ML20209G175

SG Eddy Current Insp Rept,Cycle 9 Refueling Outage (B1R09)

ML20209G175
Person / Time
Site:	Byron
Issue date:	07/08/1999
From:	COMMONWEALTH EDISON CO.
To:
Shared Package
ML20209G144	List: ML20209G139 ML20209G175
References
NUDOCS 9907190066
Download: ML20209G175 (15)

Text

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Commonwealth Edison Company (Comed)

BYRON STATION UNIT 1 4450 N. Gesman Church Road Byron, IL 61010 COMMERCIAL OPERATION: 09/16/85 STEAM GENERATOR EDDY CURRENT INSPECTION REPORT CYCLE 9 REFUELING OUTAGE (B1R09)

APRIL 1999 l

l Comed i P.O. Box 767 i Chicago, IL 60690

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Documentation Completed Date: July 8,1999

'9907190066 990709 PDR ADOCK 05000454' G ppR Page 1 of 15

Table of Contents 1.0 Introduction 2.0 Summary 3.0 Certifications 3.1 Procedures / Examinations / Equipment 3.2 Personnel 4.0 Examination Technique and Examination Scope 4.1 - Examination Techniques 4.2 Exceptions to EPRI PWR SG Examination Guidelines -

4.3 Recording of Examination Data 4.4 Witness and Verification of Examination

'5.0 Examination Results 5.1 Eddy Current inspection 5.2 Weld Plug inspection 5.3 Secondary Side VisualInspection 6.0 Repair Summary 7.0 ' Tube Integrity Assessment Summary 7.1 Condition Monitoring / Operational Assessment

' 8.0 Documentation 9.0 Tables / Figures / Attachments l

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1.0 INTRODUCTION

1 Byron Station Unit 1 operates with four Babcock & Wilcox Replacement Steam Generators (SGs) in tne four loop pressurized water reactor system. The SGs each contain 6633 thermally treated

. Inconel-690 U-tubes that have a nominal diameter of 0.6875 inches and a nominal thickness of 0.040 inches. The tubes are supported by stainless steel lattice grid structures and fan bars. The

' tubes are hydraulically expanded into the full depth of the tubesheet. Main Feedwater enters the

' SGs above the tube bundle through a feedring and J-tubes. The SG configuration is shown in Figures A.1 and A.2. The replacement SGs were installed at the end of Cycle 8 and Byron Station Unit 1 operated one cycle using these SGs prior to this inservice inspection described in this report. During the Byron Station Unit 1 Cycle 9 refueling Outage (B1R09) the first inservice inspection of the replacement SGs was performed.

In compliance with Byron Station Technical Specification 5.5.9, " Steam Generator Tube Surveillance Pro 0 ram

• and ASME Section XI, lWB 2500-1, Examination Category B-Q, item B16.20,1989 Edition, SG eddy current examinations were performed during the Byron Station Unit 1 Cycle 9 refueling outage (B1R09). In addition, the inspections were performed consistent .

with Revision 5 of the EPRI PWR Steam Generator Examination Guidelines and NEl 97-06,

? Steam Generator Program Guidelines". The inspections were conducted from April 3 through April 9,1999 by Framatome Technologies, Inc. (FTI). The following inspections were performed

- during this outage:

8

. ' 100% Full Length Bobbin Collin SGs B, C, and D -

e : Diagnostic Plus-Point inspections based on Bobbin Coil Results

' 100% Visual Inspection of installed welded plugs (2 in SG C)

.; Visual Inspection of Secondary Side Tubesheet in All SGs

. Visual Inspection of Upper Bundle and Feednng Region in SG D 2.0' -

SUMMARY

The guidance in Revision 5 of the EPRI PWR Steam Generator Examination Guidelines (EPRI Guidelines) was used during this inspection. A degradation assessment was performed prior to

. the inspection to ensure the proper EPRI Appendix H qualified inspection techniques were used 1 to detect any existing (none) and potential modes of degradation. Each technique was evaluated

.to ensure that the detection and sizing capabilities are applicaUe to the Byron Station Unit 1 site specific condition in accordance with Section 6.2.4 of the EPRI Guidelines. All data analysts were qualified to Appendix G of the EPRI Guide!ines (QDA). All data analyst and acquisition personnel satisfactorily completed site specific training and testing. An independent QDA

process control review was employed to randomly sample the data to ensure that the analysis resolution pacess was properly performed and that the field calls were properly reported. An analysis feedback process was implemented that required the data analysts to re@w their  ;

missed calls and ovsrcalls on a daily basis.

