ML050560010

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Attachments 1-4, Palisades - Tube Inspection Report
ML050560010
Person / Time
Site: Palisades Entergy icon.png
Issue date: 03/01/2005
From: Jaffe D
NRC/NRR/DLPM/LPD3
To: Domonique Malone
Nuclear Management Co
Shared Package
ML050610439 List:
References
TAC MC2747
Download: ML050560010 (15)
v • d • e


Text

ATTACHMENT 1 MATERIAL FROM LICENSEE RECEIVED AUGUST 31, 2004 AS ANNOTATED

STEAM GENERATOR INSPECTION SCOPE FOR 2004 REFUELING OUTAGE CURRENT TUBE PLUGGING HISTORY:

The steam generators that are currently in use at the Palisades Nuclear Plant, are replacement steam generators and were installed in the fall of 1990. The tube material is mill annealed Alloy 600 with a 0.75 inch outside diameter and a 0.042 inch tube wall thickness. Each steam generator has 8219 tubes.

v Prior to the installation of these steam generators CE advised Consumers Energy that the area around the center stay cylinder region was potentially susceptible to fretting wear at the bat wing locations. This region was preventatively plugged. A total of 308 tubes were preventatively plugged in Steam Generator A and 309 tubes were preventatively plugged in Steam Generator B. After initial service Steam Generator A was designated Steam Generator E-50A and Steam Generator B was designated Steam Generator E-50B.

  • After eight cycles of operation, 57 additional tubes in Steam Generator E-50A have been plugged, for a total of 365 tubes plugged. After eight cycles of operation, 51 additional tubes in Steam Generator E-50B have been plugged, for a total of 360 tubes plugged. Steam Generator E-50A has 7854 active tubes with 4.44% of its tubes plugged. Steam Generator E-50B has 7859 active tubes with 4.38% of its tubes plugged.

ACTIVE DAMAGE MECHANISMS IN 2004 REFUELING OUTAGE:

  • Tube wear at vertical straps, diagonal bars, and eggcrates in both SGs
  • Axial PWSCC at small radius U-bends in SG E-50A
  • Axial PWSCC at the hot leg expansion transition and expanded tubesheet region in SG E-50A
  • Axial and Circumferential ODSCC at the hot leg expansion transition in both SGs

50% full-length bobbin coil eddy current examination of the inservice tubes in both SG. This includes all indications less. than 40% throughwall wear left inservice. Any tube last tested with bobbin at the 1998 and 1999 inspections not tested in 2001 or 2003. DSS calls from the 2001 and 2003 inspections. NQS calls from the 2001 and 2003 inspections between 07H and 07C in Rows 80 and higher

  • 100% examination of the in-service tubes in the area of the hot leg top-of-tubesheet roll transition area in both SGs using the Plus Point coil. The inspection depth is +3 inches to -8 inches.
  • Full length tubesheet region Plus Point exam of non-expanded tubes
  • 100% examination of the in-service Rows 1-3 U-bends in E-50A and Row 1 & 2 U-bends in E-50B using Plus Point mid range coil. 100% Rows 1-3 U-bends in E-50A and Row 1 & 2 U-bends in E-50B using Plus Point high frequency coil for those tubes with noise values exceeding a critical value.
  • 25% Plus Point coil exam of freespan dings/dents >5 volts between DBH and DBC in both SGs
  • 100% Plus Point coil exam of freespan dings/dents >5 volts in both SGs in vertical straight sections
  • Special Interest freespan RPC including o Confirmation of bobbin I-code signals o RPC testing of wear scars reported as >40%TW by bobbin 7 o RPC testing of newly reported signals at structures (vertical straps, diagonal bars

& eggcrate supports) to confirm degradation mechanism mode o RPC testing through the square bend region of tubes surrounding RG C1040 in SG E-50B o RPC "boxing" of confirmed foreign object wear signals at all elevations o Outer 2 rows of tubes in the cold leg for possible loose part wear

Video inspection of tube plugs will be performed by NMC certified Level II NDE Technician using video tape recordings.

  • A Foreign Object Search And Retrieval (FOSAR) inspection will be completed on the hot and cold legs of both steam generators at the top of the tubesheet at the periphery using a manual video probe. Retrieval equipment will be available for foreign object removal.
  • A bundle flush will be completed on each steam generator concurrent with sludge lancing, which will consist of high-pressure condensate water being sprayed at the top of the tube bundle including the eggcrates and support plates to wash down any loose sludge.
  • Sludge lancing will be completed on both steam generators concurrent with bundle flushing. Sludge lancing will be completed using equipment designed for Combustion Engineering steam generator tri-pitch tubing.

