Method for repairing a steam generator tube

Repair of a steam generator tube is performed by crimping a tubular casing (18) in a zone (14) of the tube (12) in which a metallic coating (20) has been produced on the inner surface of the tube, for example by electrolytic deposition. The tubular casing (18) may consist of an attached sleeve (18), crimped in the tube (12). In the case of a tube crimped over only part of the length of the hole passing through the tube plate, the tubular casing may consist of the tube itself on which additional crimping is performed inside the hole which passes through the tube plate.

FIELD OF THE INVENTION 
The invention relates to a method for repairing a tube such as a steam 
generator tube crimped into a tube plate. 
BACKGROUND OF THE INVENTION 
Heat exchangers, such as steam generators and, in particular, the steam 
generators of pressurized-water nuclear reactors, generally comprise a 
bundle of tubes of great length and small diameter forming the exchange 
surface and permitting the heating and the vaporization of the feed water 
of the steam generator. 
In an electronuclear power station whose reactor is cooled and moderated by 
pressurized water, the heat released by the nuclear reaction is removed 
from the core by the cooling fluid or primary fluid and is transferred in 
the steam generator to secondary water which, after vaporization, drives 
the turbo-generator sets of the power station. This secondary water is 
returned in liquid form into the steam generator, after passing through 
the condenser. 
The exchange surface of a steam generator of a pressurized-water nuclear 
reactor consists of a large number of tubes (for example, 3,400 tubes for 
each one of the three steam generators of a 900 MW.e power station), 
inside which the primary fluid circulates. The secondary fluid comes into 
contact with the outer surface of the tubes. 
The tubes have an internal diameter of approximately 20 mm and are fixed at 
each of their ends into bores passing through a tube plate of great 
thickness, this thickness being of the order of 550 mm. 
The joint between the tube and the tube plate is provided by expansion of 
the tube in a corresponding bore passing through the plate and by a weld 
made at its lower end. 
The expansion of the tube may be achieved substantially over the entire 
length of the bore passing through or, on the other hand, over only a part 
of this length. 
The tubes of the bundle of a steam generator form not only the heat 
exchange surface between the primary fluid and the secondary fluid, but 
also a confinement wall for the primary fluid, fulfilling an extremely 
important function in respect of the operating safety of the nuclear 
installation. 
In the case of a power station comprising a pressurized-water reactor of 
900 MW.e power, the primary fluid is at a pressure in the region of 155 
bars and at a temperature of 300.degree. C. and the secondary fluid is at 
a pressure of 56 bars and at a temperature of 271.degree. C. 
The difference in pressure existing between the primary fluid and the 
secondary fluid results in a situation whereby deterioration of a tube of 
the bundle of the generator can lead to a leakage of primary fluid into 
the secondary fluid. The primary fluid is charged with radioactive 
substances in solution or in suspension and, consequently, even a small 
amount of leakage in a tube of the bundle of the steam generator leads to 
contamination of the secondary water and of the components of the power 
station in which this secondary water circulates. A defective operation 
regime of this type is unacceptable since the secondary fluid circulates 
outside the containment buildings of the nuclear reactor in the turbine 
set and in all the auxiliary circuits and apparatuses which are associated 
with this set. 
The tubes of the bundle of a steam generator are designed and dimensioned 
so that they can be subjected, without damage, to the various mechanical 
and thermal loads which they undergo in service; the material from which 
they are made is defined in order to avoid, as far as possible, corrosion 
of these tubes by the fluids with which they come into contact. 
Moreover, the chemical characteristics of the primary and secondary fluids 
are, during operation of the installation, continuously monitored and, if 
appropriate, rectified, in order to reduce corrosion risks. 
However, it is necessary to continuously ensure that the tube bundle of the 
steam generator is in a satisfactory condition and completely separates 
the primary and secondary fluids. This monitoring is performed using 
continuous surveillance, during operation, of the level of activity in the 
secondary water, which makes it possible to detect leakages whose flow 
rate is very small. During periods of shutdown of the nuclear 
installation, the tubes of the bundle are examined, for example using eddy 
currents, in order to detect defects whose progression could subsequently 
lead to leakage. 
Despite the various precautions taken both at the design and manufacturing 
stage and during operation of the steam generators, it became apparent 
that some materials used for manufacturing the tubes of the bundle were 
quite sensitive to stress corrosion. This applies particularly to some 
types of nickel-based alloys containing chromium and iron. 
