ML041270237

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EOC-21 Refueling Outage, Steam Generator Inservice Inspection Steam Generator Three Month Report
ML041270237
Person / Time
Site: Oconee Duke Energy icon.png
Issue date: 04/09/2004
From: Rosalyn Jones
Duke Energy Corp, Duke Power Co
To:
Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML041270237 (36)
v • d • e


Text

Duke UWPower.'

A Duke Energy Company R. A. JONES Vice President Duke Power 29672 / Oconee Nuclear Site 7800 Rochester Highway Seneca, SC 29672 864 885 3158 864 885 3564 fax April 9, 2004 U. S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555

Subject:

Both of the original Oconee Unit 1 SGs were replaced with new SGs in End-Of-Cycle outage No. 21 which began September 20, 2003. Therefore, SG tube Inservice Inspections were not performed.

The new SGs have been subjected to pre-service inspections in accordance with the requirements of EPRI PWR Steam Generator Examination Guidelines, Revision 6, to which Duke Energy Corporation committed through NEI 97-06, Steam Generator Program Guidelines and ASME Section Xl.

Attachment A provides a copy of the steam generator tube pre-service inspection summary report for the NRC information per American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section Xl, Article IWA-6230 for the subject refueling outage.

If there are any questions you may contact R. P. Todd at (864) 885-3418.

Attachment

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U. S. Nuclear Regulatory Commission April 9, 2004 xc w/attachments:

Mr. Luis -A. Reyes Regional Administrator, Region 11 xc w/o attachments:

Mr. M. C. Shannon NRC Senior Resident Inspector Mr. L. E. O'1shan ONRR, Senior Project Manager Mr. Henry Porter DHEC Page 2

Steam Generator In-service Inspection Summary Report Oconee Unit 1 2003 Outage EOC 21 Location: 7800 Rochester Highway, Seneca, South Carolina 29672 NRC Docket No. 50-269 National Board No. N/A Commercial Service Date: July 15, 1973 Owner: Duke Energy Corporation 526 South Church St.

Charlotte, N.C. 28201-1006 Revision 0 Prepared By:

Reviewed By:

Approved By:

Copy No.

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ONS Master File no. OS-208.20

Distribution For Steam Generator In-service Inspection Summary Report Oconee Unit 1 2003 Outage EOC 21 Controlled Distribution Copy No.

Assigned To Original Oconee Nuclear Station Document Control Master File OS-208.20 NRC Document Control Uncontrolled Distribution 2

Hartford Steam Boiler Inspection and Insurance Corporation (AIA)

FORM NIS-1 OWNER'S DATA REPORT FOR INSERVICE INSPECTIONS As required by the Provisions of the ASME Code Rules

1.

Owner: Duke Energv Corporation. 526 S. Church St. Charlotte. NC 28201-1006 (Name and Address of Owner)

2. Plant: Oconee Nuclear Station. 7800 Rochester Highwav. Seneca. SC 29672 (Name and Address of Plant)
3. Plant Unit: 1
4.

Owner Certificate of Authorization (if required)

B. Commercial Service Date: July 15. 1973

6. National Board Number for Unit N/A
7. Components Inspected:

N/A Component Steam Generator A Steam Generator B Manufacturer Manufacturer Serial No.

Babcock & Wilcox-Canada 006K01 Babcock & Wilcox-Canada 006K02 State or National Province No. Board No.

N/A 205 N/A 206 Note:

Supplemental sheets in form of lists, sketches, or drawings may be used provided (1) size is 81/2 in. x 11 in., (2) information in items 1 through 6 on this data report is included on each sheet, and (3) each sheet is numbered and the number of sheets is recorded at the top of this form.

FORM NIS-1 (Back)

8.

Examination Dates:

March 23, 2002 To January 6, 2004 *

9.

Inspection Period Identification:

Third Period

10.

Inspection Interval Identification:

Third Interval

11.

Applicable Edition of Section XI:

12.

Date/Revision of Inspection Plan:

1989 **

Addenda None Station Tech. Spec. 5.5.10 Steam Generator Tube Surveillance Program provides plan requirements for in-service inspections

13. Abstract of Examinations and Test.
  • No in-service inspection of the 1A and 1B original steam generators was performed during this period. Both the 1A and 1B steam generators were completelY replaced during the ONS-1 EOC-21 refueling outage in fall 2003. This NIS-1 is to document the Rre-service examination of 100% of the tubes in the replacement steam generators in August 2003.
    • 1989 edition of Section XI is code of record for the original steam generators (OTSG's). The 1998 edition thru 2000 addendum of Section XI was used for the replacement steam generator's (ROTSG's) pre-service inspection.
14. Abstract of Results of Examination and Tests. Reference attached Replacement Steam Generator Pre-service Inspection Summary Report.
15. Abstract of Corrective Measures. No corrective measures. No repairs were made (tubes removed from service) based on the results of the pre-service examinations (eddy current testing).

We certify that a) the statements made in this report are correct b) the examinations and tests meet the Inspection Plan as required by the ASME Code,Section XI, and c) corrective measures taken conform to the rules of the ASME Code,Section XI.

Certificate of Authorization No. (if applicable)

N/A Expiration Date N/A Date Harch f6, 20 04 Signed Duke Energy Corp.

By Owner CERTIFICATE OF INSERVICE INSPECTION I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and the State of Province of North Carolina employed by *The HSBI&I Co., have inspected the components described in this Owner's Report during the period 7 - 1Y-03 to &Y1

-O 5!'