ATTACHMENT 2 MATERIAL FROM LICENSEE RECEIVED SEPTEMBER 30, 2004 AS ANNOTATED

PALISADES NUEARPLANT PALISADES NUCLEAR PLANT STEAM GENERATOR STATUS REPORT SEPTEMBER 30, 2004 Steam Generator E-50@

Scope Description Eddy Current Analyzed Potential Indications And Complete Requiring Tube

._ Plugging 50% bobbin full length 60% complete scope ._40% _ _ _ _ _ _

1 wear indications >

4 'JJ 100% plus point top of 91f%complete None '4 tubesheet hot leg +31-8 ivAi°5 inches . Acl 1 . l 8% plus point top of 0% complete None tubesheet cold leg +2/-2 inches 100% plus point rows 1- 98% complete None 3 u-bend_

113 2A 25% freespan &square 0% complete None bend dings > 5 volts 3 ( 5s.4J,,v 100% visual Inspection 100% complete None of all tube plug hot and it, cold legs Sludge lancing & upper Not completed None bundle flush Hard roll 7 non- 0% completed (will be 7 non-expanded will be expanded tubes into eddy-current tested hard rolled & plugged tubesheet prior to removal from

._ service)

In Steam Generator E-50A eddy current data acquisition and analysis is at 74% completed. A total of 8 tubes require potential tube plugging.

zoof 14u2 2o03 Page 2 of 2

PALISADES NUCLEAR PLANT STEAM GENERATOR STATUS REPORT SEPTEMBER 30, 2004 Steam Generator E-50B Scope Description Eddy Current Analyzed Potential Indications And Complete Requiring Tube Plugging 50% bobbin full length 71% complete 1 wear indications >

scope 100% plus point top of 96% complete 40%

None S?,-

tubesheet hot leg +3/-8 inches 8% plus point top of 0% complete None tubesheet cold leg +2/-2 jt, W.' Ptph.App

¶fr.4 inches 100% plus point rows 1- 0% complete None 9is 2 u-bend 25% freespan & square 0% complete None bend dings > 5 volts 100% visual inspection 100% complete None of all tube plug hot and cold legs Sludge lancing & upper Not completed None bundle flush Hard roll 7 non- 0% completed (will be 1 non-expanded will be expanded tubes into eddy current tested hard rolled & plugged COO tubesheet prior to removal from A service) , C'e,,,

JA, S In Steam Generator E-50B eddy current data acquisition and analysis is at 79% completed. A total of 2 tubes require potential tube plugging.

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ATTACHMENT 3 MATERIAL FROM LICENSEE RECEIVED OCTOBER 2, 2004 AS ANNOTATED

1- CAP044212 Activity Type: CAP Submit Date: 10/2/2004 12:32:37 PM v One Line

Description:

SG E-50A/B ET Bobbin Inspection in C-2 Category Expansion for Axial Indications v Detailed

Description:

10/2/2004 12:32:37 PM - HAGER, JOHN:

The Steam Generator E-50A and E-50B Bobbin eddy current inspection program has identified a single axial indication in each SG in the square bend region. Both indications are associated with dings 2 volts or less. The Bobbin program identified these indications as requiring further screening and included these indications in the special interest program. The special interest program uses the Plus Point probe to determine if ODSCC or PWSCC indications are present. After retesting both indications with Plus Point, a single axial indication was identified in each tube.

The defective tubes put SG E-50A and SG E-50B Bobbin base scope of 50% into a C-2 inspection category. The C-2 inspection category increases the base scope from 50% to 100% in each SG. The C-2 category is per Technical Specifications (TS) 5.5.8 and EPRI PWR Steam Generator Examination Guidelines: Revision 6 (EPRI Rev 6 ISI Guidelines).

The single axial indication in each SG makes this an active damage mechanism for this refueling outage and the 2006 refueling outage.

The Bobbin scope in the 2006 refueling outage will be 100% in each SG.