Stress corrosion principally develops in the zones where the tube is 
subject to residual stresses and, in these zones, a crack may form across 
the thickness of the tube, which is liable to result finally in leakage of 
primary fluid into the secondary fluid. 
A zone which is particularly sensitive to this type of corrosion, in the 
case of a tube crimped along the entire length of a bore passing through 
the tube plate, is located at the level of the upper face of the tube 
plate. In fact, after being inserted into the tube plate and before its 
lower end is welded, the tube is subjected to an operation of crimping by 
diametrical expansion, known as widening or expansion by rolling, and 
which aims to ensure intimate contact between the outer surface of the 
tube and the surface of the bore pierced in the tube plate. Widening of 
the tube may take place over the entire height of the tube plate in order 
to eliminate the gap resulting from the diametrical play between the tube 
and the bore in the plate, this gap forming a semiconfined space in which 
concentrations of secondary water may occur, leading to considerable 
corrosion phenomena. 
Crimping of the tube may also be performed over only part of the length of 
the bore passing through the tube plate, this partial crimping generally 
being performed in the vicinity of the end of the bore located towards the 
entry face of the tube plate. 
When the tube is crimped, there remains in the wall of the tube a zone of 
transition between the part of the tube which is widened and in contact 
with the bore of the tube plate and the upper part of the tube which has 
not been subjected to diametrical expansion. In this transition zone, the 
tube is subject to residual stresses which, if the material is sensitive 
to stress corrosion, can give rise to intergranular cracking whose 
progression can lead to leakage of primary fluid across the thickness of 
the tube. 
In order to remedy this drawback, methods have.. been proposed for thermal 
or mechanical stress relaxation of the wall of the tubes of the bundle of 
a steam generator in the transition zone. 
However, it is also necessary to have available repair methods which can be 
implemented on steam generators whose tube bundle has already suffered 
stress corrosion. 
The method which seems most satisfactory for performing this repair 
consists in sheathing a part of the inner surface of the tube such that 
the sheath or sheathing sleeve covers the crack through the wall of the 
tube or which risks breaching this wall. 
The sheathing sleeve, whose diameter is smaller than the internal diameter 
of the tube, is placed in the desired position inside this tube and is 
subjected to diametrical expansion by widening which guarantees both the 
mechanical strength and the seal of the fixing of the sleeve. Widening may 
be performed over the entire height of the sleeve or only in two zones of 
this sleeve corresponding to its upper and lower ends. 
The sheathing sleeve may also be brazed inside the tube or fixed by a weld 
bead at each of its ends. 
In certain cases, one end, preferably the upper end, of the sleeve is fixed 
by widening in the tube and the other end of the sleeve is fixed by 
welding. 
Even if the tube is not fixed by crimping, it is necessary to ensure 
contact between the sheathing sleeve and the tube by using a widening 
operation in order to eliminate the radial play between the sheathing 
sleeve and the tube and to perform brazing or welding under satisfactory 
conditions. 
Known sheathing methods effectively make it possible to repair tubes with 
defects resulting from cracks caused by stress corrosion and to avoid 
leakages of primary fluid into the secondary fluid. However, it has been 
observed that, after a certain operating time of the tubes repaired in 
this way, the tube bundle again had a certain level of leakage detected by 
monitoring the . radioactivity of the secondary water. On examination, it 
appeared that new defects had developed in the tubes, generally at the 
level of the upper end for fixing the sheath in the tube or in the 
immediate vicinity of this upper end. 
The upper end of the sheathing sleeves which is located in the part of the 
tube which projects relative to the upper face of the tube plate and which 
is generally fixed by crimping inside the tube is located precisely in a 
zone where the tube is subject to a certain diametrical expansion and has 
a considerable concentration of stresses. 
In the case of partial crimping of the tube, the transition zone is located 
above the crimped portion of the tube, inside the bore passing through the 
tube plate. Cracks usually appear in this transition zone. It is thus 
possible to envisage repairing the tube by crimping the tube itself, in 
the bore of the tube plate, above the transition zone. 
However, there is a risk of new cracks subsequently appearing in the new 
transition zone created when complementary crimping of the tube is carried 
out. 
A method described in FR-A-2,565,323 is known, which makes it possible to 
protect, against stress corrosion, a tube, such as a steam generator tube 
crimped into a tube plate and, in particular, the transition zone of this 
tube located in the vicinity of the exit face of the tube plate and 
corresponding to the separation zone between the expanded part of the tube 
inside the tube plate and the non-expanded part of the tube. This 
protection method consists in depositing, using electrolysis, a metallic 
layer on the inner surface of the tube after it has been fixed in the tube 
plate. The electrolytic coating makes it possible to insulate the inner 
surface of the tube, particularly in the zone where the wall of the tube 
has a high concentration of stresses, from the exchange fluid, such as the 
pressurized water circulated inside the tube. 
