Text

Insp Rept 50-440/93-03 on 930203-12.No Violations Noted. Major Areas Inspected:Fuel Performance,Appropriate Operational Parameters During Past Several Cycles
	ML20034F220
Person / Time
Site:	Perry
Issue date:	02/22/1993
From:	Burgess B, Salehi K; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:	;
Shared Package
ML20034F215	List: IR 05000440/1993003; ML20034F214;
References
	50-440-93-03, 50-440-93-3, NUDOCS 9303020418
	Download: ML20034F220 (30)
	v • d • e

'

U.

S.

NUCLEAR REGULATORY COMMISSION

REGION III

Report No. 50-440/93003(DRS)

Docket No. 50-440 License No. NPF-58

,

Licensee:

Centerior Service Company c/o The Cleveland Electric Illuminating Co.

10 Center Road Perry, OH 44081 Facility Name:

Perry Nuclear Power Plant Inspection At:

Perry, OH 44081 Inspection Condu ted:

ary 3 - 12, 1993

<

Inspector:

AM /

>

08-22-93 K.

Sal hi Date e

'b)rMcw m/03/73

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Approved By:

B.

Burgess, Chilef Date'

Operational Prbgrams section Inspection Summarv

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Inspection on February 3 12, 1993 (Recort No.

-

50-440/93003(DRS))

Areas Inspected: Routine announced safety inspection of fuel performance; review of the appropriate operational parameters during the past several cycles, licensee activities to identify potential root causes; and the establishment of corrective actions.

Results: No violations or deviations of NRC requirements were identified during this inspection.

>

I

.9303020418 930223 PDR ADOCK 05000440 Q

PDR

i v

DETAILS 1.

Persons Contacted Cleveland Electric Illuminatina Company (CEI)

D. Igyarto, Plant' Manager

F.

Stead, Director, Nuclear Support Department

S.

Kensicki, Director, Nuclear Engineering Department

+#B.

Walrath, Manager, Performance Engineering

#K. Donovan, Manager, Licensing and Compliance

+ P.

Bordley, Lead Fuel Management

+#B. Kahler, Fuel Manager

+#T. Hogan, Compliance Engineer

K.

Phyft, Public Affairs Representative

P. Volza, Manager, Rad Protection GE Nuclear Enerav (GE Nuclear)

J.

Balcken, Site Engineering Manager

J.

Klapproth, Fuels Licensing Manager

R.

Parr, Fuels Project Manager

C.

Patterson, Fuels Performance Engineering

L.

Wallis, Media and Environs Information Manager U.

S.

Nuclear Reculatory Commission (NRC)

B.

Davis, Regional Administrator

H.

Miller, Deputy Regional Administrator

P.

Alloway, Public Affairs Officer

B.

Berson, Regional Counsel

B.

Burgess, Chief, Operational. Programs Section, DRS

J.

Jacobson, Chief, Materials and Processes Section,-DRS-

R.

Lanksbury, Chief, Reactor Projects Section 3B, DRP

R.

Lickus, Chief, State and Governmental Affairs-

P.

Liuhto, Assignee from Finnish Center for Radiation Safety

.

T.

Martin, Acting Director, Division of Reactor Safety

S.

Magruder, Reactor Engineer,-Vendor Branch, NRR

M.

Ring, Chief, Operations Branch, DRS

M.

Schumacher, Chief, Radiological Controls Section 1, DRSS

J.

Strasma, Public Affairs Officer

+#A. Vegel, Resident Inspector

B.

Wetzel, Acting Perry Project Manager, NRR

S.

Wu, Reactor Engineer, Reactor Systems Branch, NRR State of Ohio

Carol O'Claire, Assistant Supervisor, RERP

-

,

s

-

.

.- -

]

,

,.

Commonwealth Edison Company (CECO)

"

E.

Armstrong, Fuels Reliability Engineer The Cleveland Plain Dealer

J.

Kuhner, Staff Writer

+ Attended preliminary exit interview on February 5, 1993.

Attended meeting at the Region III office on February 10,

,

1993.

'

Attended telephone exit interview on February 12, 1993.

The inspector also interviewed other staff during the site inspection.

~

2.

Fuel Performance Trend The fuel failure history at Perry indicated one or more rod failures during each operating cycle since initial plant i

startup.

The inspector examined the six fuel rod failures j

and reviewed the licensee's audit reports of GE's

'

manufacturing process of Perry's fuel.