As a result of the eddy current and visuelinspections of the SGs, no degradation was found in the tubing or intemal components. There were no scanning limitations during the eddy current examinations." No tubes were repaired. Tabie 2.1 provides the total tube plugging histo;y and equivalent plugging levels to-date for the Byron Unit 1 SGs:

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Table 2.1 Eq uivalent Tube Plugging Level te ne MWW e, o a gg A : > ;3g3% ggggg #$999 T0tel s Tubes Previously Plugged

• 0 0 -1 0 1 Tubes Plugged in B1R09 0 0 0 0 0 Total Tubes Plugged 0 0 1 0 1 s Total Tubes Plugged (%) 0% 0% 0.015 % 0% 0.004 %

• Tubes plugged at factory during vessel fabrication.

3.0 CERTIFICATIONS 3.1 Procedures / Examinations / Equipment ,

- 3.1.1 The examination and evaluation procedures used during the SG eddy current l inspection were approved by personnel qualified to Level ill in accordance with the 1984 Edition of SNT-TC-1 A," Personnel Qualification and Certification in Nondestructive Testing". Comed procedures SPPM NDT-E-2, Revision 2 and SPPM NDT-E-3, Revision 1 were used for the data acquisition and analysis.

q 3.1.2 The examinations, equipment and personnel were in compliance with the requirements of the Comed and FTl Quality Assurance Programs for Inservice  !

Inspection, Byron Station Technical Specification 5.5.9,1989 Edition of ASME f Boller and Pressure Vessel Code Sections XI and V, Revision 5 of the EPRI PWR SG Examination Guidelines and NEl 97-06.

3.1.3 Certification packages for examiners, data analysts and equipment are available at l Byron Station. Tables A.1 and A.2 list all personnel who performed, supervised or evaluated the data during this SG inservice inspection.

3.1.4 Zetec MlZ-30 Remote Data Acquisition Units (RDAUs) with EddyNet 98 Version 5.16 computer software was used to acquire the eddy current data. Analysis was performed with EddyNet 98 Version 5.16 computer software.

1 3.1.5 The bobbin coil examinations of the SGs were performed with Zetec 0.560 inch i diameter M/ULC 3/8 36p Tuned probes. l 3.1.6 The rotating coil examinations in the straight tubing were planned to be performed with Zetec 0.560 inch diameter plus-point Delta Probe Head 0.115/PP/s80 probes.

The coils within this probe were a 0.115 inch diameter pancake coil, a shielded i 0.080 inch diameter mid-range pancake coil and a standard mid-range plus-point coil. No diagnostic examinations in the straight tubing were required.

3.1.7 The rotating coil examination in t! w U-bend region of the SG tubing were performed with a Zetec 0.560 inch owmeter FH/PH standard mid-range plus-point probe.

' 3.2 Personnel 3.2.1 The personnel who performed the SG eddy current inspections were qualified to Level I and Level ll certification in accordance with the 1984 Edition of SNT-TC-1 A.

The Level I personnel performed the inspections under the direct supervision of Level 11 personnel.

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3.2.2 The personnel who performed the SG eddy current data analysis were qualified to a minimum of Level 11, with special analysis training (i.e., Level llA) in accordance with the 1984 Edition of SNT-TC-1 A.

l 3.2.3 All eddy current data analysts were qualified in accordance with EPRI Appendix G for QDAs. In addition, all data analysts were trained and tested in accordance with l a site specific performance demonstration program in both the bobbin coil and plus-point inspection data analysis. Pcsolution analysts were also trained and tested specifically for the performance of data resolution. All analysts were required to achieve a score of 80% or greatu on both the written and practical examinations prior to analyzing data.