Initiator: HAGER, Initiator Department: ENPV ASME &

JOHN E Fa VALVE PROGRAMS PAL Et Date/Time of Discovery: 10/2/2004 Date/Time of Occurrence: 10/2/2004 12:23:27 12:23:27 PM PM Identified By: Site-identified System: (None)

Equipment# (1st): E-50A PAL Equipment Name (1st): 'A' STEAM GENERATOR Equipment # (2nd): E-50B PAL Equipment Name (2nd): 'B' STEAM GENERATOR Equipment # (3rd): (None) Equipment Name (3rd): (None)

Site/Unit: Palisades Why did this occur?: 10/2/2004 12:32:37 PM - HAGER, JOHN:

The single axial indication occurred in the straight bend tube location and each was associated with a ding. A ding is the result of deformities caused by the initial assembly of SG tubes into the SG. A ding creates stress risers in the tube lending susceptibility to stress corrosion cracking. Heat, stress and steam generator age result in outside diameter stress corrosion cracking (ODSCC).

Immediate Action Taken: 10/2/2004 12:32:37 PM - HAGER, JOHN:

Review of TS 5.5.8, EPRI Rev 6 ISI Guidelines Section 3.3, and Palisades Degradation Assessment for the 2004 Refueling Outage.

Notified the outage control center and engineering management.

Recommendations: 10/2/2004 12:32:37 PM - HAGER, JOHN:

The current Cycle 17 accident and transient analysis reports (EA-PPD-02-01, Revision 1, "Palisades Cycle 17 Principle Plant Parameters," EMF-2838, "Palisades Cycle 17 Safety Analysis Report") allows up to 15% of the total number of tubes in each steam generator to be plugged with maximum 9% difference between the two generators for the large break loss of coolant accident (LB LOCA). Final Recorded Calculation for Palisades Small Break Loss of Coolant Accident (SB LOCA) ECCS Performance Design Basis Analysis report allows up to 15% of the total number of tubes in each team generator to be plugged. These two tubes bring the total number of tubes plugged in SG E-50A to 4.46% and in SG E-50B 4.40%.

Both steam generators are operable. The defective tubes shall be plugged and removed from service using work orders 24323693 (SG E-50A) and 24323694 (SG E-50B).

There is no issue with SG Primary To Secondary Operational Leakage in Operational Cycle 17. See attached SG Primary To Secondary Leakage graph.

There is no issue with SG structural integrity in Operational Cycle 17.

Both SG single axial indications flaw sizes were below the screening criteria in the Palisades Degradation Assessment for the 2004 Refueling Outage. There is no issue with SG structural integrity in Operational Cycle 17 and these two indications do not require in-situ pressure testing.

@SRO Review Required?: N E Section 2 Operability Status: Inoperable v Compensatory Actions: N Basis for Operability: 10/2/2004 1:57:31 PM - SHAFFER, ROGER A:

Per tech spec programs and manuals section 5.8.C.2 The steam generator is inoperable until tubes exceeding the plugging limit are plugged 10/2/2004 2:08:57 PM - SHAFFER, ROGER A:

Both steam generators are inoperable.This is a mode constraint for leaving mode 5 Per TS 3.4.6 v Unplanned TSAC Entry: N D External Notification: N E Section 3 Screened?: Y v Significance Level: C INPO OE Reqd?: N Potential MRFF?: N v QA/Nuclear Oversight?: N v Licensing Review?: N Good Catch/Well Doc'd?:

E Section 4

Inappropriate Action:

Process: (None) Activity: (None)

Human Error Type: (None) Human Perf Fail Mode: (None)

Equip Failure Mode: GAS - Abnormal stress Process Fail Mode: (None)

Org/Mgt Failure Mode: (None) v Group Causing Prob: (None)

Hot Buttons: -n-QL) IU -

RUPTURED/CRACKED/FRACTURED B Section 5 CAP Admin: BINNINGTON, WAYNE CAP Owner: ROSS, LEONARD A a3 J a v Project: Corrective Action v State: AR Screening Que Process (CAP) v Active/inactive: Active v Submitter: HAGER, JOHN ED v Owner: BINNINGTON, WAYNE v Last Modified Date: 10/3/2004 9:08:51 A a3 AM v Last Modifier: MACKENZIE, BRUCE C v Last State Change Date: 10/2/2004 1:57:31 a PM v Last State Changer: SHAFFER, ROGER A v Close Date:

NUTRK ID: GMM

  1. of Children: 0

References:

Update:

Prescreen Comments:

Import Memo Field:

OPR Completed?: N OLDACTIONNUM:

subtsid: 0 original-projectjid: 69 originalissueid: 044212 Site: Palisades 3 Cartridge and Frame:

