05000483/LER-2004-006

LER-2004-006, AmerenUE PO Box 620
Callaway Plant Fulton, MO 65251
wAmeren
UE
May 25, 2004
U.S. Nuclear Regulatory Commission
Attn: Document Control Desk
Mail Stop P1-137
Washington, DC 20555-0001
ULNRC05011
Ladies and Gentlemen:
DOCKET NUMBER 50-483
CALLAWAY PLANT UNIT 1
UNION ELECTRIC CO.
FACILITY OPERATING LICENSE NPF-30
LICENSEE EVENT REPORT 2004-006-00
"A" Steam Generator tube inspection results classified as C-3
The enclosed licensee event report is submitted in accordance with Technical
Specification 5.5.9 and 5.6.10(c) report the Refuel 13 Inservice Inspection Results for
the "A" Steam Generator were classified as C-3 due to greater than one percent of the
inspected tubes being defective. Included with this License Event Report is the
Special Report and Attachment detailing the "A" Steam Generator tube inspection
results.
This event was initially reported in Event Notification #40705 in which it stated that
this report was required by an Administrative Technical Specification and that the
"A" Steam Generator tubes do not meet the criteria for serious tube degradation and
thus does not represent a degraded or unanalyzed condition.
This letter does not contain new commitments.
Sincerely,
tatA444.4-ailitc
Warren A. Witt
Manager, Callaway Plant
Enclosure
subsidiary of Arne= Cogoration
ULNRC05011
May 25, 2004
Page 2
Mr. Bruce S. Mallett
Regional Administrator
U.S. Nuclear Regulatory Commission
Region IV
611 Ryan Plaza Drive, Suite 400
Arlington, TX 76011-4005
Senior Resident Inspector
Callaway Resident Office
U.S. Nuclear Regulatory Commission
8201 NRC Road
Steedman, MO 65077
Mr. Jack N. Donohew (2 copies)
Licensing Project Manager, Callaway Plant
Office of Nuclear Reactor Regulation
U. S. Nuclear Regulatory Commission
Mail Stop 7E1
Washington, DC 20555-2738
Missouri Public Service Commission
Governor Office Building
200 Madison Street
PO Box 360
Jefferson City, MO 65102-0360
Records Center
Institute of Nuclear Power Operations
700 Galleria Parkway
Atlanta, GA 30339

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1. FACILITY NAME 2. DOCKET NUMBER� I3. PAGE
CALLAWAY PLANT UNIT 1 05000 483 1�OF�2
4. TITLE
"A" Steam Generator tube inspection results classified as C-3.

Docket Number
Event date:	4-26-2004
Report date:	5-25-2004
Initial Reporting
ENS 40705	Other Unspec Reqmnt
4832004006R00 - NRC Website

A. REPORTABLE EVENT CLASSIFICATION

This condition is being submitted per Technical Specification 5.5.9 and 5.6.10c requirements and reported as an "Other Unspecified Requirement" because this does not represent an actual serious S/G tube degradation as discussed in NUREG 1022 Revision 2, Section 3.2.4.

B. PLANT OPERATING CONDITIONS PRIOR TO THE EVENT

This condition was discovered during Refuel 13 while in Mode 6 with the core off loaded.

START OF THE EVENT AND THAT CONTRIBUTED TO THE EVENT

Callaway Plant was in Mode 6 with the core off loaded during Refuel 13.

D. NARRATIVE SUMMARY OF THE EVENT, INCLUDING DATES AND APPROXIMATE TIMES

See attached "Special Report to the NRC — Steam Generator A (EBBO1A) Categorized as C-3 Condition In Refuel 13" and "Attachment 1 — Indications Identified in Steam Generator A During RF13".

All indications identified at the top of the tube sheet are small in size as shown in Figures 2 and 3. None exceeded the condition monitoring limits for the specific type of degradation identified. No in-situ testing was performed based on screening criteria developed in the Plant's Degradation Assessment in accordance with the EPRI Steam Generator In-Situ Pressure Test Guidelines. The screening criterion are specified based on the type of degradation that exists or could potentially exist in the steam generators.

No indications in Steam Generator A exceeded these screening criterion.

There were no new forms of degradation found in Steam Generator A. All forms of degradation were anticipated and addressed in the Refuel 13 Degradation Assessment.

