ML051370377

EOC-21 Refueling Outage, Steam Generator Inservice Inspection and Repairs Steam Generator Tube 30-Day and Three-Month Reports

ML051370377
Person / Time
Site:	Oconee
Issue date:	05/10/2005
From:	Rosalyn Jones Duke Energy Corp
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML051370377 (37)

Text

Duke RON A. JONES PokPower 0 SS PwersOconee Vice President Nuclear Site A Duke Energy Company Duke Power ON01 VP / 7800 Rochester Highway Seneca, SC 29672 864 885 3158 864 885 3564 fax May 10, 2005 U. S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555

Subject:

Oconee Nuclear Station Docket No. 50-287 Unit 3 EOC-21 Refueling Outage, Steam Generator Inservice Inspection and Repairs Steam Generator Tube 30-day and Three-month Reports The Oconee Nuclear Station Technical Specification (TS) 5.5.10 establishes the Steam Generator (SG) tube surveillance program requirements for SGs. TS 5.6.8, a, requires a report to the NRC with the number of tubes repaired or plugged within 30 days of the completion of the plugging or repair procedure. In addition, TS 5.6.8.b, requires the results of a Steam Generator Tube Inservice Inspection be reported to the NRC within three months following completion of the inspection.

Both of the original Oconee Unit 3 SGs were replaced with new SGs in End-Of-Cycle outage No. 21 which began October 9, 2004 and completed January 2, 2005.

Therefore, SG tube Inservice Inspections were not performed on the old SGs.

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.

Very tryors, R.A Jo Attachment www.dukepower.comr

U. S. Nuclear Regulatory Commission Page 2 May 10, 2005 xc w/attachments: Mr. W. D. Travers Regional Administrator, Region 11 xc w/o attachments: Mr. M. C. Shannon NRC Senior Resident Inspector Mr. L. E. OQshan ONRR, Senior Project Manager Mr. Henry Porter DHEC

U. S. Nuclear Regulatory Commission May 10, 2005 Attachment Unit 3 End of Cycle 21 Steam Generator Inservice Inspection Steam Generator Summary ASME XI Report

Steam Generator In-serviceInspection Summary Report Oconee Unit 3 2004 Outage EOC 21 Location: 7800 Rochester Highway, Seneca, South Carolina 29672 NRC Docket No. 50-287 National Board No. N/A Commercial Service Date: December 16, 1974 Owner: Duke Energy Corporation 526 South Church St.

Charlotte, N.C. 28201-1006 Revision 0 Prepared By a-v"u4 ad Date: 4 Z3 /°5 C -/D Reviewed B1 OM 2 dla Date: ______

//twA.

Approved B1 Date: it8PSo5 1)~eo14 1 J.

XRC aJR .

Copy No. *1 Assigned Tc Controlled: _ _ Uncontrolled:

ONS Master File no. OS-208.20

Distribution For Steamn Generator In-service Inspection Sumnmary Report Oconee Unit 3 2004 Outage EOC 21 ControlledDistribution Copy No. Assigned To Original Oconee Nuclear Station Document Control Master File OS-208.20 NRC Document Control UncontrolledDistribu/ion 2 Hartford Steam Boiler Inspection and Insurance Corporation (AIA)

• t-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 Highway. Seneca. SC 29672 (Name and Address of Plant)

3. Plant Unit: 3

4. Owner Certificate of Authorization (if required) N/A

5. Commercial Service Date: December 16. 1974

6. National Board Number for Unit N/A

7. Components Inspected:

Manufacturer State or National Comnonent Manufacturer Serial No. Province No. Board No.

Steam Generator A Babcock & Wilcox- Canada 006K05 N/A 211 Steam Generator B Babcock & Wilcox- Canada 006K06 N/A 212 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: Jitne 17, 2003 To January 2, 2005 *

9. Inspection Period Identification: Third Period

10. Inspection Interval Identification: Third Interval

11. Applicable Edition of Section XI: 1989 ** Addenda None

12. Date/Revision of Inspection Plan: 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 3A and 3B original steam generators was performed during this period. Both the 3A and 3B steam generators were completely replaced during the ONS-3 EOC-21 refueling outage in fall 2004. This NIS-1 is to document the pre-service examination of 100% of the tubes in the replacement steam generators in March 2004.

• • 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 wvas 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 Dre-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 April I 2 3 20 05 Signed Duke Energy Corp. By owvner t 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-or? to /- Z- oS , 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 ,ce . O~4e Inspector's Signature National Board, State, Province, and Endorsements Date S E:

'- OS

• The Hartford Steam Boiler Inspection & Insurance Co.

