

ess

�This

failu

resh

ow

ed:

�This

fai

lure

show

ed:

�The

import

ance

of

know

ing o

per

atin

g h

isto

ry.

The

valv

e had

appar

ently

bee

n u

sed t

o t

hro

ttle

pp

yth

e flow

Apr

il 19

97

Fort

Cal

houn

(US)

Fort

Cal

houn

(US)

Apr

il 19

97

Fort

Cal

houn

(US)

(i

d)Fo

rt C

alho

un (U

S) (c

ontin

ued)

�Com

bust

ion

Engin

eering

PWR

�Com

bust

ion E

ngin

eering P

WR

�A 5

dia

met

er s

wee

p in a

hig

h p

ress

ure

ext

ract

ion lin

e fa

iled c

atas

trophic

ally

.�

Anoth

er e

lbow

loca

ted d

ow

nst

ream

was

ver

y th

in (

~

0.5

mm

).�

The

pla

nt

had

pre

viousl

yre

pla

ced

the

upst

ream

�The

pla

nt

had

pre

viousl

y re

pla

ced t

he

upst

ream

co

mponen

t, a

nd insp

ecte

d it

inst

ead o

f th

e sw

eep.

�This

fai

lure

show

ed:

�Im

port

ance

of

know

ing r

epla

cem

ent

his

tory

�N

eed t

o f

ully

im

ple

men

t CH

ECW

ORKS a

nd N

SAC-

202L

(pla

nt

only

had

par

tial

model

s,par

tial

202L

(pla

nt

only

had

par

tial

model

s, p

artial

im

ple

men

tation)

May

199

9 Po

intB

each

Uni

t1(U

S)Po

int B

each

Uni

t 1 (U

S)

#2 h

eate

r ,

oper

atin

g t

emper

ature

= 1

75°C

, st

eam

qual

ity

= 8

8%

May

199

9 Po

intB

each

Uni

t1(U

S)(

d)Po

int B

each

Uni

t 1 (U

S) (c

ontin

ued)

�W

estinghouse

PW

R

�N

om

inal

wal

l th

ickn

ess

= 1

3 m

m

�Fi

shm

outh

type

failu

rew

ith

open

ing

size

of

685

x22

�Fi

shm

outh

typ

e fa

ilure

with o

pen

ing s

ize

of

685 x

22

mm

. D

egra

dat

ion e

xten

ded

1219 m

m

�Fa

ilure

loca

tion w

as w

her

e st

eam

ente

ring t

he

gfe

edw

ater

hea

ter

hit t

he

impin

gem

ent

pla

te,

and

def

lect

ed t

o t

he

shel

l

Sim

iladeg

adat

ion

inpa

alle

lt

ain

�Sim

ilar

deg

radat

ion in p

aral

lel tr

ain

�This

fai

lure

show

ed:

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eed

for

the

insp

ection

pro

gra

mto

incl

ude

vess

els

�N

eed f

or

the

insp

ection p

rogra

m t

o incl

ude

vess

els

Aug

ust 1

999

Cal

law

ay(U

S)C

alla

way

(US)

Bli

itd

tl

Bea

m li

mite

d tra

vel

Aug

ust 1

999

Cal

law

ay (U

S)(c

ontin

ued)

y(

)()

�W

estinghouse

PWR

�W

estinghouse

PW

R�

Failu

re w

as o

n f

irst

sta

ge

rehea

ter

dra

in lin

e (1

70 m

m

dia

met

er)

just

dow

nst

ream

of

a ve

ry long h

orizo

nta

l ru

n�

A 3

80 x

530 m

m s

ection o

f pip

e w

as f

latt

ened

and

ejec

ted

ejec

ted

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per

atin

g c

onditio

ns

unce

rtai

n a

nd u

nusu

al:

�Q

ual

ity

bel

ieve

d t

o b

e ab

out

4.5

% a

t ~

215

°C

�This

was

bec

ause

the

leve

l co

ntr

ol va

lve

was

lo

cate

d n

ear

the

upst

ream

end o

f th

e lin

e. U

sual

ly,

such

valv

esar

elo

cate

dnea

rth

edow

nst

ream

end

such

val

ves

are

loca

ted n

ear

the

dow

nst

ream

end

Aug

ust 1

999

Cll

(US)

(d)

Cal

law

ay (U

S)(c

ontin

ued)