3 so 70 60 so 40 M ax im um D ep th (% th ro ug h wa il) 20 - 10 0.

180 160 411 140 '0 120 100 715 E 80 -. 40 20 0 .,`P ,t.P .;brk 1/40 ^ ao 1,0 .b0 e 0,0 ug, ao1 „.-P to to trP .‘d

• PDA (percent degraded area) Figure 3 Refuel 13 Steam Generator A Circumferential Indications ULNRC05011 May 25, 2004 Special Report -too ory Ory 01: 43 ' 0

• 04' 04 043 04' 043 04) 043 4) 4' 4' 45 '") 0

• 0

• 0

• 0

• o 0.'"‘ 0.'"I 043 04' 04' 04' Length of Axial Indication Figure 2 Refuel 13 Steam Generator Axial Indications rb 4 ULNRC05011 May 25, 2004 Special Report Table 'I Steam Generator A Indications and Tubes Repaired Since Refuel 7 Indication RFO7 *RFO8 RFO9 **RF10 RF11 RF12 RF13 Axial ID 5 9 14 15 23 39 77 Circumferential ID 4 26 17 21 2 43 25 Axial OD 0 0 1 0 0 0 0 Axial unknown 1 3 0 0 0 0 0 Circumferential OD 2 1 0 3 1 0 0 Circumferential unknown 0 6 0 0 0 0 0 Volumetric indications 0 5 0 3 0 4 0 Mixed Mode ID indications 0 0 0 0 0 0 1 Total tubes with TTS indications 11 47 32 41 26 84 100 Tubes plugged for AVB wear 0 0 0 0 0 3 0 Tube plugged for TSP wear 0 0 0 1 0 4 0 Tube plugged for loose parts 0 0 0 0 0 0 0 Total tubes repaired 11 48 32 42 26 91 100 *44 tubes sleeved with Westinghouse Laser Welded Sleeves at the top of the tube sheet.

• • 31 tubes sleeved with Framatome Electrosleeves at the top of the tube sheet.

Refuel 7 —1 tube has both axial and circumferential PWSCC Refuel 12 — 2 tubes have both axial and circumferential PWSCC Refuel 13 —1 tube has both axial and circumferential PWSCC Table 2 Steam Generator A Tubes Plu ed Inspection Period Steam Generator A Pre-service 8 Refuel 1 0 Spring '87 — Refuel 2 3 Refuel 3 - Refuel 4 6 Refuel 5 — Refuel 6 19 Refuel 7 11 Refuel 8 4 Refuel 9 32 Refuel 10 11 Refuel 11 26 Refuel 12 91 Refuel 13 100 Total 311 Steam Generator A is 5.53% plugged Equivalent plugging due to sleeves is 5.57% 5 80 70 —0—Axial PWSCC t Circ PWSCC Axial ODSCC --x-- Circ ODSCC —1k— unknown circ —41—unknown axial G7 ▪ 60 -F7 ▪ 0 a)

• 40 0 0 2 20 10 Jun-94 Oct-95 Mar-97 Jui-98 Dec-99 Apr-01 Sep-02 J an -0-1 May-05 ULNRC05011 May 25, 2004 Special Report May-05 120 000 50 60 40 20 0 —4—PWSCC —111-0DSCC Unknown r 1 Jun-94 Oct-95 Mar-97 Jul-98 Dec-99 Apr-01 Sep-02 , Jan-04 Outages Figure 4 Steam Generator A Cumulative TTS Degradation Outages Figure 5 Steam Generator A Cumulative TTS Degradation by Type N um b er o f T u b es R ep a ir ed 6 C DZ ULNRC05011 May 25, 2004 Special Report Actions to Prevent Recurrence All tubes with detected degradation at the top of the tube sheet were plugged in Steam Generator A. Additionally, all tubes with circumferential crack indications were stabilized. Callaway Plant anticipates similar degradation will be present in the steam generators at the end of Cycle 14. This is based on industry operating experience with Alloy 600 LTMA tubing and plant specific inspection results for the last 7 inspections.

Callaway will replace all four steam generators in Refuel 14.

Callaway Plant will continue to follow the requirements of NEI 97-06 and the referenced EPRI guidelines for future cycles of operation. These guidelines include requirements for primary and secondary water chemistry, primary to secondary leakage monitoring, inspection scope and frequency, pressure testing of degraded tubes, and integrity assessments to ensure tube structural and leakage integrity.