200 Ashford Center North Suite 300 Atlanta, GA. 30338

Attachment I to Form NIS-1 Replacement Steam Generator Pre-service Inspection Summary Report Oconee Nuclear Station Unit 3 - 2004 Outage EOC-21 Replacement Steam Generator Tubing - Pre-service Inspection Eddy current examinations were performed on the 0.625" OD x 0.038" wall Inconel 690 tubing for the replacement Oconee Nuclear Station Unit 3 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 2004 refueling outage.

Attached are the B&W Pre-service Inspection Summary reports for the 3A (S/N 006K-

05) and 3B (S/N 006K-06) replacement steam generators. The 3A steam generator report is number BWC-TR-2004-05. The 3B steam generator report is number BWC-TR-2004-06.

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 were no tubes plugged in either the 3A or the 3B steam generators as part of manufacturing.

Attachments: -A - BWC-TR-2004-05 Rev. 0 (Vessel 006K 3A Steam Generator) -B - BWC-TR-2004-06 Rev. 0 (Vessel 006K 3B Steam Generator)

SG Pre-service Inspection Page 1of I Prior to ONS-3 EOC-21 Summary Report

ONS-3 EOC-21 Steam Geneatprs - NIS Attacwment 14-i NYCJTR.2004.06 Rev. 0 Page I PRESERVICE EDDY CURRENT INSPECTION B&W REPORT NUMBER: BWC-TR-200406 Rev. 0 I PCATION  : Oconee Nuclear Station Units 1,2 and 3 P.O. Box 1439, Hwy 130 and Hwy 183 Seneca, SC, USA 29679 I SSUE DATE  : May 5, 2004

( WNER  : Duke Energy Corporation I W ORDER NUMBER: 006K STEAM GENERATOR SERIAL NO.: 006K-06

[ KE POWER PO NUMBER: SG82 Ftcpared by: Date: 5-- 20 -/

Mary Addario ET LIIIIQDA Supervisor Inspection Services F,viewed by: I- I I

I I

Date: ___/ ____

Randy Cherry ET LIIIQDA Resolution Analyst I pproved by: iDate:*

- O/Of Cu ~me Signature B&W NUCLEAR SERVICES 55 Savage Drive Cambridge, Ontario N1T 1S5 MRY 21 2004 08: 56 519 623 7664 PRGE.01

ONS-3 EOC-21 Steam Generatprs - NIS1 - Attachment 1-B BWC-TR-2004-06 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 PID 9.0 MASTER REPORT FOR X-PROBE EXAM 10.0 TUBESHEET MAP & LIST FOR All BOBBIN PROFILOMETRY 11.0 X-PROBE AND PROFO GRAPHICS 12.0

ONS-3 EOC-21 Steam Generatqrs - NIS Attachment 1-B BWC-TR-2004-06 Rev. 0 Page 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 7.0 DOCUMENTATION

ONS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 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. 006K06, for Oconee Nuclear Power Plant. This examination was 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 841010 Operation 0100. This report includes data from full-length 100% bobbin examination of all 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 greater than 1 volt. Data Quality Verification (DQV) was automatically run on all the X-probe acquired data.

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 1 with 2000 addenda EPRI Steam Generator Examination Guidelines Rev 6

ONS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 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 006KE121. 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.

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ONS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 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 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-RAM media for final storage. Any calibration groups, which were considered unsatisfactory (bad data acquired),

were removed from the DVD-RAM media.

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, with primary located at our Cambridge facility and Secondary located remotely in San Clemente, CA.

The Primary Resolution analyst compared the reports from the two analysts using Zetec EddyNet compare software. The Resolution Analyst resolved all final discrepancies and eliminated calls from the Primary 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 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. The data was reviewed by one analyst and results reported.

I

O-NS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 Rev. 0 Page 8 3.3 Data Management Results of the evaluations (analysis) were loaded into the EIMS Data Management System. 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 mapping and final reporting.

4.0 EXAMINATION TECHNIQUES 4.1 Bobbin All data acquisition was performed using RD Tech TC 7700-14D via Eddyview software and all analysis platforms were performed 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 20 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 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.

750 kHz Absolute Used for defect confirmation, and an absolute mix component.

380 kHz Differential Used for the screening of data and defect confirmation.

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

ONS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 Rev. 0 Page 9 190 kHz Differential Used as a mix component and for defect confirmation.

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

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-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 Rev. 0 Page 10 FIGURE #2 BOBBIN ANALYSIS FLOW CHART Duke Power Oconee Nuclear Power Plant Bobbin Coll Indication Flow Chart

ONS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 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 is 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.