However, a method of this type has never been used for repairing a tube by 
sheathing and involving. deformation by diametrical expansion of the tube 
in its part projecting relative to the tube plate or in the case of 
partial repair of a crimped tube by complementary crimping above the 
transition zone. 
SUMMARY OF THE INVENTION 
The invention thus aims to propose a method for repairing a tube, such as a 
steam generator tube crimped into a tube plate, over at least part of the 
length of a hole passing through the tube plate and having inner and outer 
surfaces which come into contact respectively with a first and a second 
exchange fluid, the repair being performed by crimping a tubular casing, 
which may consist of the tube itself, inside the tube or the hole passing 
through the tube plate, so as to isolate at least one defective zone of 
the wall of the tube from one of the exchange fluids, this method making 
it possible to prevent the appearance of new cracks when the heat 
exchanger or steam generator is put back into service after repair. 
To this end, prior to the insertion and the fixing of the sheathing sleeve 
in the tube, a metallic coating is produced on the inner surface of the 
tube, in a zone located downstream of the defective zone, in the direction 
of circulation of the first exchange fluid inside the tube, and the 
tubular casing is crimped in the zone of the tube in which the metallic 
coating is produced.

DETAILED DESCRIPTION 
FIG. 1 shows the tube plate 1 of a steam generator having a great 
thickness, of the order of 550 mm, in which one end of a tube 2 of the 
bundle of the steam generator is fixed inside a bore 3 passing through the 
entire thickness of the tube plate between its entry face 1a and its exit 
face 1b. The tube 2 is fixed in the tube plate 1 so that it is practically 
flush with the entry face 1a and projects relative to the exit face 1b of 
the tube plate. The entry face 1a of the tube plate forms one of the walls 
of the water box of the steam generator into which the primary fluid, 
which is caused to circulate inside the tubes 2, penetrates. 
The tubes 2 project relative to the exit face 1b of the tube plate which 
delimits the upper part of the steam generator in which the tube bundle is 
disposed. 
The feed water of the steam generator penetrates into this upper part in 
order to come into contact with the outer surface of the tubes 2. 
The ends of the tubes 2 of the bundle are fixed in the holes 3, which pass 
through the tube plate 1, by widening of the tube inside the bore 3, 
resulting in a diametrical expansion and crimping of the tube which is 
deformed in contact with the surface of the bore 3. The fixing and the 
seal of the tube 2 are completed by a weld joint 4 made at the level of 
the entry face 1a of the tube plate. 
In the vicinity of the exit face 1b of the tube plate, the tube 2 has a 
transition zone 5 between the lower zone of the tube which is deformed by 
diametrical expansion and the upper zone of the tube which is not 
deformed. In this zone 5, the wall of the tube 2 has a high concentration 
of stresses which favors stress corrosion of the tube in the steam 
generator during operation. 
In the case of steam generator tubes made from an alloy sensitive to this 
type of corrosion, for example a nickel-based alloy containing chromium 
and iron, the stress corrosion in the transition zone 5 may be high and 
may result in the formation of a crack 6 across the wall of the tube 2 in 
the transition zone 5, as may be seen in FIG. 2. 
Progression of the crack 6 may lead to leakage of the primary fluid 
circulating in the tube 2 towards the part of the steam generator 
containing the feed water located above the plate 1b. 
In this case, it is possible to repair the tube 2 by sheathing, as shown in 
FIG. 2. 
A sheathing sleeve 8, whose external diameter is a few tenths of a 
millimeter smaller than the nominal internal diameter of the tube 2, is 
inserted in the tube 2 via its end flush with the entry face 1a of the 
tube plate in order to cover the zone with the crack 6 and, more 
generally, all the transition zone 5 of the tube 2 crimped in the tube 
plate 1. 
The sheathing sleeve 8 is subjected to diametrical expansion in two end 
zones 8a and 8b by widening. This widening operation crimps the sleeve 8 
inside the tube 2, on the one hand inside the tube plate 1 and, on the 
other hand, in the part of the tube 2 projecting relative to the exit face 
1b of the tube plate. 