Condition Monitoring and Operational Assessments were performed in accordance with the EPRI Integrity Assessment Guidelines to address the as-found condition of the steam generator tubing to justify operation through Cycle 14. The assessments are based on identified degradation and use conservative analysis to assure tube structural and leakage integrity for the entire cycle length.

7 ATTACHMENT 1- INDICATIONS IDENTIFIED IN STEAM GENERATOR A DURING RF 13

REPAIR

IN-SERVICE HOT LEG- COLD LEG 11 33 PLUGGED PLUGGED SAI @ TSH +0.05 NO 11 48 PLUGGED PLUGGED SAI @ TSH -0.35 NO " .. PLUGGED PLUGGED SAI @ TSH +0.06 NO 11 53 PLUGGED PLUGGED SAI @ TSH +0.14 NO 11 54 PLUGGED PLUGGED SAI @ TSH +0.10 NO

• 11 57 PLUGGED PLUGGED SAI @ TSH +0.11 NO 12 59 PLUGGED PLUGGED SAI @ TSH +0.08 NO 12 74 PLUGGED PLUGGED SAI a TSH +0.12 NO 12 96 PLUGGED PLUGGED SAI @ TSH -0.00 NO 13 51 PLUGGED PLUGGED SAI @ TSH +0.00 NO 14 60 PLUGGED PLUGGED SAI @ TSH +0.10 NO 15 40 PLUGGED PLUGGED SAI @ TSH +0.04 NO 16 55 PLUGGED PLUGGED SAI @ TSH -0.18 NO 16 57 PLUGGED PLUGGED SAI @ TSH +0.10 NO 16 65 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.18 NO 16 68 PLUGGED PLUGGED SAI @ TSH +0.10 NO 17 36 PLUGGED PLUGGED SAI @ TSH +0.06 NO 18 20 PLUGGED PLUGGED MAI @ TSH +0.06 NO 18 47 PLUGGED PLUGGED SAI @ TSH +0.06 NO 19 44 PLUGGED PLUGGED MAI @ TSH +0.03 NO 19 50 PLUGGED PLUGGED SAI @ TSH +0.05 NO 19 67 PLUGGED PLUGGED SAI @ TSH +0.15 NO 19 74 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.15 NO 19 86 PLUGGED PLUGGED SAI @ TSH +0.09 NO 19 97 PLUGGED PLUGGED SAI @ TSH +0.04 NO 19 100 PLUGGED PLUGGED SAI @ TSH -0.06 NO 20 52 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.08 NO 20 67 PLUGGED PLUGGED SAI @ TSH +0.12 NO 20 85 PLUGGED PLUGGED SAI @ TSH +0.10 NO 21 36 PLUGGED PLUGGED SAI @ TSH +0.09 NO 21 46 PLUGGED PLUGGED MAI @ TSH +0.05 NO 21 52 PLUGGED PLUGGED MAI @ TSH +0.09 NO 21 85 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.13 NO 22 38 PLUGGED PLUGGED SAI @ TSH +0.15 NO 22 52 PLUGGED PLUGGED MAI @ TSH -0.09 NO 22 68 PLUGGED PLUGGED SAI @ TSH +0.04 NO 22 71 PLUGGED PLUGGED MAI @ TSH +0.07 NO 22 90 PLUGGED PLUGGED MAI @ TSH -0.03 NO 23 71 PLUGGED-STABILIZED PLUGGED SCI @ TSH -0.25 NO .