The causes for the failures could not be positively identified at the present

,

time.

j i

3.

Operational Data The inspector examined operational data of various core parameters during the last several cycles.

This included j

review of all thermal limits (MFLCPR, MAPLHGR, MFLPD) on P3 and P1 process computer program edits, and reactor water chemistry results.

The inspector did not identify any anomalies related to three thermal limits based on review of-the computer edits.

The review of reactor coolant system water chemistry samples also did not reveal any apparent cause which could be attributed to'the fuel failures.

In addition, the inspector examined other distinct, yet related parameters.

This. included the licensee's response.to the radiation alarms for this latest fuel failure event; location of the radiation monitors on the refueling floor and in the fuel bundling building; and the nuclear engineers' log books.

The reviews did not reveal any anomaly.

4.

Recion III Public Meetina On February.10, 1993, a public meeting was held in-the Region III office and attended by regional management and staff, members of NRR, CEI, GE Nuclear, CECO, the State of Ohio, and a local newspaper, the Cleveland Plain Dealer.

The purpose of the meeting was to discuss the history of

-

.

-,

-

,

'

i fuel failures at the Perry Nuclear Power Plant, proposed changes to the failed fuel action plan, and the status of the licensee's investigation and corrective actions for the latest fuel failure.

Specifically, the licensee discussed four distinct areas:

A perspective of the operating history and the

locations of the six failed fuel rods at the Perry Nuclear Power Plant.

Actions taken to identify, isolate, and determine root

causes of the last two cycles of failed fuel rods.

To complete this action, the licensee has formed a task force consisting of both CEI plant and GE Nuclear staff.

This group was assigned the task of evaluating the root causes of all of the fuel failures at Perry.

Changes to the failed fuel action plan, utilized to

identify, respond and mitigate the consequences of a future fuel failure.

The near and long term corrective action plans to

address fuel failures.

As an example, one near term option being considered by the licensee was a change to the startup procedures to control power increases'to minimize the stresses on the fuel cladding.

This consideration, as well as other design or operational changes, will be reviewed by the task force.

The meeting consisted of presentations by several members of CEI, and its fuel supplier, GE Nuclear.

There was no proprietary information discussed during this meeting.

A copy of material presentea by the licensee and GE Nuclear is attached as Enclosure 2.

5.

Exit Meetina A preliminary exit interview was held with licensee representative (denoted in Section 1) prior to leaving the site on February 5, 1993.

A final telephone exit was held on February 12, 1993.

During both exits, the inspector summarized the scope and findings of the inspection.

The inspector also discussed the likely informational content of the inspection report concerning documents or processes

,

reviewed by the inspector.

The licensee. identified some information provided to the inspector during the inspection as proprietary.

The proprietary informationiwas reviewed and is not included in this inspection report.

The inspector will handle all identified proprietary information consistent with the requirements of 10 CFR 2.790.

4~9 11.!93 15:10 PERRY ftJCLEAR PL4t4T PLPJ4T p2

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ENCIOSURE 2

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CEI/GE/NRC FUEL PRESENTATION

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o INTRODUCTION (KENSICKI, CEI)

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GENuclewEnergy

.

I Perry-1 FuelInspection Results February 10,1993

-

.

-

,.

_

.

Perry-j FuelInspection Results

-

Overview of Fuel Performance - 17 Year, BWR Reliability Trend Based on

EPRI Data

,

!

.

!

s 81.7

_

,

From:" Excellence in Nuclear y

fuel Performance,"W. F. Naughton,

'

USCEA NuclearFuel y

Defective Cycle 91 Conference,3/27)91 Assemblies

,5'

parGM7 l 1.11.1.1.1.n...n..

14 75 N 77 M M N - 81 RDM M M 87 N 89 %

Years i

,

t

.

..

.

-

.

-

^

Perry-j Fuelinspection Results

+

.

!

Overview of Fuel Performance - EPRI Evaluation of BWR and PWR Fuel Reliability

.

I

M PWR PWR EZlBWR average

u

,

Defective

hvemblies

..

RWR

.

!

per GW(e)

average

,

V g

i

,i i

1NIF 1M7 1NC 1M9 1990

.

}

.

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _,

.-m

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=

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_

e

.

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s.

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,

..

"

p l Perry-lFuelInspection Results Inspection results: Bundle LYO382, Rod E6

~

. Cycle 1 failure

- 1 Exposure at e.nd of cycle: 1t2 GWd/MTU l/

. Member of initial core

.