3.2.4 All SG eddy current data acquisition personnel were trained and tested in accordance with a site specific performance demonstration program. The data i acquisition operators were required to achieve a written test score of 80% or l greater prior to acquiring data.

3.2.5 The SG eddy current analysis was subject to two independent analyses. Primary analysis of all data was performed by FTl and Rockridge Technologies, Inc. The following inspectior, agencies were subcontracted by FTl: Tecnatom, Verner & I James and Master-Lee. An independent company, Zetec, performed the seconda y analysis Secondary analysis was performed by an automated data screening analysis system. The system was required to successfully pass the site specific performance demonstration practical examination prior to analyzing field data.

3.2.6 An independent SG eddy current Level ill QDA was employed to serve as a process control reviewer, in accordance with EPRI Guideline Section 6.3.3.4, to randomly sample the data to ensure the resolution process was proper 1y performed and that the field calls were properly reported. The Independent Level ll1 QDA also provided data acquisition oversight to ensure that the data collectioq process was in compliance with appropriate procedures and all essential variables were set in accordance with the applicable Examination Technique Specification sheet (ETSS). The independent Level 111 QDA was employed by a third inspection company, ANATEC, and reported directly to the Comed Level lli inspector.

4.0 EXAMINATION TECHNIQUES AL EXAMINATION SCOPE All SG eddy current examination techniques used were qualified in accordance with Appendix H of the EPRI PWR SG Examination Guidelines. Each examination technique was evaluated to be applicable to the tubing and conditions of the Byron Station Unit 1 SGs.

4.1 Examination Techniques 4.1.1 All inservice tubes in SGs B, C and D were inspected full length utilizing a bobbin coil probe described in Section 3.1.5 of this report. Nominal probe inspection speed was 40 inches per second. Sufficient sampling rates were used to maintain a minimum digitizing rate of 30 samples perinch. The bobbin probes were operated in both the differential and absolute modes at frequencies of 650 kHz, 320kHz,160 kHz, and 35 kHz. The following suppression mrxes were used to enhance the inspection: 650/160 kHz differential mix,320/ S0 kHz absolute mix, 650/320/160 kHz differential mix, and a 650/320 kHz differential mix.

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I 4.1.2 Diagnostic examinations were performed on non-quantifiable Indications and hot leg dents / dings greater than 5.0 volts that were dete ted by the bobbin coil examination. The diagnostic examinations were performed using a plus-point probe as described in Section 3.1.6 and Section 3.1.7. Axial probe inspection speed was 0.6 inches per second for straight tubing and 0.15 inches per second for U-bend region of the tubing and dents / dings. Sample rates and rotation speeds were used to maintain a minimum of digitizing rate of 30 samples per inch (i.e.,25 samples per inch for the axial direction and 30 samples per inch for the circumferential direction). The rotating probes were operated in the absolute test mode at frequencies of 300 kHz,200kHz,100 kHz and 20 kHz. In addition to the

~ four base frequencies, three process channels were used to display axial indications in the positive trace.

4.1.3 The SG eddy current examination techniques used during this inspection were equivalent to the EPRI Appendix H techniques listed in Table 4.1of this report.

Each technique was evaluated and determined to be applicable to the site conditions.