A selection of MBM calls greater than 1volt 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 three hundred and eighty-three (383) non-commercial MBM indications were observed in this vessel.

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

Three, Freespan Differential indications (FSD) were reported using the bobbin technique.

ONS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 Rev. 0 Page 12 One hundred and eighteen (118) tubes were addressed with the code, NSY.

These indications are small voltage, less than the MBM reporting criteria and several of these indications are dispersed through out the tube. This code will allow us to flag these tubes to Duke Power.

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 tube were expanded and no AVG were observed beyond the expansion parameters.

5.3 Special Interest X-probe Analysis X-probe analysis was performed on 15 indications: 3 FSD's, 2 NQl's and 10 MBM's. The FSD and NQI tubes and their location are as follows:

Row Tube Location Indication 029 104 014 + 10.53 FSD 029 104 014 + 12.91 FSD 029 104 014 + 16.12 FSD 103 025 005 + 03.84 NQI 070 127 004 + 36.21 NQI The NQI calls were found to be NDD, after X-probe characterization. The FSD calls were found to. have an ID indication component, which remains acceptable to leave inservice.

X-probe analysis was performed on the ten (10) MBM calls greater than one volt (Vmx).

ONS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 Rev. 0 Page 13 i

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 indications and the quantity of reportable indications.

SUMMARY

REPORT OCONEE BASELINE SERIAL 006K06 Tubes to Inspect: 15631 Tubes Through Resolution: 15631 100% COMPLETE Tubes Remaining to Resolve: 0 BOBBIN RESULTS INDICATION TYPE QTY OF TUBES WITH INDICATION # OF INDICATIONS Wall loss> 7% 0 TUBES 0 Wall loss <7% 0 TUBES 0 FSD 1 TUBE 3 MBM 357TUBES 383 NQI 2 TUBES 2 BOBBIN PROFILOMETRY RESULTS INDICATION TYPE QTY OF TUBES WITII INDICATION OXP 0 TUBES No Tube Expansion 0 TUBES X-PROBE SPECIAL INTEREST RESULTS

• v INDICATION TYPE QTY OF TUBES WITH INDICATION # OF INDICATIONS 1tube with 3 possible indications ID 2OI 2 tubes with 2 possible indications NDD MBM tubes with 3357 Tubes 383possible wiath 33 i possible s All MBM's volt over 1 were reviewed indications with X-probe

ONS-3 EOC-21 Steam Generatprs - NIS Attachment 1-B BWC-TR-2004-06 Rev. 0 Page 14 6.0 PLUGGING LIST No tubes were plugged on this steam generator:

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

BWC Quality Records shall retain one copy of the DVD-RAM media containing the acquired and analysed data, 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-3 EOC-21 Steam Genwators - NIS-I - Attachment I-A BWC-TR-2004-05 Rev. 0 Paae 1 PRESERVICE EDDY CURRENT INSPECTION B&W REPORT NUMBER: BWC-TR-2004-05 Rev. 0 LOCATION  : Oconee Nuclear Station Units 1,2 and 3 P.O. Box 1439, Hwy 130 and Hwy 183 Seneca, SC, USA 29679 ISSUE DATE March 31, 2004 OWNER Duke Energy Corporation B&W ORDER NUMBER: 006K STEAM GENERATOR SERIAL NO.: 006K-05 DUKE POWER PO NUMBER: SG82 I

Prepared by: Bengal -. Date: 4- .4'Af -o9 Mary Addarlo ET LIII/QDA Supervisor Inspection Services Reviewed by: 7/ D ate: _ _ _ _ _ _

Henry Myderwyk ET LI11QDA Lead Analyst Approved by: _ Date: ____ _

%AI tC7. / 2 Customer Signature B&W NUCLEAR SERVICES 55 Savage Drive Cambridge, Ontario NIT 1S5

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 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 MBM 5.0 TUBESHEET MAP & LIST FOR NQI 6.0 TUBESHEET MAP & LIST FOR NSY 7.0 MASTER REPORT FOR X-PROBE EXAM 8.0 TUBESHEET MAP & LIST FOR All BOBBIN PROFILOMETRY 9.0 X-PROBE AND PROFO GRAPHICS 10.0

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 Rev. 0 Page 3 I

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

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 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. 006K05, for Oconee Nuclear Power Plant. This examination was conducted as a pre-service inspection of this steam generator prior to shipment from the BWC facility inCambridge, Ontario, Canada as per Shop Floor Routing 841010 Operation 0100. This report includes data from full-length 100% bobbin examination of all 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.