" PLUGGED-STABILIZED PLUGGED SAI @ TSH +0.14 NO 23 83 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.02 NO 23 88 PLUGGED PLUGGED SAI @ TSH -0.03 NO 23 94 PLUGGED PLUGGED MAI @ TSH +0.09 NO 24 101 PLUGGED PLUGGED MAI @ TSH +0.08 NO 25 66 PLUGGED PLUGGED MAI @ TSH +0.10 NO t ATTACHMENT 1- INDICATIONS IDENTIFIED IN STEAM GENERATOR A DURING RF 13 26 43 PLUGGED PLUGGED SAI @ TSH +0.07 NO 26 52 PLUGGED PLUGGED SAI @ TSH +0.11 NO 26 56 PLUGGED PLUGGED SAI @ TSH +0.05 NO 26 72 PLUGGED PLUGGED SAI @ TSH +0.06 NO 27 73 PLUGGED PLUGGED SAI @ TSH -0.00 NO 27 75 PLUGGED PLUGGED SAI @ TSH +0.06 NO 27 85 PLUGGED PLUGGED SAI @ TSH +0.06 NO 27 88 PLUGGED PLUGGED SAI @ TSH +0.03 NO 30 45 PLUGGED PLUGGED SAI @ TSH -0.02 NO 30 61 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.10 NO 30 96 PLUGGED-STABILIZED PLUGGED MMI @ TSH +0.11 NO 31 53 PLUGGED PLUGGED MAI @ TSH +0.11 NO 32 52 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.08 NO 32 61 PLUGGED-STABILIZED PLUGGED SCI @ TSH -0.17 NO 32 93 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.06 NO 33 69 PLUGGED-STABLIZED PLUGGED SCI @ TSH +0.05 NO 33 100 PLUGGED PLUGGED SAI @ TSH +0.03 NO 35 53 PLUGGED-STABILIZED PLUGGED MCI @ TSH +0.11 NO 35 63 PLUGGED PLUGGED SAI @ TSH +0.05 NO 35 94 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.12 NO 35 108 PLUGGED PLUGGED SAI @ TSH +0.05 NO 36 99 PLUGGED PLUGGED SAI @ TSH +0.10 NO 36 102 PLUGGED PLUGGED SAI @ TSH +0.10 NO 37 103 PLUGGED PLUGGED SAI @ TSH +0.05 NO 38 89 PLUGGED PLUGGED MAI @ TSH +0.11 NO 38 91 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.13 NO 38 97 PLUGGED PLUGGED SAI @ TSH +0.14 NO 39 84 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.10 NO 39 89 PLUGGED PLUGGED SAI @ TSH +0.04 NO 40 51 PLUGGED PLUGGED SAI @ TSH +0.09 NO 40 53 PLUGGED PLUGGED SAI @ TSH -0.01 NO 40 58 PLUGGED PLUGGED SAI @ TSH +0.03 NO 40 60 PLUGGED PLUGGED SAI @ TSH +0.08 NO 41 62 PLUGGED-STABILIZED PLUGGED MCI @ TSH +0.11 NO 41 85 PLUGGED PLUGGED SAI @ TSH +0.10 NO 41 86 PLUGGED PLUGGED SAI @ TSH +0.10 NO 42 54 PLUGGED PLUGGED SAI @ TSH +0.04 NO 42 57 PLUGGED PLUGGED SAI @ TSH +0.03 NO 43 57 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.05 NO 43 62 PLUGGED-STABILIZED PLUGGED SCI @ TSH -0.03 NO 44 50 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.04 NO 44 54 PLUGGED PLUGGED MAI @ TSH +0.06 NO 45 71 PLUGGED PLUGGED SAI @ TSH +0.01 NO 45 74 PLUGGED PLUGGED MAI @ TSH +0.08 NO 45 82 PLUGGED PLUGGED SAI @ TSH +0.05 NO 46 59 PLUGGED-STABILIZED PLUGGED MCI @ TSH +0.11 NO 46 74 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.11 NO 47 73 PLUGGED-STABILIZED PLUGGED SCI @ TSH +0.04 NO 49 66 PLUGGED-STABILIZED PLUGGED SCI @ TSH -0.03 NO ATTACHMENT 1— INDICATIONS IDENTIFIED IN STEAM GENERATOR A DURING RF 13 50 61 PLUGGED PLUGGED MAI @ TSH +0.06 NO 50 62 PLUGGED PLUGGED MAI @ TSH +0.05 NO 51 55 PLUGGED PLUGGED SAI @ TSH -0.06 NO 51 62 PLUGGED-STABILIZED PLUGGED MCI @ TSH +0.06 NO 51 80 PLUGGED-STABILIZED PLUGGED SCI @ TSH -0.13 NO 54 61 PLUGGED PLUGGED SAI @ TSH +0.11 NO 55 60 PLUGGED PLUGGED SAI @ TSH +0.17 NO 55 61 PLUGGED PLUGGED MAI @ TSH +0.14 NO

SAI

Single Axial Indication

MAI

Multiple Axial Indication

SCI

Single Circumferential Indication

MCI

Multiple Circumferential Indication

MMI

Mixed Mode Indication

TSH

Tube Sheet Hot