Table 4.1 EPRI Appendix H Techniques i 4 9 P Ria <

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96004 Bobbin Fan Bar/ Lattice Grid / Foreign Object Wear and Free Span Flaws 96910 Plus-Point Foreign Object Wear / Free Span Flaws 96509 Plus-Point Dents / Dings - Primary Water Stress Corrosion Cracking (PWSCC) 96703 Plus-Point Dents / Dings - PWSCC sizing 96402 Plus-Point Dents / Dings - Outer Diameter Stress Corrosion Cracking (ODSCC) l 96010 Bobbin Manufacturing Bumish Marks '

96006 Bobbin Tubesheet Expanded Region, excluding expansion transition 4.2 Exceptions to EPRI PWR Steam Generator Examination Guidelines As stated in Section 1.1 of the EPRI PWR SG Examination Guidelines, " Utilities may be able to deviate from specific requirements of this document by providing a documented technicaljustification for each deviation or through the application of performance-based criteria and risk-based methodologies." Below are instances where technical justifications were provided to take exception to specific guideline requirements.

4.2.1 Section 3.4.1 of the referenced EPRI Guidelines requires that 20% of the active SG tube population be inspected from tube end to tube end with an EPRI Appendix H qualified technique. Technicaljustification was completed and documented to exempt the 20% examination of the top of the tubesheet expansion transition and low row U-bends with a plus-point probe dunng B1R09 (i.e., the first outage following SG replacement).

4.2.2 Section 3.3.1 of the referenced EPRI Guidelines requires that a 100% fulllength inspection with a general purpose probe be performed on aN SGs during the first outage following SG replacement. Technicaljustification was completed and documented to exempt eddy current inspections in SG "A " during B1 R09.

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4.3 Recording of Examination Data Results of the SG eddy current data analysis were recorded on optical disks. The data was then loaded into a Zetec SG eddy current data managernent system. The system was used to track the completion of the examinations and was used to generate the final SG eddy current report summaries.

4.4 Witness and Verification of Examination SG eddy current inspections were witnessed and/or verified by the Authorized Nuclear Inservice inspectors, Mr. Jeff Hendricks and Mr. Duane Oakley of the Hartford Steam Boiler Inspection and Insurance Company of Hartford Connecticut, Chicago Branch,2443 Warrenville Road, Suite 500, Lisle, Illinois 60532-9071, AGME Form NIS-1, " Owners Report f ' ' -';vice inspections" , is contained in Figure B.1.  ;

5.0 EXAMINATION RESULTS 5.1 Eddy Current inspection Full length bobbin coil examination was performed on 100% of the tubes in SGs "B", "C" and "D". No indication of tube degradation was found in any SG tube. Diagnostic plus-point examination was performed on SG tubes that contained non-quantifiable t obbin coil signals located in the U-bend region of seven tubes (see Table 5.1). The plus-point examination confirmed that the tubes did not contain any tube degradation.

Table 5.1 Diagnostic Plus-Point inspection

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ju g4 ,W s 19090R h * ' "' ' 4 3 B 112 51 NQI NDF FB6 +3.11 to +84.9 C 4 123 DFl NDF 'FB1 +13.93 C 12 69 DFl NDF FB1 +29.5 C 14 73 DFl NDF FB6 +6.28 D 15 102 DFl NDF FB1 +5.36 D 15 104 DFl NDF FB1 +5.46 D 20 19 DFl NDF FB1 +6.36-(NQI - Non-Quantifiable Indication; DFl - Differential Freespan Indication; NDF- No Degradation Found; FB - Fan Bar) 5.2 Weld Plug inspection The Byron Station Unit 1 replacement SGs have one tube that is removed from service and is plugged with an inconel-690 welded plug at each tut,e end. This tube, tube 34-129 in SG "C", was plugged during initial vessel febrication. Both welded plugs were visually inspected during this outage. The inspection was performed by a Level 11 VT-1 qualified inspector using the Comed VT-1 visual inspection procedure.

No indications or degradation was found in either of the welded plugs.

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l 5.3 Secondary Side Visualinspection -

Visualinspection of the secondary side of the SGs were performed hithe following regions:

. Top of the tubesheet in each SG

. Top Lattice Grid in SG "D"

. Feedring/J-Tube Region in SG "D" The top of the tubesheet inspections encompassed the outer tube annulus, tube free dividerlane and two inner bundle passes on each of the hot and cold leg sides of the SG.