�The

void

frac

tion

was

estim

ated

tobe

about

55%

Most

�The

void

fra

ctio

n w

as e

stim

ated

to b

e ab

out

55%

. M

ost

tw

o-p

has

e lin

es in n

ucl

ear

pla

nts

either

hav

e:�

Void

fra

ctio

ns

of ve

ry n

ear

one

(e.g

., e

xtra

ctio

n lin

es),

or

or

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fra

ctio

ns

nea

r ze

ro (

e.g.,

cas

cadin

g d

rain

s)�

A b

acki

ng r

ing w

as in t

he

line

and c

ontr

ibute

d t

o t

he

wea

r�

The

thin

nin

g d

id n

ot

affe

ct a

ll si

ster

loca

tions

�This

fai

lure

show

ed:

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port

ance

ofex

tra

insp

ections

ifunce

rtai

nor

unusu

alIm

port

ance

of ex

tra

insp

ections

if u

nce

rtai

n o

r unusu

al

oper

atin

g c

onditio

ns

�Im

port

ance

of

extr

a in

spec

tions

in lin

es w

ith b

acki

ng

rings

rings

�Im

port

ance

of in

spec

ting p

aral

lel tr

ains

Mar

ch 2

000

Susq

ueha

nna

Uni

t1(U

S)Su

sque

hann

a U

nit 1

(US)

Mar

ch 2

000

Susq

ueha

nna

Uni

t1(U

S)(

d)Su

sque

hann

a U

nit 1

(US)

(con

tinue

d)

�G

E B

WR

�D

amag

e to

#3 f

eedw

ater

hea

ters

(oper

atin

g

tem

per

ature

= 1

42

°C,

stea

m q

ual

ity

= 9

1%

)�

Shel

lsT

bt

�Tube

support

s�

Tie

rods

�This

even

tsh

ow

ed:

�This

eve

nt

show

ed:

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port

ance

of

insp

ecting b

oth

the

shel

ls a

nd t

he

inte

rnal

ele

men

ts o

f su

scep

tible

equip

men

t

July

200

2W

agne

r3

Foss

ilPl

ant(

US)

Wag

ner

3 Fo

ssil

Plan

t (U

S)

Feed

wat

er H

eate

r dra

in L

ine

Aug

ust 2

004

Mih

ama

Uni

t3(J

apan

)M

iham

a U

nit 3

(Jap

an)

Conden

sate

lin

e dow

nst

ream

of a

flow

mea

suring o

rifice

Aug

ust 2

004

Mih

ama

Uni

t3(J

apan

)(i

d)M

iham

a U

nit 3

(Jap

an) (

cont

inue

d)

�M

itsu

bis

hi PW

R�

560 m

m p

ipe

had

thin

ned

fro

m 1

0 m

m t

o ~

1.4

mm

�Fi

vew

ork

ers

wer

eki

lled

and

six

wer

ein

jure

d�

Five

work

ers

wer

e ki

lled a

nd s

ix w

ere

inju

red.

�Lo

cation h

ad n

ever

bee

n insp

ecte

d�

The

loca

tion

was

sim

ilar

toth

eSurr

y&

Lovi

isa

failu

res

�The

loca

tion w

as s

imila

r to

the

Surr

y &

Lovi

isa

failu

res

�Im

med

iate

ly d

ow

nst

ream

of

an o

rifice

�Appro

xim

ate

oper

atin

g c

onditio

ns:

�Tem

per

ature

~ 1

40

°C

�Pr

essu

re ~

0.9

3 M

PaVel

oci

ty1

94

m/s

�Vel

oci

ty ~

1.9

4 m

/s

Mar

ch 2

005

Edw

ards

Foss

ilPl

ant(

US)

Edw

ards

Fos

sil P

lant

(US)

Failu

re L

oca

ted B

etw

een M

ain F

eedw

ater

Reg

ula

tor

and

the

Reg

ula

tor

Dis

char

ge

Blo

ck V

alve

Aug

ust 2

005

Sout

h U

krai

ne U

nit 2

(Ukr

aine

)(

)

Aug

ust 2

005

Sout

hU

krai

neU

nit2

(Ukr

aine

)(d)

Sout

h U

krai

ne U

nit 2

(Ukr

aine

) (co

ntin

ued)

