Secondary Circuit Mapping of FAC and High Velocity -Two ...€¦ · 19,00 19,30 bar kg/h ºC 62,1...
Transcript of Secondary Circuit Mapping of FAC and High Velocity -Two ...€¦ · 19,00 19,30 bar kg/h ºC 62,1...
11IAEA WK on ECIAEA WK on EC-- April 2009April 2009
M. Chocrón1, I. Rodriguez1, M. Contino1, R.Saucedo2 andJ.Duca
(1)Comisión Nacional de Energía Atómica (CNEA)-Argentina(2) Central Nuclear Embalse-Nucleoeléctrica Argentina S.A. (NASA)
(3) UG-Atucha II - Nucleoeléctrica Argentina S.A. (NASA)
IAEA Workshop on Erosion-Corrosion (E/C) Including Flow Accelerated Corrosion (FAC) and Environmentally
Assisted Cracking (EAC) Issues in Nuclear Power Plants. 21-23 April 2009, Moscow, Russian Federation.
SecondarySecondary CircuitCircuit MappingMapping ofof FAC FAC andandHighHigh VelocityVelocity --TwoTwo PhasePhase FlowFlowMechanicalMechanical DegradationDegradation EffectsEffects
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Contents
•Overview•Objectives: BOP integrated assessment program•Evaluation of FAC•Mechanical degradation effects:Jet impingementCavitation-flashingDropplet erosion•Water Chemistry improvements•Atucha II: BOP and Water Chemistry•Acknowledgements
33IAEA WK on ECIAEA WK on EC-- April 2009April 2009
Overview: Operating N.P.Ps.
Atucha I – PVHWR – SIEMENS KWU - 1974Embalse CANDU®600 PHWR- AECL-Cordoba-1984Atucha II – PVHWR – SIEMENS KWU – Buenos Aires – In Construction
44IAEA WK on ECIAEA WK on EC-- April 2009April 2009
� Since the start-up (1984) Embalse has been carrying out a program of Piping Thickness Inspection guided by measurement results
� Since 2004, with the start up of the PLiM/LTO Project, an integrated program for FAC evaluation began to be developed in order to determine the wall thinning rate of the Secondary Circuit piping and components
� The Program has been developed by Embalse NPP engineering staff along with the Comision Nacional de Energia Atómica (National Atomic Energy Commision). It is documented in several international workshops and conferences.
Objectives
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Objectives
66IAEA WK on ECIAEA WK on EC-- April 2009April 2009
• Understanding the Flow Assisted Corrosion Degradation Mechanism and its related variables (hydrodynamics, chemistry, etc.), already acquainted after PHTS components.
• Development of a Calculation Code to predict thinning rate in relevant steam/water cycle points based on FAC theory and assisted by CFDtools.
• Creation of a detailed Data Base for piping and accessories (dimensions, materials, process data, chemistry conditions, inspection data, etc.)
• Identification and Screening of components to be inspected, repaired or replaced (ISI optimization).