, and state that to the best of my knowledge and belief, the Owner has performed examinations and tests and taken corrective measures described in the Owner's Report in accordance with the Inspection Plan and as required by the ASME Code,Section XI.

By signing this certificate neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the examinations, test, and corrective measures described in this Owner's Report.

Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal injury or property damage or a loss of any kind arising from or connected with this inspection Commissions JC-1eI

/

AlA'04Z

-iirspector's Signature National Board, S r

Date A/:

20¶A'

  • The Hartford Steam Boiler Inspection & Insurance Co.

200 Ashford Center North Suite 300 Atlanta, GA. 30338 State, Province, and Endorsements to Form NIS-1 Replacement Steam Generator Pre-service Inspection Summary Report Oconee Nuclear Station Unit 1 - 2003 Outage EOC-21 Replacement Steam Generator Tubing - Pre-service Inspection Eddy current examinations were performed on the 0.625" OD x 0.037" wall Inconel 690 tubing for the replacement Oconee Nuclear Station Unit 1 steam generators. The inspections were performed by Babcock & Wilcox Canada (B&W) and subcontracted personnel prior to delivery of the replacement steam generators to the ONS site. The steam generators were replaced during the fall 2003 refueling outage.

Attached are the B&W Pre-service Inspection Summary reports for the 1A (S/N 006K-

01) and 1 B (S/N 006K-02) replacement steam generators. The 1A steam generator report is number BWC-TR-2003-01 0. The 1 B steam generator report is number BWC-TR-2003-01 1.

The reports are a summary of the eddy current testing results for each of the two replacement steam generators. The examination techniques performed during this inspection were bobbin coil and X-probe simultaneously. The inspections were performed on 100% of the tubes from tube end to tube end. The X-probe technique was used to characterize reportable and special interest indications.

There were no tubes identified in either steam generator that contained eddy current indications that required repairs. There is one tube in each of the two steam generators that was removed from service by plugging due to damage that occurred during manufacturing.

Attachments: -A-BWC-TR-2003-01 0 -B -

BWC-TR-2003-011 SG Pre-service Inspection Page 1 of 1 Prior to ONS-1 EOC-21 Summary Report

ONS-1 EOC-21 Steam Generators - NIS-1 -A Bwc-TR-2003-010 Rev. 0 Page I PRESERVICE EDDY CURRENT INSPECTION B&W REPORT NUMBER: BWC-TR-2003-010 Rev. 0 LOCATION ISSUE DATE OWNER

Oconee Nuclear Station Units 1,2 and 3 P.O. Box 1439, Hwy 130 and Hwy 183 Seneca, SC, USA 29679
August 11, 2003 Duke Energy Corporation B&W ORDER NUMBER: 006K DUKE POWER PO NUMBER: SG82 STEAM GENERATOR SERIAL NO.: 006K-01 Prepared by:

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c2-Dat Mary Addario ET LIIUQDA Supervisor Inspection Services e.Ot1203 Reviewed-by:

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3 Henry Myderwyk ET LIIIQDA Lead Analyst Approved by:

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Date:

1/863/AD B&W NUCLEAR SERVICES 55 Savage Drive Cambridge, Ontario NIT 1$5

ONS-? E0,C-21 Steam Generatoe - NIS-I Attachment I-A Bwc-TR-2003-010 Rev. 0 Page 2 TABLE OF CONTENTS SECTION INTRODUCTION 1.0 TECHNICAL

SUMMARY

- EDDY CURRENT 2.0 TUBESHEET MAP & INSPECTION

SUMMARY

- 100% BOBBIN INSPECTION 3.0 MASTER LIST (100% BOBBIN INSPECTION) 4.0 TUBESHEET MAP & LIST FOR FSD 5.0 TUBESHEET MAP & LIST FOR MBM 6.0 TUBESHEET MAP & LIST FOR NQI 7.0 TUBESHEET MAP & LIST FOR NSY 8.0 TUBESHEET MAP & LIST FOR PLG 9.0 MASTER REPORT OF X-PROBE EXAM 10.0 TUBESHEET MAP & LIST FOR All BOBBIN PROFILOMETRY 11.0 TUBESHEET MAP & LIST FOR BOBBIN PROFILOMETRY OXP 12.0 X-PROBE AND PROFO GRAPHICS 13.0 PERSONEL QUALIFICATIONS 14.0 PROBE CERTIFICATIONS & EQUIPMENT CALIBRATION CERTIFICATES 15.0

ONS-1 EOC-21 Steam GeneramU AcmSett -A Bwc-TR-2003-010 Rev. 0 Paae 3 TECHNICAL

SUMMARY

1.0 OVERVIEW 2.0 STEAM GENERATOR EXAMINATION INFORMATION Note: Tube Numbering B&W Drawing Number 006KE121 OR 006KE122 3.0 EXAMINATION METHODOLOGY 4.0 EXAMINATION TECHNIQUES 5.0.

EXAMINATION RESULTS 6.0 PLUG LIST

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7.0 DOCUMENTATION

ONS-EOC-21 Steam Generaotsi--NlS.

At -A Bwc-TR-2003-010 Rev. 0 Page 4 INTRODUCTION This report provides the results of the Eddy Current (ET) Examination performed by B&W Nuclear Services on the Alloy 690 tubing in the replacement, once-through steam generator, serial no. 006K01, for Oconee Nuclear Power Plant. These examinations were conducted as a pre-service inspection of this steam generat6r prior to shipment from the BWC facility in Cambridge, Ontario, Canada as per Shop Floor Routing 840780 Operation 0110. This report includes data from full-length bobbin examination of all (100%) tubes including bobbin profilometry of each tube end and 100% X-probe acquired data. X-probe data was only analyzed for special interest areas and a sample of the MBM indications.