Data Quality Verification (DQV) was automatically run on all the X-probe acquired data.

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 1with 2000 addenda EPRI Steam Generator Examination Guidelines Rev 6

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 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 006KE1 21. 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.

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ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 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-RAM media for final storage. Any calibration groups, which were considered unsatisfactory (bad data acquired),

were removed from the DVD-RAM media.

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, with primary located at our Cambridge facility and Secondary located remotely in San Clemente, CA.

The Primary Resolution analyst compared the reports from the two analysts using Zetec EddyNet compare software. The Resolution Analyst resolved all final discrepancies and eliminated calls from the Primary 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 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. The data was reviewed by one analyst and results reported.

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 Rev. 0 Page 8

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3.3 Data Management Results of the evaluations (analysis) were loaded into the EIMS Data Management System. 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 mapping and final reporting.

4.0 EXAMINATION TECHNIQUES 4.1 Bobbin All data acquisition was performed using RD Tech TC 7700-14D via Eddyview software and all analysis platforms were performed 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 20 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 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.

750 kHz Absolute Used for defect confirmation, and an absolute mix component.

380 kHz Differential Used for the screening of data and defect confirmation.

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

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 Rev. 0 Page 9 190 kHz Differential Used as a mix component and for defect confirmation.

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

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-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 Rev. 0 Page 10 i'

FIGURE #2 BOBBIN ANALYSIS FLOW CHART Duke Power Oconee Nuclear Power Plant Bobbin Coll Indication Flow Chart Is the indication associated with a NO dent or ding? Flaw like and Ohs 3 and 5 correlate L iii

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ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 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 380kHz 190 kHz 70 kHz Additional process channels were also used. Their identification is 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.

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 ninety (990) non-commercial MBM indications were observed in this vessel.

One, non-quantifiable indication (NQI) was reported using the bobbin technique.

Four (4)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.

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 Rev. 0 Page 12 No Wall Loss indications were reported in this steam generator.

During this preservice bobbin baseline inspection we encountered distorted broach plate support signals, causing frustration during acquisition troubleshooting. After our troubleshooting efforts, it was determined, RD Tech, our probe supplier integrated a ferromagnetic stainless steel cable in the bobbin probe head, causing this distortion. Duke Power was notified immediately. To document this finding RD Tech filed a customer complaint, corrective action and engineering change notice.

B&W rescanned over 4000 tubes, bobbin only, for Duke Power's information.

These cal groups were only analyzed for data quality and tube location. Duke Power will receive a copy of the raw data from these tubes. These rescanned tubes are not part of the preservice baseline inspection database.

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 tube were expanded and no AVG were observed beyond the expansion parameters.

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 Rev. 0 Page 13 5.3 Special Interest X-probe Analysis X-probe analysis was performed on 39 indications: 1 NOI and 38 MBM's. The NQI tube and its location are as follows:

I Row Tube Location Indication I l 067 125 008 +20.89 NQI The one NQI call was found to be NDD, after X-probe characterization.

X-probe analysis was performed on thirty-eight (38) MBM calls greater than one volt (Vmx). Ten from the thirty-eight MBM indications were noted as non-commercial MBM's.

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 indications and the quantity of reportable indications.

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SUMMARY

REPORT OCONEE BASELINE SERIAL 0061K05 Tubes to Inspect 15631 Tubes Through Resolution: 15631 100% COMPLETE Tubes Remaining to Resolve: 0 BOBBIN RESULTS INDICATION TYPE OTY OF TUBES WITH INDICATION # OF

._ INDICATIONS Wall loss > 7% 0 TUBES 0 Wall loss < 7% 0 TUBES 0 t NOI 1 TUBE 1 MBM 880TUBES 990 BOBBIN PROFILOMETRY RESULTS l INDICATION TYPE QTY OF TUBES WITH INDICATION l OXP 0 TUBES No Tube Expansion 0 TUBES X-PROBE SPECIAL INTEREST RESULTS INDICATION TYPE QTY OF TUBES WITH INDICATION # OF INDICATIONS NQI 1 tube with 1 possible indications 0 became NDD All MBM's over 1 MBM 880 Tubes with 990 possible volt were reviewed indications with X-probe

ONS-3 EOC-21 Steam Generators - NIS Attachment 1-A BWC-TR-2004-05 Rev. 0 Page 15 6.0 PLUGGING LIST No tubes were plugged on this steam generator:

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

BWC Quality Records shall retain one copy of the DVD-RAM media containing the acquired and analysed data, 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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