( )' 1 1( )w
d m e
S Cm
k k k
−=
+
Evaluation of FAC
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• Examples of Data Bases
Evaluation of FAC
Extracción de turbina BP A (VEX TBP) al precalentador E-102A - DN 600 43119 0165 43119-5004-01-DD
VEX TBP A a E-102A - DN 600 43119 0165 43119-5004-01-DD
IDENTIFICACION
Descripción Código BSI Número de línea Plano Isométrico
σ ( N /m 2 ) D e 1 ( m ) S ( m 2 ) S c h% C r % M o
A 1 0 6 B 0 ,0 3 0 ,0 3 1 ,0 3 1 E + 0 8 0 ,6 0 9 6 0 ,2 7 3 9 2 0
A 2 3 4 W P B 0 ,0 3 0 ,0 3 1 ,0 3 1 E + 0 8 0 ,6 0 9 6 0 ,2 7 3 9 2 0
M A T E R IA L Y D A T O S G E O M E T R IC O SD e 2 ( m ) ( S ó lo p a r a
r e d u c c io n e s )M a t e r ia l C o m p o s ic ió n
e 1 (m ) e c a lc (m ) e t f ( m ) D i 1 ( m ) L (m ) S t ( m 2 )
0 ,0 0 9 5 0 ,0 0 7 0 ,0 0 8 0 ,5 9 0 5 6 0 ,4 6 0 ,8 5 3
0 ,0 0 9 5 0 ,0 0 7 0 ,0 0 8 0 ,5 9 0 5 6 2 ,6 6 4
M A T E R IA L Y D A T O S G E O M E T R IC O Se 2 (m )
(S ó lo p a ra r e d u c c io n e s )
D i 2 (m ) ( S ó lo p a ra
r e d u c c io n e s )
Dens idads V iscos idads T ítu lo DFe(OH )2 Sw CoK g /m 3 K g /m seg x s m 2/se g (pp b) (p pb )
1 ,0 8 1 ,2 9E -05 0 ,95 59 8 ,52 E -0 9 2 0 ,2 00 1
1 ,0 8 1 ,2 9E -05 0 ,95 59 8 ,52 E -0 9 2 0 ,2 00 1
D A T O S T E R M O D IN A M IC O S Y P R O P IE D A D E S
88IAEA WK on ECIAEA WK on EC-- April 2009April 2009
Data: Data: TemperatureTemperature, , PressurePressure andand FlowFlow RateRate
3.26699,712,50
3.26619012,50
2.548.872330,05
19013
3.105.251
249.305
2.827.057
19012,4
233
278.194
190
190
190
026046,9
46,9260
136.75970,43
19,00 19,30
bar
kg/hºC
62,1
257
12,5
2603.113.411
260
8.582
QTP
257
249.305
58.790
249.305260
45,50
46,8746,9260726
3.365.837260
2.699
46,9
46,873.116.532
42226046,87
3.373.300
278.194
12,40
8.160
118,67,36
11221,10
158,4416,78 6,77
3720,40
6,77 1,75701.327117,64 115,69
824.428
0,27
69
0,731,75 0,27
0,73337.50342,33
66,0085,00
162,83 116,50 90,46
1,900,52
2.548.8722.548.872
33
41.729 159.01582
66,540,30
12,04
2.136.534
157,44
26046,9 12,50
190
123.101
12,40
195
6.737330,06
3.373.300
1,21
6.737
171.129
105
647.000
20.30345,50
0,16
0,05
5.316
56
0,7993
116.456
46,87260
3.366.563
46,87 3
G
SSR1-2-3
1
2
CS
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Data: Data: TemperatureTemperature andand vapor vapor fractionfraction
0,9975
0,9975
0,00
260
2600,9975(0105)
260 190
37,21
190(0312)
0,00
0,00
(0318)
194,6
(0176)
0,731,75
(0532A)116,50
(0165)
1050,5867(36319-W1)
118,6(0162)0,9980
0,9975(0105)
260
647.000
56
(0532)
33
93,20,8093256,9
0,00 (0168)
(0553)0,00
0,00
70,43
(0342)115,69
0,9559
90,46
85,00
0,2081
(0541)117,64
(0547)0,00
0,00
(0371)
158,440,00
1126,77
0,9975
162,83
(0193)
162,83(0519A)
0,00(0519)
260(0106)
(0204)
189,5 189,5
0,9975
190(0511)0,00
190
(0114)
0,00(0505)
260
260
0,9975(0126)
260 T
233(0120)
X
1,000
ºC
257
260
260
(0110)
190(0174)
0,673082,150,2651
68,86
(0349)99,66
0,270,00
TítuloN° de l ínea
330,00
33
0,9975(0105)
(0559)
(0326)
42,330,00
(0169)
66,00 37,21
66,54
(0415)
0,00(0353)
157,440,00(0380)
162,83
0,00115,69
0,0578
3
G
SSR1-2-3
1
2
CS
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As a result of the Integral BOP Life Assessment System, a wall As a result of the Integral BOP Life Assessment System, a wall thinning rate categorizationthinning rate categorization is divided into five areas as shown is divided into five areas as shown in the following flow sheet:in the following flow sheet:
��Green lines (very low thinning rate)Green lines (very low thinning rate)��Blue lines (low thinning rate)Blue lines (low thinning rate)��Yellow lines (moderate thinning rate)Yellow lines (moderate thinning rate)��Orange lines (relevant thinning rate)Orange lines (relevant thinning rate)��Red lines (high thinning rate)Red lines (high thinning rate)
This considers not only the predicted wall thinning rate but alsThis considers not only the predicted wall thinning rate but also o the different manufacture thickness in their respective locationthe different manufacture thickness in their respective location
Evaluation of FAC
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(0415)
136,61(0353)
157,44157,91(0380)
162,83
64,44115,69 7,14
( 0559)
8,50(0326)
42,33
(0505)260
260216,39(0105)
219,69(0105)
7,40
µm /añoN° de línea
334,26
33
(0318)8,50
(0349)99,66
0,2766,00 37,2161,10
66,54
(0193)
190(0174)
472,37
189,5 189,5
90,46
ºC
257
260
260
(0110)
260 T
233(0120)
m'
179
(0204)13,44
260
260
1,78(0126)
626,88
202,47
190(0511)12,23
190
(0114)
260(0106)211,34
162,83 116,50
(0165)700,84
3,60
28,33(0519)
85,00
115,69
(0532A)
(0371)
158,44143,24
112
(0519A )
(0547)86,67
6,77 73,22 0,73
81,22(0553)7,5070,43
(0342)
(0541)117,64
1,75
(36319-W1)
616,10162,83
118,6(0162)
647.000
56
(0532)
33
93,2690,78256,9
15,47 (0168)
190105215,15
219,70(0105)
82,1565,57
260
194,6
2604,10
(0169)
124,42 231,58
190
37,21
68,86(0176)
(0312)
3
G
SSR1-2-3
1
2
CS
Evaluation of FAC: Relative WTR due to FAC
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Mechanical degradation effects
�Under FAC conditions, mass transfer dominates while over a criticalvelocity-Two phase flow, the protective oxide is mechanicallyremoved and even the base metal attacked.�There are no theories at the macro level capable of predictingdegradation as in the case of FAC.
�It has been part of the BOP assessment program to develop a map for1- Jet impingement2- Cavitation-flashing3- Dropplet erosion
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Jet impingement
•Heat and mass transfer in turbulet jets extensively studied.•Four zones can be distinguished: A-Laminar stagnation, B-Highturbulence, C-Low turbulence and D-Turbulent Boundary layer as distance from jet increases.
•It can be related to FAC by shear stress analogy.•However, CFD modeling helps with the location, extension andinterpretation of damage.•Typical of Tees and Turbine extraction lines at preheater entranceshells.
2 0.182 2.00
0
0.179 Re ( )w
rUr
ρ − −Γ =
1414IAEA WK on ECIAEA WK on EC-- April 2009April 2009
Jet impingement
1 9
2
3
4
5 6
78
10
E-101 APreheater showing LPT extraction lines
CFD modeling atpreheater entrance
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Cavitation-flashing
•In cavitation, after a depression where the fluid approachessaturation, pressure is recovered and the bubbles implote creating a microjet that damages the surface•In flashing, bubbles tend to remain eroding the surface•While principles are well fundamented at microscale, a SC map can only be based on the, rather obvious, cavitation number as a potentialof approaching bubble pressure.
2
( )12
vP PKVρ
∞ −=
K>>1 Subcooled liquid with low linear velocity and absolute pressure higher enough than saturation pressure at temperature.
K<0 Supersaturated steam.
K=0 Local steam quality must be analized. If saturated liquid, the creation of bubbles is feasible. With high steam quality, there is no posibility of cavitation.
K≈0 High posibility of cavitation-flashing is expected at those locations.