This technical summary reports the information as required by BWC Bobbin and X-probe Analysis Procedure No. 259088 and BWC Bobbin tubesheet expansion Profilometry Analysis Procedure No. 259089.

The inspection staff of BWC Nuclear Seruices provides this report to Oconee Nuclear Power Plant in compliance with the following guidelines.

BWC Written Practice QCI-702-039 BWC Technical Specification TS-2480 Section Xl ASME Boiler and Pressure Vessel Code 1998 Edition Appendix IV, with 2000 addenda Section V ASME Boiler and Pressure Vessel Code 1998 Article 8, Appendix 1.with 2000 addenda EPRI Steam Generator Examination Guidelines Rev 6

ONS4t EOC-21 Steam Genera.trs - NIS-1 -A Bwc-TR-2003-010 Rev. 0 Page 5 TECHNICAL

SUMMARY

1.0 OVERVIEW This document provides a technical summary of the pre-service examination and is the final report which includes all the reported entries for each tube examined, inspection tube sheet maps for the reportable tube indications identified in the eddy current analysis procedures and printouts of these reportable indications.

2.0 STEAM GENERATOR EXAMINATION INFORMATION The steam generator referred to in this report is a Babcock & Wilcox Designed Once-through Type, containing 15631 straight Alloy 690 (BWC TS-2480) 0.625 inch outside diameter (OD) by 0.038 inch wall tubing.

There are fifteen (15) broach support structures constructed from SA 240 410 Stainless steel material within the tube bundle of this vessel. The supports are identified as per the Tube Support Layout for this steam generator (Figure 1).

The examination techniques performed during this inspection were Bobbin Coil and X-probe simultaneously. The bobbin coil and X-probe technique were performed on 100% of the tubing in the tube bundle to provide general information of tube integrity from tube end to tube end. The X-probe technique was also used to characterize reportable and special interest indications discovered by the bobbin examination technique.

The tube examinations were performed from the inlet side of the steam generator. Tube numbering of this steam generator was identified as per BWC drawing 006KE621. As per this drawing, Row 1, Tube 1 is located on the Y2, X2 side of the vessel. All Rows and Tubes are numbered the same from both the inlet and outlet sides of the steam generator. To remain consistent with the utility's numbering scheme all tube holes were numbered as tube coordinates.

ONS-I EOC-21 Steam Generat.rs.- NISIA m -A Bwc-TR-2003-010 Rev. 0 Page 6 Replacement Steam Generator For Oconee Tube Support Layout Figure #1 I

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ONS4 EOC-21 Steam Gen tos-- NS Atm Attachment I-A

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Bwc-TR-2003-010Rev.0 Page7 3.0 EXAMINATION METHODOLOGY The examinations, personnel and equipment complied with BWC Quality Assurance Manual for Nuclear Products, the applicable Duke Power Corp specification and Section Xl of the ASME Boiler and Pressure Vessel Code, 1998, with 2000 Addenda.

The examination data was acquired using the RD Tech TC7700-14D Multi frequency Acquisition System. The raw data was recorded onto hard drives and spooled from the acquisition server to the main server at Savage Drive in Cambridge. Following the completion of analysis, all evaluation results and calibration setups were copied to DVD for final storage. Any calibration groups which were.considered. unsatisfactory (bad data acquired), were removed from the DVDs.

3.1 Bobbin Examination All bobbin data generated from these examinations underwent two (2) separate analysis reviews. They were independent of each other and were referred to as Primary and Secondary analysis. The evaluations performed by each analysis review were to determine data quality and completeness. If evidence of defect indications, loose parts detection and other undetermined condition of the installed tubing, appropriate calls were made in accordance with the referenced data analysis guidelines, BWC SIS 259088 Rev. 1 for the bobbin technique.

Primary and Secondary analysis were performed manually by different remote site analysts. The results from these two analysts were compared through Zetec EddyNet98 compare software, by a Primary and Secondary Resolution analyst, both being independent from each other. The final discrepancies were resolved by the Resolution Analyst in accordance with the data analysis guidelines.

3.2 Bobbin Profilometry Examination The Bobbin Profilometry analysis was performed utilizing BWC SIS 259089 Rev 0 and consisted of a single analyst reviewing the results of each tubesheet hole.

Bobbin Tubesheet Profilometry analysis consisted of evaluating the tube expansion profile to determine if the tube was expanded, where the closure gap location was with relation to the top of the tubesheet, diameter of the expansion, and any abnormal signals within the tubesheet expansion.

3.3 Data Management Results of the evaluations (analysis) were loaded into the EIMS and STMax Data Management Systems. These systems were used to check that all the tubes were inspected and results reviewed through the analysis program. The EIMS system was used to perform data manipulation for data inquiry, tube sheet

ONS1 EOC-21 Steam Generakot-N.KS A

m -A Bwc-TR-2003-010 Rev. 0 Page 8 mapping and final reporting.

4.0 EXAMINATION TECHNIQUES 4.1 Bobbin All acquisition examinations, were performed using RD Tech TC 7700-14D via Eddyview software and all analysis platforms were perform using Zetec EddyNet Analysis Systems, running HP UNIX based EddyNet 98 Software Version 2 Patch 2.42. Bobbin Profilometry was performed using Westinghouse Anser Auto Profilometry software version 8.3.