.LGE6B design

. Manufacturing dates: 7/83 - 8/83 ~

-.~ Description of failure

- Short (-1 in.) crack with secondary hydride. damage at 10.in. elevation

-

.

Possible fretting marks at 12 in. elevation

- Short crack at 31 in. elevation

.

-- -...

.

... -.. -.

.,. _.

.

..

-

-.....-..-.-.

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.

...

.

-

.

+

.

.x_

y Perry-1 FuelinspectionResults

_

Inspection results: Bundle LYO191, Rod D1 ^

l

-.- Cycle 1! failure

,

i

. Exposure at end of cycle: 11.8 GWd/MTU L

. -Member of initial core

. - GE6B design

. Manufacturing dates: 7/83 -- 8/83

. Description of failure Debris induced fretting. observed at 91 and 98_ in. elevations

--

Visually cannot prove fretting penetrates cladding wall

-

Slight bulges and small, tight cracks at 16

"9 in. elevation

-

NoLother damage discernable-

/

-

,

-

-.

k w--

.wm s-a a

.a vm

- i T mm-

'%

w-m --

F*,e diwtd se

,-I--4-m

.u.

..

...

Perry-1 Fuelinspection Results inspection results: Bundle LYO465, Rod A4

-. Cycle 2 failure

.

Exposure at end of cycle: 17.7 GWd/MTU

. Member of initial core

. GE68 design

Manufacturing dates: 7/83 -8/83

. Description of failure

,

Discontinuous, through-wall crack < 1 in. long at 25 in. elevation

- Hydride blister with perforation at 27,40 and 90 in. elevations

- Narrow crack - 1 -in. long at 45 in. elevation with slight bulge

- Numerous through-wall eddy current signals along length of rod

- No fretting

_

..

-

.

..

.

..

.. L

..

-

.

m

- - - - - - - - - - - - - -

- - - - -

-

~

.:

'

j Perry-1 FuelInspection Results Inspection results: Bundle LYP301, Rod DB

. Cycle 3 failure i

'

. Exposure at end of cycle: 23.9 GWd/MTU I

. Member of Reload 1 l

. GE8B design

'

. Manufacturing dates: 9/88 - 11/88 l

l

. Description of failure

- Longitudinal crack between the 16 to 28 in. elevations

- Slight bulges with short, tight cracks at 5,7 36 and 37 in. elevations

- No fretting H

_ -

_ _ _ _-

__

_

-

--

-

--

-- - -- - -------

-

[.f '__

.

,

e

'

y Perry--1 FuelInspection Results

!

Inspection results: Bundle LYW156, Rod E2 l'

. Cycle 3 failure

. Exposure at end of cycle: 13.0 GWd/MTU

. - Member'of Reload 2

-

. GE8B design

. Manufacturing dates: 1/90 - 3/90

. L Description of failure

- Longitudina! crack 3 in. long at 36.in. elevation

- Slight bulges with short, tight cracks at:10,12 ano 25 in. elevations-

~

- Debris in center of bundle on loweritie plate, but no evidence of fretting

.

- Primary failure site not located

.

-. _ _

__.u.._.

...,

-..m

.-

u

.._,A_._

-..s..

. _ -<-_

.s

.-.s.m%a___.mc._

- -.,A_._-u-___---

-u:.__ _ _ - - - - _ _ _

h ma--

hs

,

.,

,-

[

Perry-1 Fuelinspection Results Inspection results: Bundle LYP358, Rod B3

. Cycle 4A failure

. Exposure at end of cycle: 26.0 GWd/MTU

. Member of Reload 1

. GE8B design

. Manufacturing dates: 9/88 - 11/88

. Description of failure

- Longitudinal crack ~ 2 in. long at 35 in. elevation

- 4 axial cracks with lengths of 2 to.13 in. between 93 and 118 in. elevations

- Bulge with through wall pit at 60 and 125 in. elevations

- Numerous eddy current signals along rod between 27 and 147 in. elevations

- - -

- -

- - - - -

- - -

- -

- - -

-

_ -

.,

.

,

-

p Perry-1 FuelInspection Results

Evaluation of results

. Potential causes of failure:

- Fretting due to spurious (i.e., infrequent and isolated) debris

- Undetected manufacturing defects

. Failures in Perry being evaluated by recently formed, joint CEl-GE task force

'

(Task force discussed in subsequent presentation)

. Workin progress

- Probable cause identified for three assemblies

- Premature to speculate on probable cause for other three assemblies

,

'

-- a

- --

- -

z-,

- ------

--

-

-,

e

+-

e--

.