In the part of the tube projecting relative to the tube plate, the 
diametrical expansion of the sleeve 8 in the zone 8b brings about contact 
between the sleeve 8 and the inner surface of the tube 2. The widening 
operation is continued until there is slight deformation due to 
diametrical expansion of the tube 2 at the level of the zone 8b of 
expansion of the sleeve 8. The stresses created in the tube 2 and the 
sleeve 8 produce a crimping, ensuring the fixing of the sleeve in the 
projecting part of the tube 2. The sealed fixing of the sleeve 8 is 
completed by a weld 9 at its lower end. 
The deformation of the tube 2 at the level of the zone 8b of the sleeve 
causes the formation of a new transition zone 5' between a deformed part 
and a nondeformed part of the tube 2, in which the wall of the tube 2 has 
a high concentration of stresses. 
During operation, in the steam generator, the tubes such as the tube 2 
which have been sheathed are liable to have cracks 6' which generate 
leakage in the transition zones such as the zone 5'. 
The presence of cracks 6' passing through may result in leakages of primary 
fluid into the secondary fluid. 
The object of the method according to the invention, which will be 
described with reference to FIG. 3, is to prevent the formation of cracks 
due to stress corrosion in the zones of transition of the tubes of the 
steam generator which have been created during sheathing. 
It should be noted that, even if the upper end of the sheathing sleeve 8 
were fixed inside the tube 2 by welding or brazing, it is necessary to 
perform a widening in order to produce a diametrical expansion of the 
sleeve in the tube in order to obtain satisfactory contact between the 
sleeve and the inner surface of the tube. Although less than in the case 
of crimping the sleeve, this widening gives rise to the presence of 
stresses in a zone of the tube 2 and to the formation of a transition 
zone. 
FIG. 3 shows the end of a tube 12 of a steam generator fixed by crimping 
and by welding in a bore 13 passing through a tube plate 10 of great 
thickness. 
The tube 12 has undergone considerable stress corrosion in its transition 
zone 15 and a crack 16 generating leakage has formed in this zone 15. 
During a shutdown of the power station in which the steam generator is 
used, the tube 12 is sheathed by using the method according to the 
invention. 
Firstly, the inner surface of the tube 12 is cleaned and descaled in order 
to remove any trace of oxide from this surface in a zone 14 covering the 
upper zone for fixing a sheathing sleeve 18 which must be fixed by 
crimping in the part of the tube 12 projecting relative to the tube plate 
10. 
The position and the length of the zone 14 are defined as a function of the 
position of the crack 16 and of the transition zone 15 of the tube 12 and 
as a function of the length of the zone of the sleeve and of the tube 
which have to undergo diametrical expansion in order to produce efficient 
crimping of the upper part of the sleeve 18 inside the tube 12. 
The zone 14 must at least cover the zone of the tube in which crimping of 
the upper part 18b of the sleeve will take place and the transition zones 
17 and 17' on either side of the zone of the tube 12 deformed by 
diametrical expansion during crimping of the sleeve. 
After cleaning of the zone 14, nickel is electrolytically deposited in this 
zone on the inner surface of the tube. 
This electrolytic coating, of a thickness of the order of a tenth of a 
millimeter, may be performed by using a known device comprising plugs or 
seals for sealed closure of the tube on either side of the zone 14 and 
means for feeding the zone delimited by the plugs with electrolytic 
liquid, as well as means for supplying the electrolysis current to the 
zone 14. 
After the electrolytic coating 20 has been produced, a sleeve 18, whose 
external diameter is a few tenths of a millimeter smaller than the 
internal diameter of the tube 12, is inserted into this tube in order to 
cover the crack 16 and the transition zone 15 of the tube 12, the upper 
end of the sleeve 18 being positioned inside the zone 14 previously coated 
with the electrolytic deposit 20 of nickel. 
The sleeve 18 positioned in the tube 12 is diametrically expanded in its 
two end zones 18a and 18b in order to fix the sleeve 18 into the tube 12 
by crimping. 
In its part projecting relative to the plate 10, the tube 12 is deformed by 
diametrical expansion in accordance with the zone 18b for fixing the 
sleeve 18 by crimping. The zone of the tube 12 deformed by diametrical 
expansion and the two transition zones 17 and 17' coincide with the zone 
14 of the tube in which the electrolytic coating 20 of nickel has been 
produced. 
The electrolytic deposit 20 of nickel is sufficiently ductile and adherent 
to undergo the deformation which accompanies the expansion of the sleeve 
18 and of the tube 12 without suffering any cracking or tearing. 
Moreover, although it is deformed and has a certain concentration of 
stresses, the electrolytic layer 20 of nickel is not sensitive to stress 
corrosion under the conditions of use of the steam generator. 