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0,9975
0,9975
0,00
260
2600,9975(0105)
260 190
37,21
190(0312)
0,00
0,00
(0318)
194,6
(0176)
0,731,75
(0532A)116,50
(0165)
1050,5867(36319-W1)
118,6(0162)0,9980
0,9975(0105)
260
647.000
56
(0532)
33
93,20,8093256,9
0,00 (0168)
(0553)0,00
0,00
70,43
(0342)115,69
0,9559
90,46
85,00
0,2081
(0541)117,64
(0547)0,00
0,00
(0371)
158,440,00
1126,77
0,9975
162,83
(0193)
162,83(0519A)
0,00(0519)
260(0106)
(0204)
189,5 189,5
0,9975
190(0511)0,00
190
(0114)
0,00(0505)
260
260
0,9975(0126)
260 T
233(0120)
X
1,000
ºC
257
260
260
(0110)
190(0174)
0,673082,150,2651
68,86
(0349)99,66
0,270,00
Títu loN° de l ínea
330,00
33
0,9975(0105)
(0559)
(0326)
42,330,00
(0169)
66,00 37,21
66,54
(0415)
0,00(0353)
157,440,00(0380)
162,83
0,00115,69
0,0578
3
G
SSR1-2-3
1
2
CS
Cavitation-flashing
Cavitation-flashing expected zones (red symbols)
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Dropplet erosion
•Depends on the flow, velocity, temperature, base metal and waterchemistry (pH and ECP).
•In SCs of NPPs, dropplet erosion prone zones are those of straightpipes with annular flow or dropplet dispersed flow close toaccesories (elbows, tees) where liquid phase impacts the walls.
•Therefore, effort has been devoted to better prediction of voidfraction-TPF zones with annular flow by comparison amongseveral correlations considering angles (Tandon, Baker and Taitel-Dukler for horizontal flow and Hewitt-Roberts for vertical flow).
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0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10.75
0.8
0.85
0.9
0.95
1
Homogeneous ModelModified Smith ModelCrisholm ModelArmand ModelLockhart-Martinelli ModelZivi ModelMartinelli-Nelson ModelThom ModelAverage between models
10-6 10-5 10-4 10-3 10-2 10-1 100 101 10210-3
10-2
10-1
100
101
Stratified Flow
Transition Range
Annular Flow
Spray Flow
Plug Flow
Slug Flow
Bubly Flow
SM ModelMN ModelT ModelZ ModelC Model
Predicted void fraction after severalmodels Predicted flow regime after
Tandon Map for horizontal flow
Dropplet erosion
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Table VI Line Tag T
(ºC) P
(bar) x W
(Kg/s) Taitel Tandon SM
Tandon MN
Tandon T
Tandon Z
Tandon C Baker H-R
(Vertical) 120 233 12 1 130.882 162 194.6 7.36 0.998 15.845 * * * * * * * 105 260 46.9 0.998 935.156 * * * * * * * * 105 260 46.9 0.998 934.955 * * * * * * * * 126 260 46.9 0.998 0.202 114 260 46.9 0.998 34.626 * * * * * * * * 105 260 46.9 0.998 865.703 * * * * * * * * 204 260 46.9 0.998 0.117 106 260 46.9 0.998 216.21 * * * * * * * * 193 260 46.9 0.998 0.25 165 118.6 1.9 0.956 11.398 * 110 189.5 12.4 0.91 215.642 * * * * * * * * 168 93.2 0.79 0.809 10.783 * 176 68.86 0.3 0.673 14.724 * 169 105 1.21 0.587 1.88 174 82.15 0.52 0.265 3.864 0532 A 162.8 6.77 0.208 11.542 * * * 0519 A 162.8 6.77 0.058 12.879 * * *
SM: Modified Smith; MN: Martinelli-Nelson; Z: Zivi; C: Crisholm; T: Thom; H-R: Hewitt-Roberts
10-5 10-4 10-3 10-2 10-1 100 101 102 1032 3 45 2 3 45 2 3 45 2 3 45 2 3 45 2 3 45 2 3 45 2 3 45
X
100
101
102
103
104
2346
2346
2346
2346
K
10-3
10-2
10-1
100
101
2
3457
2
3457
2
3457
2
3457
T or
F
FTK
Annular Flow
Wav y Flow
Stratified Flow
Bubbly Flow
Intermittent (plug/slug flow)
Flow Pattern Chart for Horizontal Tubes (Taitel and Dukler)
Dropplet erosion