--

m a=

= ~

.e a

-

o

-. : a

.

.-.

j Perry--1 FuelInspection Results L

Evaluation of Results-Continued

. Initial core bundles: LYO191, LYO382 and LYO465

- Probable cause: Undetected tubing flaws

-. Primary perforation not evident in one assembly (LYO191)

,

o Debris fretting present, but cannot prove fretting penetrates cladding

o Therefore, assume failure is due to undetected manufacturing defect

. Reload 1 bundles: LYP301 and LYP358.

- Possible causes: Debris fretting or undetected manufacturing defect

- Task force evaluation in progress

. Reload 2 bundle:- LYW156

- Possible causes: Debris fretting or undetected manufacturing defect.

.

- Task force evaluation in progress

,

-

<

,, -,.

+,

,,

~

,---v,,

- - -.-,

n

-

.

_

-

..

i

'#... Lo

,

GLOSSARY-

'

Crud

.

Acronym for. activated metallic deposits on reactor components, principally iron oxides from feedvater piping.

Discharge Batch The fuel that is spent and is removed from the reactor to the spent fuel pool during a refueling outage.

FRI INP0 Fuel Reliability Indicator - An index of offgas

~

activity used to detect the existence of pinhole fuel'

defects.

Level 1 Perry Failed Fuel Action Plan' level at which fuel-

.

defects are suspected and investigations are started.

Level 2 Perry Failed Fuel Action Plan level at which. fuel defects are confirmed and minor compensating actions may be required.

Level 3 Perry Failed Fuel Action Plan' level at which more significant measures are taken to prevent further fuel'

' degradation.

,

Level 4 Perry Failed Fuel Action Plan level at which a technical e'aluation is performed to determine if continued'

v operation is justifiable. This evaluation must be approved by the V.P. Nuclear.

Localization The systematic movement of control: rods while closely-monitoring offgas activity-to determine the location of failed fuel rods.

.

Long-lived Activity Fission product activity due to long-lived (half-' lives greater than a few hours) isotopes.

Since the transport time through the fuel cladding of microscopic' fuel defects'is often much greater than 1 day,~a-comparison-of long-lived to short-lived activity can be used to-determine the size of.a defect without physical inspection.

Offgas Activity Activity released from the reactor core in gaseous form.

The relevant isotopes for this topic are from the. noble.

gas fission product chains,- mainly xenons and kryptons.

Short-lived Activity Fission product activity vith half-lives shorter than a few hours.

These are mainly seen due to direct ~ contact

/

of the coolant with fissionable material.

Sipping A fuel failure determination method.

1.

A bundle is isolated in a sealed can.

2.

A vacuum is drawn, drawing off gases from the bundle.

3.

The activity of the gases is measured.

l

>'

,

.

, o q

,

E Slow-riser An anomalous sipping indication. The indication seems

.

to be caused by gases that have become trapped in the fluffy crud deposited on fuel rods.

Sum of six The sum of the activities of 6 predominant fission product chain radionuclides - Xel33, Xe135, Xe138, Kr85m, Kr87,-Kr88. These isotopes cover a range of half-lives, and thus the overall fission product release

'

from the reactor can be gauged by this number.

Tight Defect A pinhole defect in fuel cladding,Loften not visible without magnification.

,-

/

i s

v t e Inspection Report - Perry - 1993003
80 \| 81 \| 82 \| 83 \| 84 \| 85 \| 86 \| 87 \| 88 \| 89 \| 90 \| 91 \| 92 \| 93 \| 94 \| 95 \| 96 \| 97 \| 98 \| 99 00 \| 01 \| 02 \| 03 \| 04 \| 05 \| 06 \| 07 \| 08 \| 09 \| 10 \| 11 \| 12 \| 13 \| 14 \| 15 \| 16 \| 17 \| 18 \| 19 \| 20 \| 21 \| 22 \| 23 \| 24 \| 25 \|
1993 Quarterly Integrated 1Q (0) 2Q (0) 3Q (0) 4Q (0) Assessments Mid Cycle End of Cycle 7(0) 8(0) 10(0) 11(0) 12(0) 13(0) 14(0) 15(0) 16(0) 18(0) 19(0) 20(0) 21(0) 22(0) Security Operator Exams Emergency Planning Other

IR 05000440/1993003

Text

REGION III

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