The top lattice grid / upper bundle inspection encompassed inspection of the lattice grid, lattice grid support rim, lattice grid acorn nuts, acom nut tack welds, U-bend region tube surfaces, in bundle tube surfaces, and general condition of areas surrounding the 8 inch diameter handhole where access was gained.

The feedring and J-tube inspection encom med inspection of the feedwater header i outside and inside surfaces, two J-tubes, J-Tube / Header welds and general condition of l areas surrounding the 6 inch diameter handhole where necess was gained.

l No observations of degradation were found during the visualinspections described above.

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6.0 REPAIR

SUMMARY

Since the SG eddy current and visual examinations resulted in no tube or component degradation, no tubes were plugged or repaired.

7.0 TUBE INTEGRITY ASSESSMENT SUMMAP.Y -

SG tube integrity assessments were performed to demonstrate that SG performance met  !

the required structuralintegrity and leakage requirements for the previous operating period (i.e., condition monitoring) and for the next operating per:od (i.e., operational assessment). )

There was no primary to secondary leakage detected during Cycle 9 or during plant shutdown for refueling outage B1R09.

7.1 Condition Monitoring / Operational Assessment Since no degradation was found in the SG tubes, plugs or intemal components during the SG inspections, there is no impact to any structural or leakage performance criteria. ,

Therefore, SG structural and leakage performance cri'eria were maintained within the l original design limits. This results in an acceptable condition monitoring and operational assessment 8.0 DOCUMENTATION All original SG eddy current optical disks have been provided to Comed and are maintained at Byron Station. The final data sheets and pertinent SG tube sheet plots are ,

contained in the FTl Final Outage Report for Byron Station Unit 1, B1R09, and is also '

maintained at Byron Station.

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9.0 TABLES / FIGURES / ATTACHMENTS

- Table A.1 Data Acquisition Personnel Certification Table A.2 Data Analysis Personnel Certification Figure A.1 Babcock & Wilcox Replacement Steam Generator Configuration Figure A.2 Byron Station Unit 1 Steam Generator Tubesheet Configuration Figure B.1 ASME Form NIS-1, " Owners Report for Inservice Inspection" Page 9 of 15 L.

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TABLE A.1 DATA ACQUISITION PERSONNEL CERTIFICATIONS

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Abendanio, H FTl 11 N Ashford, GS FTl 11 N Bautista, MR FTl 11 N Camacho, E FTl 11 N Daley, SA FTl I N Gardner, EL FTl 11 N Gardner, JL FTl 11 N Gomez, AJ FTl ll N Goodwin, MD FTl ll N Greenquist, GJ FTl ll N Gresham, BG FTl llA Y Knox,BL FTl llA Y Leach, CA FTl i N Lutz, RE FTl I N Markham, JH FTl Il N Martin, AC FTl llA Y Maxwell, JF FTl 11 N McMillan, WP FTl llA Y Munsterman, JW FTl I N Mutschler, TL FTl 11 N Nelson, MA FTl 11 N Stromer, RG FTl I N Taylor, SC FTl llA Y Ward, ET FTl 11 N Welsh, JP FTl i N Wright, JA FTl 11 N l

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TABLE A.2 i DATA ANALYSIS PERSONNEL CERTIFICATIONS

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Alspaugh, KS Zewc Illa Y Bjerke, DA Zetec ilA Y j Boudreaux, WM FTl Ill Y j Bridt;forth, WD FTl llA Y Bryant, DN FTl llA Y Cochaud,A FTl ll1 Y Colado, LE FTl llA Y Cox, JE Zetec lilA Y Crittenden, JG Zetec lilA Y Darst, DR Zetec lilA Y Deddens, JC FTl llA Y Dlabik, AJ Master-Lee Illa Y Farenbaugh, NJ Zetec tilA Y Frye, PC Zetec IIA Y Fuse, K Zetec flA Y l Garcia, AM Tecnatom IIA Y I