E Attachments and Parent/Child Links Primary To Secondary Leakrate for Operational Cycle 17.doc (18944 bytes) by HAGER, JOHN (10/2/2004 12:26:32 PM) 6 9Principal to CA025454: SG E-50A/B ET Bobbin Inspection in C-2 Category Expansion for Axial Indications by MACKENZIE, BRUCE C (10/3/2004 9:08:51 AM) E

ATTACHMENT 4 MATERIAL FROM LICENSEE RECEIVED OCTOBER 6, 2004 AS ANNOTATED

PALISADES NUCLEAR PLANT STEAM GENERATOR STATUS REPORT OCTOBERS 2004 Steam Generator E-50A Scope Description Eddy Current Analyzed Potential Indications And Complete Requiring Tube Plugging 50% bobbin full length 100% complete 1 wear indications > q9' VI scope 40% Pot,I illi 4 axial indication in a NQI (non quantifiable indication) /allow 50% bobbin full length 100% completed 1 axial indication in a CV-,c it's ,A expanded to 100% DSI (distorted support ,011t$

indication) /2 5 603(,G) 100% plus point top of 100% complete None tubesheet hot leg +3/-8 inches 8% plus point top of 100% complete None tubesheet cold leg +2/-2 inches 100% plus point rows 1- 100% complete None J 3 u-bend 25% freespan & square 100% complete None bend dings > 5 volts 100% visual Inspection 100% complete None of all tube plug hot and cold legs Sludge lancing & upper In progress None bundle flush ..

Hard roll 7 non- 100% completed (will 1 circumferential OA P, expanded tubes into be eddy current tested Indication in a tack tubesheet prior to removal from weld near end of hot t"Wr.

service) tubesheet 7 non-expanded will be .16_

hard rolled & plugged In Steam Generator E-50A eddy current data acquisition and analysis is 100% completed (this includes expanded bobbin scope). A total of 13 tubes require potential tube plugging.

- :1

PALISADES NULKAR PLANT PALISADES NUCLEAR PLANT STEAM GENERATOR STATUS REPORT OCTOBERS, 2004 Steam Generator E-50B Scope Description Eddy Current Analyzed Potential Indications And Complete Requiring Tube Plugging 50% bobbin full length %9Q% complete . 1 wear indications >

scope (vv40%

1 axial indication in a ( 5tG DNI (ding with

{0 o indication) R :Y 50% bobbin full length S% complete expanded to 100%

100% plus point top of b9Yo complete None tubesheet hot leg +3/-8 (oo inches 8% plus point top of 100% complete None tubesheet cold leg +2/-2 inches 100% plus point rows 1- 100% complete None 2 u-bend 25% freespan & square 92% complete None bend dings > 5 volts eV f III >9,.9 >YV 100% visual inspection 100% complete None of all tube plug hot and cold legs Sludge lancing & upper Completed 29 pounds of sludge bundle flush removed Hard roll 1 non- 100% completed (will 1 non-expanded will be expanded tubes into be eddy current tested hard rolled & plugged tubesheet prior to removal from service)

In Steam Generator E-50B eddy current data acquisition and analysis is at

/(o779/o completed (this includes expanded bobbin scope). A total of 3 tubes require potential tube plugging.

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Name Description TEH Tube End - Hot Side TSH Top of Tubesheet - Hot Side 01H First Eggcrate - Hot Side 02H Second Eggcrate - Hot Side 03H Third Eggcrate - Hot Side 04H Fourth Eggcrate - Hot Side 05H Fifth Eggcrate - Hot Side 06H Sixth Eggcrate - Hot Side 07H Seventh Eggcrate - Hot Side 08H Eighth Eggcrate - Hot Side DBH Diagonal Strap - Hot Side VS1 First Vertical Strap VS2 Second Vertical Strap VS3 Third Vertical Strap VS4 Fourth Vertical Strap VS5 Fifth Vertical Strap VS6 Sixth Vertical Strap VS7 Seventh Vertical Strap DBC Diagonal Strap - Cold Side 08C Eighth Eggcrate - Cold Side 07C Seventh Eggcrate - Cold Side 06C Sixth Eggcrate - Cold Side 05C Fifth Eggcrate - Cold Side 04C Fourth Eggcrate - Cold Side 03C Third Eggcrate - Cold Side 02C Second Eggcrate - Cold Side 01C First Eggcrate - Cold Side TSC Top of Tubesheet - Cold Side TEC Tube End - Cold Side Figure 3. Palisades Support Structure Naming Convention

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