Ri

bil

PWR

�Russ

ian b

uilt

PW

R�

Failu

re w

as in a

45

°ca

rbon s

teel

elb

ow

of

the

mois

ture

separ

ator

firs

tst

age

dra

inta

nk

toth

em

ois

ture

sep

arat

or

firs

t st

age

dra

in t

ank

to t

he

dea

erat

or

�Pi

pe

size

was

219 x

8 m

m�

Pipe

wal

l had

thin

ned

to 0

.5 -

2.5

mm

�

Tw

o-p

has

e co

nditio

ns

19 k

gf/

cm2 a

nd 2

11

°CA

tht

di

Jl

2005

th�

Anoth

er r

uptu

re o

ccurr

ed in J

uly

2005 o

n t

he

dra

in lin

e fr

om

hig

h p

ress

ure

hea

ter

6A t

o t

he

dea

erat

or

Febr

uary

200

6 K

akra

par

Uni

t2(In

dia)

Kak

rapa

r U

nit 2

(In

dia)

orifi

ce

flow

Febr

uary

200

6 K

akra

par

Uni

t2(In

dia)

Kak

rapa

r U

nit 2

(In

dia)

�U

tilit

y built

PH

WR

�Fa

ilure

was

in t

he

10%

fee

dw

ater

sys

tem

d

tf

ifi

dow

nst

ream

of

an o

rifice

.

�Pi

pe

size

was

80 m

m.

Mat

eria

l w

as A

106 G

rade

B.

�This

loca

tion h

ad b

een p

lanned

for

repla

cem

ent

but

was

not

repla

ced.

Wha

t D

o Th

ese

Pict

ures

Hav

e in

Com

mon

?

Clo

se-u

p of

Rup

ture

O

vera

ll V

iew

pp

Wha

t can

be

lear

ned

from

hist

ory?y

FAC

fil

ill

fl

�FA

C fai

lure

s occ

ur

in a

ll ty

pes

of

pow

er p

lants

�Equip

men

t an

d e

quip

men

t in

tern

als

are

also

su

scep

tible

toFA

Csu

scep

tible

to F

AC

�Lo

cations

dow

nst

ream

of

orifice

s an

d c

ontr

ol

valv

es a

re e

spec

ially

susc

eptible

�It

is

import

ant

to k

now

rep

lace

men

t his

tory

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cation o

f m

axim

um

thin

nin

g v

arie

s, e

.g.,

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avaj

ow

ason

upst

ream

intr

ados

of

elbow

�N

avaj

o w

as o

n u

pst

ream

intr

ados

of

elbow

�Surr

y w

as o

n u

pst

ream

sid

e of

elbow

�Fo

rt C

alhoun a

nd S

outh

Ukr

aine

wer

e on

extr

ados

Wha

t can

be

lear

ned

from

hist

ory?

(con

tinue

d)y

()

�It

is

import

ant

to k

now

act

ual

oper

atin

g c

onditio

ns

of

the

lines

and if

they

are

bei

ng u

sed d

iffe

rently

than

des

igned

than

des

igned

�It

is

import

ant

to look

in n

ew loca

tions

around t

he

pla

nt

as c

onditio

ns

are

not

alw

ays

as a

ssum

edp

y�

Know

ledge

of

chro

miu

m is

import

ant

�Pa

ralle

l tr

ains

can w

ear

diffe

rently

Con

clus

ion

“You c

an e

ither

insp

ect

it a

ll (e

very

outa

ge)

, re

pla

ce

p(

yg

),p

it a

ll, o

r ru

n s

om

e le

vel of

risk

”D

avid

Sm

ith,

Duke

Ener

gy,

Pas

t Chai

rman

of

CH

UG

�The

cause

s an

d p

reve

ntion o

f FA

C a

re w

ell kn

ow

n�

An

inte

lligen

tw

ellim

ple

men

ted

pro

gra

mca

n�

An inte

lligen

t, w

ell im

ple

men

ted p

rogra

m c

an

min

imiz

e risk

at

a re

asonab

le c

ost

�Pa

rtic

ula

rly

as r

egar

ds

to lar

ge-

bore

pip

ing a

nd

vess

els

�But

ther

e w

ill a

lway

s be

som

e risk

for

curr

ent

pla

nts

par

ticu

larly

asre

gar

ds

smal

l-bore

pip

ing

pla

nts

, par

ticu

larly

as r

egar

ds

smal

lbore

pip

ing

The

Goo

dN

ews

The

Goo

d N

ews

�The

less

ons

lear

ned

fro

m h

isto

ry h

ave

bee

n

inco

r pora

ted into

the

requirem

ents

of

NSAC-

pq

202L-

R3

�N

opla

nt

that

has

fully

imple

men

ted

NSAC

202L

�N

o p

lant

that

has

fully

im

ple

men

ted N

SAC-2

02L

has

eve

r had

a m

ajor

failu

re

�D

etai

ls o

f th

e pro

cess

to b

e dis

cuss

ed t

om

orr

ow