_Hayashi, T Zetec IIA Y J Hower, SL Zetec illa Y l Jimenez, LP Tecnatom IIA Y Johnson,KL FTl llA Y Komatsu, K Zetec IIA Y Korkowski, EM FTl ill Y Kovalesky, TL FTl llA Y Lee, RE FTl llA Y l Loer, MS FTl llA Y Lucier, LJ Zetec illa Y Mathison, CM Zetec illa Y McLeod, E Verner & James llA Y Merriam, SP Zetec illa Y Merriman, RH FTl til Y Nakano,H Zetec IIA Y Navratil, GL FTl ill Y Oliver, JC FTl llA Y Paine, RJ FTl llA Y Palmer, RK Vemer & James llA Y Popkirov, I Tecnatom lli Y Porras, PD Tecnatom lll Y Ribaric, TA FTl lli Y Richards, TA FTl lil Y Shepherd, MD FTl llA Y Shields, GK FTl llA Y Silus, GK Zetec fila Y Singh, MT Anatec til Y Spencer, JL Vemer & James lilA Y Terhaar, MA Zetec llA Y Tommarello, DJ M-L lilA Y Toral, MD Tecnatom IIA Y Villanueva, LF Tecnatom lll Y Vollmer, RA Zetec tilA Y Page 11 of 15

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, FIGURE A.1 Babcock & Wilcox Replacement Steam Generator Byron Unit 1 Configuration  ;

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FIGURE B.1 FORM NIS-1 OWNER'S REPORT FOR INSERVICE INSPECTIONS As Required by the Provisions of the ASME Code Rules

1. Owner: Commonwealth Edison Comnany (Comed) P.O. Box 767. Chicaco. Illinois 60690 (Name and Address of Owner)

2. Plant: Byron Station 4450 N. German Church Rd . Byron. Illinois 61010 (Name and Address of Plant)

3. Plant Unit: One (1) 4. Owner Certificate of Authorization (if required): N_/% )

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5. Commercial Service Date: 09/16/85 6. Naticnal Board Number for Unit: N-198

7. Components Inspected: Steam Generator Eddy Current inspction Component or Manufacturer or Manufacturer or State or Province National Board No. l Appurtenance Installer Installer Serial No. No. l l

1RC01BB Babcock & Wilcox 7720-03 ILU-242903 166 1RColBC Babcock & Wilcox 7720-01 ILU-242902 164  ;

IRCO1BD Babcock & Wilcox 7720-04 ILU-242901 167 I

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FORM NIS-1 (Back)

8. Examination Dates 4/3/99 to 4/9/99 9. InspectionInterval from 6/30/% to 9/16/05

10. Abstract of Exandnations. Include a list of exandnatiens and a statement concerning status of work required for current interval.

Refer to the Attached Steam Generator Eddy Current Report i1. Abstract of'Corxlitions Noted Refer to the Attached Steam Generator Eddy Current Report

12. Abstract of Corrective Measures Reconunended arxl Taken l

Refer to the Attached Steam Generator Eddy Current Report We certify that the statements made in this report are correct and the exandnations anx! corrective measures taken conform to the rules of the ASME Code,Section XI.

Certi ficate of Authorization No. (if applicable) ' Not Annlicable Expiration Date Not Annlicable Date dels i 19 D

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Signed For Comed By s M

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1 Owner CERTIFICATE OF INSERVICE INSPECTION 1, the uixlersi gned, holding a valid commission issued by the National Board of Boiler and Presswe Vessel Inspectors and the State or Province of ///, and employed by #fMI.nltc of /sr/4M t"T have inspected the components described in this Owner's Report during the period gif#F to 48/r , and state that to the best of my knowledge atxl belief, the Owner has performed examinations atirl'tiken corrective ineasures described in this Owner's Report in accordance with the requirements of the ASME Code,Section XI.

By signing this ce xificate neither the Inspector nor Ids employen makes any warranty, expressed or implied, concerning the examinations arxl 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 loss of any kirxl arising from or connected with this inspection.

AM &MW Commissions ///-//SV IIispector's Signature - National Board, State Province, and Endorsements Date MM # _

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