Predicted flow regime after Taitel-Dukler Map for horizontal flow
Annular flow prediction andcomparison after several models
2020IAEA WK on ECIAEA WK on EC-- April 2009April 2009
Cavitation-flashing
Annular flow-Dropplet erosion according to different models (circles)
0,9975
0,9975
0,00
260
2600,9975(0105)
260 190
37,21
190(0312)
0,00
0,00
(0318)
194,6
(0176)
0,731,75
(0532A)116,50
(0165)
1050,5867(36319-W1)
118,6(0162)0,9980
0,9975(0105)
260
647.000
56
(0532)
33
93,20,8093256,9
0,00 (0168)
(0553)0,00
0,00
70,43
(0342)115,69
0,9559
90,46
85,00
0,2081
(0541)117,64
(0547)0,00
0,00
(0371)
158,440,00
1126,77
0,9975
162,83
(0193)
162,83(0519A)
0,00(0519)
260(0106)
(0204)
189,5 189,5
0,9975
190(0511)0,00
190
(0114)
0,00(0505)
260
260
0,9975(0126)
260 T
233(0120)
X
1,000
ºC
257
260
260
(0110)
190(0174)
0,673082,150,2651
68,86
(0349)99,66
0,270,00
TítuloN° de línea
330,00
33
0,9975(0105)
(0559)
(0326)
42,330,00
(0169)
66,00 37,21
66,54
(0415)
0,00(0353)
157,440,00(0380)
162,83
0,00115,69
0,0578
3
G
SSR1-2-3
1
2
CS
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Monitoring Results
• Turbine extraction lines (TBP-A) and drainage lines during 2005 Outage. Regions with localized degradation (8 out of 21 measured areas show a localized degradation > 30% ) have been found in the extractions of the TBP-A toward the preheater E-104A. The highest wall thinning has been observed in the areas of the straight pipe toward the preheater, adjacent to 45º elbow.
• Turbine extraction lines TBP-A/C during 2007 outage: regions with localized degradation (13 out of 20 measured areas have shown localized degradation > 30 %) have been found in the extractions of the TBP-A/C toward E-104-A/C preheaters., again close to 45o elbows.
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Monitoring Results
•Wall thickness measurements of CS high pressure preheater shells (E-101/102) to obtain information about the equipment status.
•Extension of piping thickness measurements in SGs feedwater lines during 2007 outage: given that in 2006 a break ocurred in other NPP, downstream of a flow element, the plant decided to extend program considering new 45 critical zones. Only 4 (90o elbows) have shown wall thinning > 12.5 % but < 30 % referred to nominal thickness.•Moisture Separator Reheater entrance pipe.
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New specifically inspected zones
Monitoring Results
(0415)
136,61(0353)
157,44157,91(0380)
162,83
64,44115,69 7,14
(0559)
8,50(0326)
42,33
(0505)260
260216,39(0105)
219,69(0105)
7,40
µm/añoN° de línea
334,26
33
(0318)8,50
(0349)99,66
0,2766,00 37,2161,10
66,54
(0193)
190(0174)
472,37
189,5 189,5
90,46
ºC
257
260
260
(0110)
260 T
233(0120)
m'
179
(0204)13,44
260
260
1,78(0126)
626,88
202,47
190(0511)12,23
190
(0114)
260(0106)211,34
162,83 116,50
(0165)700,84
3,60
28,33(0519)
85,00
115,69
(0532A)
(0371)
158,44143,24
112
(0519A )
(0547)86,67
6,77 73,22 0,73
81,22(0553)7,5070,43
(0342)
(0541)117,64
1,75
(36319-W1)
616,10162,83
118,6(0162)
647.000
56
(0532)
33
93,2690,78256,9
15,47 (0168)
190105215,15
219,70(0105)
82,1565,57
260
194,6
2604,10
(0169)
124,42 231,58
190
37,21
68,86(0176)
(0312)
3
G
SSR1-2-3
1
2
CS
2424IAEA WK on ECIAEA WK on EC-- April 2009April 2009
Water Chemistry Improvements
•pH has been gradually augmented with eventual replacement ofMorpholine by ETA•Highly beneficial impact on reduction of Fe transport along the circuit has been observed