The bobbin coil examinations were performed with a RD Tech combination Bobbin-X probe (XP-510-214-083-41). The primary probe utilized for this inspection was a 0.510-inch/ 2 x 14 pancake array diameter probe.

During the inspection, this probe traversed the tube at a speed of 24.inches per second coupled with a sampling rate of 780 samples per second. This provides a digitization rate of greater than 30 samples per inch of the tubing examined.

The examination frequencies follows:

750 kHz Differential 750 kHz Absolute 380 kHz Differential 380 kHz Absolute 190 kHz Differential 190 kHz Absolute used -and their purpose for the inspection are as this is the primary inspection frequency and provides, in close proximity the phase separation between the 100% through hole and 4x20% OD flat bottom holes to meet ASME Code requirements. This frequency was also used as a mix component.

Used for defect confirmation, and an absolute mix component.

Used for the screening of data and defect confirmation.

Used as absolute percent through wall calling channel, for defect confirmation.

Used as a mix component and for defect confirmation.

Used as a reporting channel for non-commercial MBM.s. Also as a mix component and for defect confirmation.

ONS-E EOC-21 Steam Genmrators - NIS-1 Attachment I -A Bwc-TR-2003-010 Rev. 0 Page 9 70 kHz Differential Locator channel for support and tube sheet locations and loose parts detection.

70 kHz Absolute Locator channel for support and tube sheet locations and loose parts detection.

In addition, mixing of frequencies were performed to produce process channels, which suppress the effects of tube support structures on eddy current signals, thus enhancing the evaluation of results at these locations.

The process channels and their purpose are as follows:

PROCESS CHANNEL 1 (P1) - 750/190 kHz. Differential (broach support suppression) used for detecting indications at broach support locations.

PROCESS CHANNEL 2 (P2) - 380/190 kHz. Absolute (broach support suppression) used for detecting indications at broach support locations.

Evaluation of the results used the as-built dimensions from the ASME calibration standard to develop calibration curves of PHASE ANGLE versus PERCENT (%)

DEPTH. DEPTH from signal responses produced by the 100% through wall

.052" diameter hole, 60% O.D. flat bottom hole and the 4 - 20% O.D. flat bottom holes. Discontinuities which were produced through the tube manufacturing process were reported regardless of voltage.

Analysis was performed as per BWC procedure 259088 and the analysis flow chart seen in Figure 2.

ONS-4 EOC-21 Steam Generateo.- NIS-t Attachment l-A Bwc-TR-2003-010 Rev. 0 Page 10 FIGURE #2 BOBBIN ANALYSIS FLOW CHART Duke Power Oconee Nuclear Power Plant Bobbin Coll Indication Flow Chart Indication noted on channels J

NOm YES Is the Indication assoclatedwith a NO Is" r:2 a

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ONS1 EOC-21 Steam Generatom, NtS41 Attachment I -A r

Bwc-TR-2003-010 Rev. 0 Page 11 4.2 X-Probe The X-probe examinations were performed using a 0.510 inch diameter RD Tech (XP-510-214-083-41) probe consisting of 2 x 14 pancake array arrangement.

The frequencies utilized for the X-probe acquisition and analysis are as follows:

750 kHz 380 kHz 190 kHz 70 kHz Additional process channels were also used. Their identification are noted in ETSS #3 (BWC number ETS-023)

Specific calibration, data screening and indication reporting methodologies were used in accordance with the data analysis guidelines. The primary purpose of the X-probe technique was to have full-length array probe data on each tube for future reference. It was also used to characterize discontinuities identified from

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.lbobbin analysis to determine the relevance of these indications and to assist in the final reporting of tube condition.

All reported NQl.s, a selection of MBM calls and some special interest tubes selected by the Resolution Analyst were analyzed using the X-probe inspection technique to characterize these areas of concern 5.0 EXAMINATION RESULTS 5.1 Bobbin Analysis The majority of discontinuities exhibited in this steam generator were indicative of MBM (Manufacturing Burnish Mark) signals. The MBM.s may be caused by tube conditioning at the tube manufacturer to remove localized tubing imperfections on the outside diameter (OD) or removal of imperfections caused by the installation of the tubes into the tube bundle. The process of tube conditioning was performed using approved process procedures. A total of one thousand two hundred and sixty-five (1265) non-commercial MBM indications were observed in this vessel.

Two, non-quantifiable indications (NQI) were reported using the bobbin technique.

Two, free span differential indications (FSD) were reported using the bobbin technique.

QH.S-EOC-21 Steam GenrtmtoS --NtS-1 -.4 Bwc-TR-2003-010 Rev. 0 Page 12 Four hundred and forty-one (441) tubes were addressed with the code, NSY.

Small voltage indications, less than the reporting criteria for MBM indications, were observed through out the tubes addressed in this vessel. This code will allow us to flag these tubes to Duke Power.

No Wall Loss indications were reported in this steam generator.

5.2 Bobbin Profilometry Analysis Bobbin Profilometry Analysis was performed on all tube sheet holes of this steam generator. Analysis was performed using Westinghouse Anser Bobbin Profilometry Auto Analysis Software and the resultant reporting measurements performed were as follows:

AVG Average expansion diameter throughout the tubesheet DEV Deviation in measurement of expansion from the average tube expansion (AVG) diameter.

