Roll-expanded plugs for steam generator heating tubes verification of leak tightness over the component lifetime

Steam generator heating tubes are the boundary between the irradiated primary cycle and the conventional secondary cycle in a pressurized water reactor. Despite their operational task to transfer the heat from the primary to the secondary cycle, these tubes have a crucial safety function: the retention of irradiated primary coolant inside the circuit in all operating, emergency and off-design conditions. The heating tubes are subject to various degradation mechanisms during operation. To verify the integrity of each single tube, nuclear power plants carry out frequent in-service inspections. In case of a tube wall degradation beyond the permissible limit, the tube needs to be taken out of service in order to maintain the overall component integrity. The most common method to do so is to plug a damaged tube by a roll-expanded plug. After plugging, the roll-expanded plug acts as pressure boundary between the primary and the secondary cycle instead of the damaged heating tube. The plug must be able to maintain this function, previously provided by the heating tube, in all operational, emergency and off-design conditions. rticle describes the approach to this verification by launching several comprehensive process qualification programmes consisting of mechanical analyses as well as static and dynamic testing programmes. The result was a qualified roll-expanded plug which remains leak-tight even during off-design conditions.