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***• Boguslaw J. Olech CONTINUED*** The worst case forecast indicated that this plugging level could be reached by approximately 2012. All the considerations mentioned above prompted Edison to make a conservative decision to replace the SONGS OSGs in both Units prior to that date. The contract for design, fabrication and delivery of the RSGs was awarded to Mitsubishi Heavy Industries Ltd. (MHI). As specified, the RSGs were supposed to be a replacement in-kind for the OSGs in terms of form, fit and function. At the same time, however, the RSG specification included many new requirements derived from both industry and SONGS operating experience, and the requirement to use the best and most suitable materials of construction. These requirements were aimed at improving the RSG longevity, reliability, performance and maintainability. Also, the specification called for very tight fabrication tolerances of the components and sub-assemblies, especially the tubesheet and the tube U-bend support structure. In addition, SONGS steam generators are one of the largest in the industry, which called for innovative design solutions and improved fabrication processes when working on the RSGs. Conceivably, the MHI and Edison project teams faced many tough challenges throughout the entire project in the design, manufacturing and QC areas, when striving to meet the specification requirements. Both teams jointly tackled all these challenges in an effective and timely manner. At the end, MHI delivered the RSGs, which incorporated all the latest improvements found throughout the industry, as well as innovative solutions specific to the SONGS RSGs. In Unit 2, the RSGs were installed and tested in 2009/10 and in Unit 3 in 2010/11. The RSG post-installation test results met or exceeded the test acceptance criteria for all specified test parameters, thus properly rewarding the effort put into their fabrication.”
— June 19, 2014 5:45 p.m.

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***Yet another Example***; • Boguslaw J. Olech (Retired from Southern California Edison) and Tomoyuki Inoue (Mitsubishi Heavy Industries Ltd.) in an International Engineer Magazine said, “The SONGS is majority owned and operated by Southern California Edison Company (Edison). The SONGS consists of twin plants (Units 2 and 3) rated at 3358 MWt (~1180 MWe) each. SONGS Unit 2 began commercial operation in 1983 and Unit 3 in 1984. The plants were originally equipped with CE Model 3340 recirculating steam generators. The Original Steam Generators (OSGs) employed heat transfer tubing made of Alloy 600 Mill Annealed (MA) and the carbon steel egg-crate type tube supports. The OSGs were designed for a 40-year service life. The main function of steam generators in PWR power plants is to transfer heat from the reactor core and in doing so produce steam. The steam, in turn, drives the main turbine/electric generator to produce electricity. Within the steam generator pressure vessel, a bundle of U-tubes, typically made of nickel-based alloy, provides surface area required for heat transfer from the primary to secondary coolant. The primary coolant flows through the tubes and causes the secondary coolant, which is in contact with the exterior surface of the tubes to boil, generating wet saturated steam. After passing through the moisture separators and steam dryers, essentially dry, saturated steam leaves the steam generator on its way to the high-pressure turbine. Over the years of operation of the PWR plants, it became evident that the steam generator tubes, made predominantly of Alloy 600, were susceptible to primary water stress corrosion cracking (PWSSC). This corrosion mechanism was resulting in tube degradation necessitating plugging large numbers of tubes after each inspection of the tubing. In addition, the SONGS OSG design has shown to be susceptible to tube through-wall wear and severe corrosion of the tube supports. It became evident that the OSG would have to be replaced much sooner than stipulated by their design service life. Continuing to operate with highly degraded steam generators can involve substantial economic risks from forced outages, extended refueling outages, as well as the direct costs of inspections and repairs. To address these risks, and consistent with industry experience, Edison has set a 21.4% plugging level as the technical end-of-life of the SONGS OSGs.
— June 19, 2014 5:44 p.m.

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