The coating 20 thus prevents the appearance of new cracks, such as the 
crack 6' shown in FIG. 2, in the steam generator during operation after 
sheathing of the tube 12 using the method according to the invention. 
In fact, the primary fluid circulating in the zone 21 in the vicinity of 
the upper end of the sleeve 18 comes into contact with the layer 20 which 
is not sensitive to stress corrosion. This prevents new cracking of the 
tube in the transition zone 17. 
The feed water of the steam generator which is liable to penetrate into the 
space existing between the tube 12 and the sleeve 18 via the cracked zone 
16 comes into contact with the electrolytic coating 20 in the zone 21' in 
the vicinity of the lower end of the zone for fixing the sleeve 18 in the 
projecting part of the tube 12 by crimping. This prevents cracking due to 
stress corrosion, in particular in the transition zone 17'. 
In this way, an effective protection of the tube in the upper crimping zone 
of the sleeve and in the transition zones is thus obtained. 
Fixing of the sleeve may be completed by a circular weld 19 at its lower 
part. 
It is also quite obvious that the sleeve could be fixed inside the tube, at 
each of its ends, by welding and brazing after diametrical expansion by 
widening to a lesser extent than is necessary to ensure crimping thereof. 
In an advantageous manner, this operation of fixing by diametrical 
expansion followed by welding or brazing may be performed after producing 
an electrolytic coating on the inner surface of the tube in its part 
projecting relative to the tube plate receiving the upper part of the 
sheathing sleeve 18. 
FIG. 4 shows the end of a tube 22 of a steam generator fixed by partial 
crimping into an opening 23 passing through the tube plate 24 of the steam 
generator. 
Partial crimping of the tube 22 into the opening 23 is performed by 
diametrical expansion and widening of a part 22a of the tube 22 disposed 
in the vicinity of the entry end of the opening 23. Partial widening of 
the tube 22 in its part 22a leads to the formation of a transition zone 25 
located between the widened part 22a and the non-deformed part of the tube 
22. Cracks, such as 26, are likable to form in the transition zone 25 
during operation of the steam generator. 
As may be seen in FIG. 5, the tube 22 may be repaired by performing an 
additional crimping of the tube 22 in a zone 27 located downstream of the 
crack 26 when considering the circulation of the primary fluid inside the 
tube 22. Crimping of the zone 27 of the tube into the opening 23 makes it 
possible to prevent any leakage of primary fluid into the part of the 
steam generator receiving the water to be vaporized which comes into 
contact with the outer surface of the tube 22 above the zone 27. 
Additional crimping of the tube 22 leads to the formation of transition 
zones 28 and 28' on either side of the zone 27. In order to prevent the 
formation of cracks in the zones 28 and 28', according to the invention, 
an electrolytic nickel layer 30 is deposited on the inner surface of the 
tube 22, in the zone 27, prior to the additional operation of crimping by 
widening. Although deformed, the nickel layer 30 is not sensitive to 
stress corrosion and ensures the protection of the tube in the zones 28 
and 28'. 
It is also possible to perform the electrolytic deposition 30 of nickel, in 
the zone 27, after the operation of crimping by widening. 
Instead of an electrolytic coating of nickel, as a function of the material 
of the tube to be repaired and its conditions of use, it is possible to 
deposit a coating made from another metal or, more generally, a coating of 
a suitable metallic chemical compound. 
The thickness of the coating may differ by a tenth of a millimeter, as a 
function of the nature of the coating, of the size of the tube and of the 
geometrical characteristics of the sheathing sleeve. 
In the case of a repair by sheathing, the zone in which the tube is 
cleaned, followed by its coating, may extend towards the base of the tube 
beyond the zone for fixing the sleeve and the corresponding lower 
transition zone. 
The coating may be produced in a zone extending inside the tube plate so as 
to ensure increased protection of the tube against corrosion. 
The tube may be repaired by crimping any tubular casing, it being possible 
for this casing to consist of the tube itself, in a zone of the tube in 
which a protective metallic coating is produced. 
The invention applies not only in the case of steam generator tubes of 
pressurized-water nuclear reactors but also in the case of tubes located 
in other parts of the nuclear power station which come into contact with 
the primary fluid. In particular, the invention may be applied 
advantageously in the case of perforations penetrating the shroud of the 
pressurizer of a pressurized-water nuclear reactor. 
More generally, the invention may be applied wherever tubes are subjected 
to stress corrosion.