Types and analysis of defects in welding junctions of the header to steam generator shells on power-generating units with VVER-1000

Investigation objects were metal templates, which were cut during the repair of welding junction no. 111 (header to the steam generator shell) on a power-generating unit with VVER-1000 of the South-Ukraine NPP, and substances of mud depositions collected from walls of this junction. Investigations were carried out using metallography, optical microscopy, and scanning electron microscopy with energy dispersion microanalysis by an MMO-1600-AT metallurgical microscope and a JEOL JSM-7001F scanning electron microscope with the Shottky cathode. As a result of investigations in corrosion pits and mud depositions in the area of welding junction no. 111, iron and copper-enriched particles were revealed. It is shown that, when contacting with the steel header surface, these particles can form microgalvanic cells causing reactions of iron dissolution and the pit corrosion of metal. Nearby corrosion pits in metal are microcracks, which can be effect of the stress state of metal under corrosion pits along with revealed effects of twinning. The hypothesis is expressed that pitting corrosion of metal occurred during the first operation period of the power-generating unit in the ammonia water chemistry conditions (WCC). The formation of corrosion pits and nucleating cracks from them was stopped with the further operation under morpholine WCC. The absence of macrocracks in metal of templates verifies that, during operation, welding junction no. 111 operated under load conditions not exceeding the permissible ones by design requirements. The durability of the welding junction of the header to the steam generator shell significantly depends on the technological schedule of chemical cleaning and steam generator shut-down cooling.