OXP These are indications within the tubesheet with a deviation of 0.005 inches or greater from the nominal tube expansion diameter of each tube hole.

TMR Tube Expansion Transition (Closure Gap) This is a linear measurement from the end of the expansion with relation to the secondary face of the tubesheet.

Of the tubes inspected, tube holes did not exhibit any OXP signals, all tubes were expanded and no AVG were observed beyond the expansion parameters.

5.3 Special Interest X-probe Analysis X-probe analysis was performed on 4 indications, 2 NQI and 2 FSD. The tubes and the location of indications scanned are as follows:

Row Tube Location Indication 017 001 LTS + 17.91 NQI 015 047 LTS + 29.02 NQI 048 109 008 + 14.32 FSD 046 058 01-2 + 26.31 FSD Two FSD calls were NDD calls, after X-probe characterization.

Two NQI calls were NDD calls, after X-probe characterization.

Several MBM calls were characterized with the X-probe

ONS-1 EOC-21 Steam Generatios - NIS-1 -A-Bwc-TR-2003-010 Rev. 0 Page 13 The following Summary Report on the Oconee Baseline Inspection identifies the quantity of tubes inspected, the number of tubes resolved, the quantity of tubes which contain the indication and the quantity reportable of indications.

SUMMARY

REPORT OCONEE BASELINE SERIAL 006K01 Tubes to Inspect 15631 Tubes Through Resolution:

15631 100% COMPLETE Tubes Remaining to Resolve : 0 BOBBIN RESULTS INDICATION TYPE QTY OF TUBES WITH INDICATION

  1. OF INDICATIONS Wall loss > 7%

0 TUBES 0

Wall loss <7%

0 TUBES 0

FSD 2

TUBES 0

NQI 2

TUBES 0

MBM 1044 TUBES 1265 DNT/DNG 0/0 TUBES 010 BOBBIN PROFILOMETRY RESULTS I INDICATION TYPE I OTY OF TUBES WITH INDICATION Il OXP 0

TUBES No Tube Expansion 0

TUBES I

QNS-t EOC-21 Steam Genemto~rs. - NIS-1 -A Bwc-TR-2003-010 Rev. 0 Paae 14 X-PROBE SPECIAL INTEREST RESULTS INDICATION TYPE QTY OF TUBES WITH INDICATION

  1. OF INDICATIONS FSD 2 Tubes with 2 possible indications 0 all became NDD NQI 2 Tubes with 2 possible indications 0 all became NDD MBM 1044 Tubes with 1265 possible vAol MBMw s over w

indictionswith X-probe 6.0 PLUGGING LIST One tube was plugged on this steam generator:

Row 118 Tube 73 Reason for Plugging Damaged during manufacturing 7.0 DOCUMENTATION One copy of DVD containing the acquired and analyzed data plus two copies of the inspection report shall be provided to Duke Power for record purposes and.

archival storage.

One copy of the DVD containing the acquired and analyzed data shall be retained, by BWC Quality Records, for use as a working copy, for future evaluation.

Copies of the procedures used for these examinations have already been provided to Duke Power for their approval before commencing the eddy current inspection.

ONS-1 EOC-21 Steam Generators - NIS-1 -8 Bwc-TR-2003-011 Rev. 0 Paqe I

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PRESERVICE EDDY CURRENT INSPECTION B&W REPORT NUMBER: BWC-TR-2003-011 Rev. 0 LOCATION ISSUE DATE OWNER Oconee Nuclear Station Units 1,2 and 3 P.O. Box 1439, Hwy 130 and Hwy 183 Seneca, SC, USA 29679

August 11, 2003 Duke Energy Corporation B&W ORDER NUMBER: 006K DUKE POWER PO NUMBER: SG82 STEAM GENERATOR SERIAL NO.: 006K-02 Prepared by: _

Date: _dr-/Z-OS Mary Addarlo ET LIII/QDA Supervisor Inspection Services Reviewed by:

L 8J<Il

.Gte:

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a o3 Henry Myderwyk ET LIIIQDA Lead Analyst.

Approved by:.

Cus mer Si nature Date:

18 J

a B&W NUCLEAR SERVICES 55 Savage Drive Cambridge, Ontario NIT IS.5

ONS-1 E Z

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Attachment I rB Bwc-TR-2003-011 Rev. 0 Page 2 TABLE OF CONTENTS SECTION INTRODUCTION 1.0 TECHNICAL

SUMMARY

- EDDY CURRENT 2.0 TUBESHEET MAP & INSPECTION

SUMMARY

- 100% BOBBIN INSPECTION 3.0 MASTER LIST - 100% BOBBIN INSPECTION 4.0 TUBESHEET MAP & LIST FOR DNG 5.0 TUBESHEET MAP & LIST FOR MBM 6.0 TUBESHEET MAP & LIST FOR NQI 7.0 TUBESHEET MAP & LIST FOR NSY 8.0 TUBESHEET MAP & LIST FOR PVN 9.0 TUBESHEET MAP & LIST FOR PLG 10.0 MASTER REPORT FOR X-PROBE EXAM 11.0 TUBESHEET MAP & LIST FOR All BOBBIN PROFILOMETRY 12.0 TUBESHEET MAP & LIST FOR BOBBIN PROFILOMETRY OXP 13.0 X-PROBE AND PROFO GRAPHICS 14.0

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ONS-1 EOC-21 Steam GenecatQm - Ntl!lt Akqb ij.etrl - EL.