3 02 52 01 51 05
B a s e C o n c e n t ra t i o n (mg / K g )7 8 9 1 0 1 1 1 2 1 3 1 4 1 5
Conductivity (µS/cm)9.4
9.49.59.59.69.69.79.7
9.89.8
9.99.9
1010
pH at
25ºC
pH at
25ºC
1 8/ 0 1
/ 2 00 7
2 8/ 0 4
/ 2 00 7
0 6/ 0 8
/ 2 00 7
1 4/ 1 1
/ 2 00 7
2 2/ 0 2
/ 2 00 8
0 1/ 0 6
/ 2 00 8
0 9/ 0 9
/ 2 00 8
1 8/ 1 2
/ 2 00 8
2 8/ 0 3
/ 2 00 9 Date
2
7
12
17
22
27
Base
Conc
entra
tion (
mg/K
g)0.0
0.5
1.0
1.5
2.0
2.5
3.0
Iron C
once
ntrati
on (µ
g/Kg)
F e in FWBas e Concentrat ion in F W
Fe and Base ConcentrationPeriod 2007-2009
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GV
Line 5
Line
2
Line
1
to line 13Line 3
Line 4
Line 6
Line
7
Line
11
Line
8
Line
10
Line
9
Line
12
Line
14
Line 13
Line
16
Line
15
Line
17
Line
18
Line 19
Line 20
Line 24
Line 25
Line 21
Line 26
Line
37
Line
36
Line
35
Line
34
Line
33
Line 29
Line 30
Line 31
Line 32
Line 28Line 23
Line 27Line 22
SteamGenerator
Reactor
Feed WaterTank
Turbine Turbine
Power 744,7/693 Mwe Cycle water Demineralized water Thermal power 986,35 MW x 2 = 1972,7 MW No of tubes in the SGs 6524 x 2 = 13.048 Tube material and dimensions Incolloy 800/18 x 1 mm TSPs DIN 1-4550 U-bend Incolloy 800 TP cladding DIN 1-4550 Inlet and outlet SGs temperature 313,8/277,5 oC Temperature and quality of steam 271,0 oC/54,9 bar/0,9975 Nº of Moderator HXs 4 Thermal power 50,7 x 4 = 202,8 MW No of tubes 1065 x 4 = 4260 Material and dimensions 12 x 1 mm Incolloy 800 TSPs DIN 1-4550 TP cladding DIN 1-4550 Inlet and outlet Moderator HX 194,2/140,0 oC FW train St 37-0 Low pressure preheaters AISI 316 L High pressure preheaters AISI 316 L FW tank temperature 121 oC Condenser tubing AISI 316 L Nº of tubes and dimensions 2 x 35.358 = 70.716 / 21 x 0,7 x 15239
mm Material AISI 316 L Gases extraction box AISI 316 L Chemistry High AVT
Water Chemistry-Atucha II
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Steam Generator Blowdown
Control Parameters Normal Operation Values Action Level 1 Action Level 2 Action Level 3
Cation Conductivity [µS/cm]1) < 0.2 > 1.0 > 2.0 > 7.0 Sodium [mg/Kg] < 0.005 > 0.05 > 0.1 > 0.5
1) Caused by only strong anions; organics and CO2 are not to be considered.
Diagnostic Parameters Normal Operating Values pH at 25ºC > 9.6 Chlorides (Cl-) [mg/Kg] < 0.01 Sulphates (SO4=) [mg/Kg] < 0.01 Ammonia [mg/Kg] < 1,5
Complementary Parameters Normal Operating Values
Iron [mg/Kg] < 0.005 SiO2 [mg/Kg] < 0.1
Feed Water
Control Parameters Normal Operation Values Action Level 1 Action Level 2 Action Level 3
pH a 25ºC > 9.8 < 9.8 --- --- Cationic Conductivity [µS/cm]1) < 0.15 > 0.2 --- --- Oxygen [mg/Kg] < 0.005 > 0.005 > 0.02 2) > 0.1 (1) Caused by only strong anions; organics and CO2 are not to be considered. (2) Power reduction is not required.
Diagnostic Parameters Normal Operating Values Hydrazine [mg/Kg] > 0.02 Specific Conductivity [µS/cm] < 15.0 Ammonia [mg/Kg] 10.0 - 12.0
Complementary Parameters Normal Operating Values
Iron [mg/Kg] < 0.001
Water Chemistry-Atucha II
Feed water specifications
Steam Generator specifications
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Acknowledgements
• The IAEA is gratefully acknowledged for the support giventhrough the Projects RLA 4021 and 4091
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Thank you for your attention!