Bwc-TR-2003-011 Rev. 0 Paae 3

, -U-TECHNICAL

SUMMARY

1.0 OVERVIEW 2.0 STEAM GENERATOR EXAMINATION INFORMATION Note: Tube Numbering B&W Drawing Number 006KE121 OR 006KE122 3.0 EXAMINATION METHODOLOGY 4.0 EXAMINATION TECHNIQUES 5.0 EXAMINATION RESULTS 6.0 PLUG LIST 7.0 DOCUMENTATION

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ONS-1 EOC-21 Steam Generatom. - NIS7.-.1' Attamrent'-lB&

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Bwc-TR-2003-011 Rev. 0 Page 4 INTRODUCTION This report provides the results of the Eddy Current (ET) Examination performed by B&W Nuclear Services on the Alloy 690 tubing in the replacement, once-through steam generator, serial no. 006K02, for Oconee Nuclear Power Plant. These examinations were conducted as a pre-service inspection of this steam generator prior to shipment from the BWC facility in Cambridge, Ontario, Canada as per Shop Floor Routing 840769 Operation 0110. This report includes data from full-length bobbin examination of all (100%) tubes including bobbin profilometry of each tube end and 100% X-probe acquired data. X-probe data was only analyzed for special interest areas and a sample of the MBM indications.

This technical summary reports the information as required by BWC Bobbin and X-probe Analysis Procedure No. 259088 and BWC Bobbin tubesheet expansion Profilometry Analysis Procedure No. 259089.

The inspection staff of BWC Nuclear Services provides this report to Oconee Nuclear Power Plant in compliance with the following guidelines.

BWC Written Practice QCI-702-039 BWC Technical Specification TS-2480 Section Xl ASME Boiler and Pressure Vessel Code 1998 Edition Appendix IV, with 2000 addenda Section V ASME Boiler and Pressure Vessel Code 1998 Article 8, Appendix I with 2000 addenda EPRI Steam Generator Examination Guidelines Rev 6

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ONS4 EQ-C-21 Steam Generators - NIS-1 Aftbrm.Q~ntrl~E.&

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Bwc-TR-2003-011 Rev. 0 Page 5 TECHNICAL

SUMMARY

1.0 OVERVIEW This document provides a technical summary of the pre-service examination and is the final report which includes all the reported entries for each tube examined, inspection tube sheet maps for the reportable tube indications identified in the eddy current analysis procedures and printouts of these reportable indications.

2.0 STEAM GENERATOR EXAMINATION INFORMATION The steam generator referred to in this-report is a Babcock & Wilcox Designed Once-through Type, containing 15631 straight Alloy 690 (BWC TS-2480) 0.625 inch outside diameter (OD) by 0.038 inch wall tubing.

There are fifteen (15) broach support structures constructed from SA 240 410 Stainless steel material within the tube bundle of this vessel. The supports are identified as per the Tube Support Layout for this steam generator (Figure 1).

The examination techniques performed during this inspection were Bobbin Coil' and X-probe simultaneously. The bobbin coil and X-probe technique were performed on 100% of the tubing in the tube bundle to provide general information of tube integrity from tube end to tube end. The X-probe technique was also used to characterize reportable and special interest indications discovered by the bobbin examination technique.

The tube examinations were performed from the inlet side of the steam generator. Tube numbering of this steam generator was identified as per BWC drawing 006KE621. As per this drawing, Row 1, Tube I is located on the Y2, X2 side of the vessel. All Rows and Tubes are numbered the same from both the inlet and outlet sides of the steam generator. To remain consistent with the utility's numbering scheme all tube holes were numbered as tube coordinates.

ONS4 EOC-21 Steam Generators - NIS-1.-8 Bwc-TR-2003-011 Rev. 0 Page 6 Replacement Steam Generator For Oconee Tube Support Layout Figure #1

ONSET EOC-21 Steam utOss - NISt Aft;qb Mg.* n1'p- &

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Bwc-TR-2003-011 Rev. 0 Page 7 3.0 EXAMINATION METHODOLOGY The examinations, personnel and equipment complied with BWC Quality Assurance Manual for Nuclear Products, the applicable Duke Power Corp specification and Section XI of the ASME Boiler and Pressure Vessel Code, 1998, with 2000 Addenda.

The examination data was acquired using the RD Tech TC7700-14D Multi frequency Acquisition System. The raw data was recorded onto hard drives and spooled from the acquisition server to the main server at Savage Drive in Cambridge. Following the completion of analysis, all evaluation results and calibration setups were copied to DVD for final storage. Any calibration groups which were considered unsatisfactory (bad data acquired), were removed from.

the DVDs.

3.1 Bobbin Examination All bobbin data generated from these examinations underwent two (2) separate analysis reviews. They were independent of each other and were referred to as Primary and Secondary analysis. The evaluations performed by each analysis review were to determine data quality and completeness. If evidence of defect indications, loose parts detection and other undetermined condition of the installed tubing, appropriate calls were made in accordance with the referenced data analysis guidelines, BWC SIS 259088 Rev. 1 for the bobbin technique.

Primary and Secondary analysis were performed manually by different remote site analysts. The results from these two analysts were compared through Zetec EddyNet98 compare software, by a Primary and Secondary Resolution analyst, both being independent from each other. The final discrepancies were resolved by the Resolution Analyst in accordance with the data analysis guidelines.

3.2 Bobbin Profilometry Examination The Bobbin Profilometry analysis was performed utilizing BWC SIS 259089 Rev 0 and consisted of a single analyst reviewing the results of each tubesheet hole.

Bobbin Tubesheet Profilometry analysis consisted of evaluating the tube expansion profile to determine if the tube was expanded, where the closure gap location was with relation to the top of the tubesheet, diameter of the expansion, and any abnormal signals within the tubesheet expansion.

3.3 Data Management Results of the evaluations (analysis) were loaded into the EIMS and STMax Data Management Systems. These systems were used to check that all the tubes were inspected and results reviewed through the analysis program. The EIMS system was used to perform data manipulation for data inquiry, tube sheet

1N$4 E-OC-21 Steam Generators - NIS-1 Attache 14

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Bwc-TR-2003-011 Rev. 0 Page 8 mapping and final reporting.

4.0 EXAMINATION TECHNIQUES 4.1 Bobbin All acquisition examinations, were performed using RD Tech TC 7700-14D via Eddyview software and all analysis platforms were perform using Zetec EddyNet Analysis Systems, running HP UNIX based EddyNet 98 Software Version 2 Patch 2.42. Bobbin Profilometry was performed using Westinghouse Anser Auto Profilometry software version 8.3.

The bobbin coil examinations were performed with a RD Tech combination Bobbin-X probe (XP-510-214-083-41). The primary probe utilized for this inspection was a 0.51 0-inch/ 2 x 14 pancake array diameter probe.

During the inspection, this probe traversed the tube at a speed of 24 inches per second coupled with a sampling rate of 780 samples per second. This provides a digitization rate of greater than 30 samples per inch of the tubing examined.

The examination frequencies used and their purpose for the inspection are as follows:

750 kHz Differential 750 kHz Absolute 380 kHz Differential 380 kHz Absolute 190 kHz Differential 190 kHz Absolute this is the primary inspection frequency and provides, in close proximity the phase separation between the 100% through hole and 4x20% OD flat bottom holes to meet ASME Code requirements. This frequency was also used as a mix component.

Used for defect confirmation, and an absolute mix component.

Used for the screening of data and defect confirmation.

Used as absolute percent through wall calling channel, for defect confirmation.

Used as a mix component and for defect confirmation.

Used as a reporting channel for non-commercial MBM.s. Also as a mix component and for defect confirmation.

ONSt1 EOC-21 Steam Generators - NIS-1 -8

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Bwc-TR-2003-011 Rev. 0 Page 9 70 kHz Differential 70 kHz Absolute Locator channel for support and tube sheet locations and loose parts detection.

Locator channel for support and tube sheet locations and loose parts detection.

In addition, mixing of frequencies were performed to produce process channels, which suppress the effects of tube support structures on eddy current signals, thus enhancing the evaluation of results at these locations.

The process channels and their purpose are as follows:

PROCESS CHANNEL 1 (P1) - 750/190 kHz. Differential (broach support suppression) used for detecting indications at broach support locations.

PROCESS CHANNEL 2 (P2) - 380/190 kHz. Absolute (broach support suppression) used for detecting indications at broach support locations.

Evaluation of the results used the as-built dimensions from the ASME calibration standard.to develop calibration curves of PHASE ANGLE versus PERCENT (%)

DEPTH. DEPTH from signal responses produced by the 100% through wall

.052" diameter hole, 60% O.D. flat bottom hole and the 4 - 20% O.D. flat bottom holes. Discontinuities which were produced through the tube manufacturing process were reported regardless of voltage.

Analysis was performed as per BWC procedure 259088 and the analysis flow chart seen in Figure 2.

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ONS-1 EOC-21 Steam Generators-NSl-11 Afto-uetM!!*k I,

Bwc-TR-2003-011 Rev. 0, Page 10 FIGURE #2 BOBBIN ANALYSIS FLOW CHART Duke Power Oconee Nuclear Power Plant Bobbin Coil Indication Flow Chart YES

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SteamqGenerators.- NIS-1 Att4c. Reo1:-.E Bwc-TR-2003-O11 Rev. 0 Page 11 4.2 X-Probe The X-probe examinations were performed using a 0.510 inch diameter RD Tech (XP-510-214-083-41) probe consisting of 2 x 14 pancake array arrangement.

The frequencies utilized for the X-probe acquisition and analysis are as follows:

750 kHz 380 kHz 190 kHz 70 kHz Additional process channels were also used. Their identification are noted in ETSS #3 (BWC number ETS-023)

Specific calibration, data screening and indication reporting methodologies were used in accordance with the data analysis guidelines. The primary purpose of the X-probe technique was to have.full-length array probe data on each tube for future reference. It was also used to characterize discontinuities identified from bobbin analysis to determine the relevance of these indications and to assist in the final reporting of tube condition.

All reported NQI.s, a selection of MBM calls and some special interest tubes selected by the Resolution Analyst were analyzed using the X-probe inspection technique to characterize these areas of concern 5.0 EXAMINATION RESULTS 5.1 Bobbin Analysis The majority of discontinuities exhibited in this steam generator were indicative of MBM (Manufacturing Burnish Mark) signals. The MBM.s may be caused by tube conditioning at the tube manufacturer to remove localized tubing imperfections on the outside diameter (OD) or removal of imperfections caused by the installation of the tubes into the tube bundle. The process of tube conditioning was performed using approved process procedures. A total of nine hundred and twenty (920) non-commercial MBM indications were observed in this vessel.

Four, non-quantifiable indications (NQI) were reported using the bobbin

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technique.

One, ding (DNG) was reported using the bobbin technique.

One, permeability variation (PVN) was reported using the bobbin technique.

QNS-t EOC-21 Steam Generators -. NISt-h Attachmenvi1-:;

Bwc-TR-2003-011 Rev. 0 Page 12 Thirty (30) tubes were addressed with the code, NSY. Small voltage indications, less than the reporting criteria for MBM indications, were observed through out the tubes addressed in this vessel. This code will allow us to flag these tubes to Duke Power.

No Wall Loss indications were reported in this steam generator.

5.2 Bobbin Profilometry Analysis Bobbin Profilometry Analysis was performed on all tube sheet holes of this steam generator. Analysis was performed using Westinghouse Anser Bobbin Profilometry Auto Analysis Software and the resultant reporting measurements performed were as follows:

AVG Average expansion diameter throughout the tubesheet DEV Deviation in measurement of expansion from the average tube expansion (AVG) diameter.

OXP These are indications within the tubesheet with a deviation of 0.005 inches or greater from the nominal tube expansion diameter of each tube hole.

TMR Tube Expansion Transition (Closure Gap) This is a linear measurement from the end of the expansion with relation to the secondary face of the tubesheet.

Of the tubes inspected, tube holes did not exhibit any OXP signals, all tubes were expanded and no AVG were observed beyond the expansion parameters.

5.3 Special Interest X-probe Analysis X-probe analysis was performed on 6 indications, 4 NQI, I DNG and I PVN. The tubes and the location of indications scanned are as follows:

Row Tube Location Indication 075 054 LTS +01.79 NQI 074 002 LTS + 02.55 NQI 074 023 LTE + 15.49 NQI 062 030 LTS + 02.66 NQI 030 025 014 + 32.56 DNG 031 106 014 + 08.39 PVN

ONS-1 EOC-21 Steam Generators - NIS-1 :rB

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Bwc-TR-2003-011 ReV. 0 Page 13 Four NQI calls were NDD call, after X-probe characterization.

One DNG call was DNG call, after X-probe characterization.

One PVN call was PVN call, after X-probe characterization Several MBM calls were characterized with the X-probe The following Summary Report on the Oconee Baseline Inspection identifies the quantity of tubes inspected, the number of tubes resolved, the quantity of tubes which contain the indication and the quantity reportable of indications.

SUMMARY

REPORT OCONEE BASELINE SERIAL 006K02 Tubes to Inspect Tubes Through Resolution:

Tubes Remaining to Resolve 15631 15631.100% COMPLETE

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BOBBIN RESULTS INDICATION TYPE QTY OF TUBES WITH INDICATION

  1. OF INDICATIONS Wall loss> 7%

0 TUBES 0

Wall loss <7%

0 TUBES 0

NQI 4

TUBES 0

PVN I

TUBES 1

MBM 835TUBES 920 DNT/DNG 0/1 TUBES 0/1 BOBBIN PROFILOMETRY RESULTS Q

I INDICATION TYPE I QTY OF TUBES WITH INDICATION I OXP I

0 TUBES I

No Tube Expansion I0 TUBES I

S G

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ONSt EOC-21 Steam Generators - NIS-11 Attachment I -13

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Bwc-TR-2003-011 Rev. 0 Paqe 13 Four NQI calls were NDD call, after X-probe characterization.

One DNG call was DNG call, after X-probe characterization.

One PVN call was PVN call, after X-probe characterization Several MBM calls were characterized with the X-probe The following Summary Report on the Oconee Baseline Inspection identifies the quantity of tubes inspected, the number of tubes resolved, the quantity of tubes which contain the indication and the quantity reportable of indications.

SUMMARY

REPORT OCONEE BASELINE SERIAL 006K02

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Tubes to Inspect 15631 Tubes Through Resolution:

.15631 100% COMPLETE Tubes Remaining to Resolve:

0 BOBBIN RESULTS INDICATION TYPE QTY OF TUBES WITH INDICATION

  1. OF INDICATIONS Wall loss> 7%

0 TUBES 0

Wal loss <7%

0 TUBES 0

NQI 4 TUBES 0

PVN 1 TUBES I

MBM 835TUBES 920 DNT/DNG 0/1 TUBES 01 BOBBIN PROFILOMETRY RESULTS INDICATION TYPE l QTY OF TUBES WITH INDICATION OXP I

0 TUBES No Tube Expansion 0

TUBES

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Ij ONS-1 EOC-21 Steam Generators - NIS-1 -B Bwc-TR-2003-011 Rev. 0 Page 14 X-PROBE SPECIAL INTEREST RESULTS INDICATION TYPE QTY OF TUBES WITH INDICATION

  1. OF INDICATIONS NQI 4 Tubes with 4 possible indications 0 all became NDD DNG I Tubes with I possible indications I DNG PVN 1 Tubes with 1 possible Indications I PVN MBM 835 Tubes with 920 possible indications volt were reviewed with X-probe 6.0 PLUGGING LIST.

One tube was plugged on this steam generator.

Row 121 Tube 105 Reason for Plugging Damaged during manufacturing

  • 7.0 DOCUMENTATION One copy of DVD containing the acquired and analyzed data plus two copies of the inspection report shall be provided to Duke Power for record purposes and archival storage.

One copy of the DVD containing the acquired and analyzed data shall be retained, by BWC Quality Records, for use as a working copy, for future evaluation.

Copies of the procedures used for these examinations have already been provided to Duke Power for their approval before commencing the eddy current inspection.

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