05000272/LER-1995-023, :on 940106,failed to Plug SG Tubes.Caused by Lack of Contractor Oversight in Area of Eddy Current Testing.Analyst Guidelines Specific to Salem,Units 1 & 2 & Performance Demonstration Program Were Developed

:on 940106,failed to Plug SG Tubes.Caused by Lack of Contractor Oversight in Area of Eddy Current Testing.Analyst Guidelines Specific to Salem,Units 1 & 2 & Performance Demonstration Program Were Developed

ML18106A237
Person / Time
Site:	Salem
Issue date:	12/30/1997
From:	Duca P Public Service Enterprise Group
To:
Shared Package
ML18106A236	List: 05000272/LER-1995-023, :on 940106,failed to Plug SG Tubes.Caused by Lack of Contractor Oversight in Area of Eddy Current Testing.Analyst Guidelines Specific to Salem,Units 1 & 2 & Performance Demonstration Program Were Developed 05000272/LER-1995-023-01, Forwards Supplemental LER 95-023-01 Re Failure to Plug SG Tubes Due to Missed Eddy Current Indications.Suppl Being Submitted to Discuss Cause & Safety Significance of Event
References
LER-95-023, LER-95-23, NUDOCS 9801130418
Download: ML18106A237 (5)

LER-1995-023, on 940106,failed to Plug SG Tubes.Caused by Lack of Contractor Oversight in Area of Eddy Current Testing.Analyst Guidelines Specific to Salem,Units 1 & 2 & Performance Demonstration Program Were Developed

Event date:
Report date:
Reporting criterion:	10 CFR 50.73(a)(2)(i)(B), Prohibited by Technical Specifications 10 CFR 50.73(a)(2)(viii) 10 CFR 50.73(a)(2)(x) 10 CFR 50.73(a)(2)(iii) 10 CFR 50.73(a)(2)(iv), System Actuation 10 CFR 50.73(a)(2)(v), Loss of Safety Function
2721995023R00 - NRC Website

text

I NRC FORM 366 U.S. NUCLEAR REGULATORY COMMISSION APPROVED BY OMB NO. 3150..{)104 (4-95)

EXPIRES 04/30/98 ESTIMATED BURDEN PER

RESPONSE

TO COMPLY WITH THIS MANDATORY INFORMATION COLLECTION REQUEST:

50.0 HRS.

LICENSEE EVENT REPORT (LER)

REPORTED LESSONS LEARNED ARE INCORPORATED INTO THE LICENSING PROCESS AND FED BACK TO INDUSTRY.

FORWARD COMMENTS REGARDING BURDEN ESTIMATE TO THE INFORMATION AND (See reverse for required number of RECORDS MANAGEMENT BRANCH (T-6 F33~,

U.S.

NUCLEAR REGULATORY COMMISSION, WASHINGTON, DC 205 5-0001, AND TO THE digits/characters for each block)

PAPERWORK REDUCTION PROJECT g150-0104).

OFFICE OF MANAGEMENT AND BUDGET, WASHINGTON, C 20503.

FACILITY NAME (1)

DOCKET NUMBER (2)

PAGE(3)

SALEM UNIT 1 05000272 1 OF 5 TITLE (4)

FAILURE TO PLUG STEAM GENERATOR TUBES DUE TO MISSED EDDY CURRENT INDICATIONS EVENT DATE (5)

LER NUMBER (6)

REPORT DATE (7)

OTHER FACILITIES INVOLVED (8)

I FACILITY NAME DOCKET NUMBER MONTH DAY YEAR YEAR SEQUENTIAL I REVISION MONTH DAY YEAR NUMBER NUMBER 01 06 94 95 023 01 11 xx 97 FACILITY NAME DOCKET NUMBER OPERATING THIS REPORT IS SUBMITTED PURSUANT TO THE REQUIREMENTS OF 10 CFR §: (Check one or more) (11)

MODE (9) 4 20.2201 (b) 20.2203(a)(2)(v) x 50.73(a)(2)(i)(B) 50.73(a)(2)(viii)

POWER 20.2203(a)(1) 20.2203(a)(3)(i)

50. 73(a)(2)(ii) 50.73(a)(2)(x)

LEVEL (10)

ODO 20.2203(a)(2)(i) 20.2203(a)(3)(ii) 50.73(a)(2)(iii) 73.71

ll!l!ll!llliiji.1.ll!lllli!lllllllllll!lll!lllllilll!llllllll!illllllllJlllllilllil!llll 20.2203(a)(2)(ii) 20.2203(a)(4) 50.73(a)(2)(iv)

OTHER 20.2203(a)(2)(iii) 50.36(c)(1) 50.73(a)(2)(v)

Speci~ in Abstract below or in NR Form 366A

-~~~~~~~~f~~~tt~~~~~~~~~~~~~~~~~~~~~tt~~tt?~~~~~tt~tf~

20.2203(a)(2)(iv) 50.36(c)(2)

50. 73(a)(2)(vii)

LICENSEE CONTACT FOR THIS LER (12)

NAME TELEPHONE NUMBER (Include Area Code)

Philip J. Duca Jr., Salem Licensing (609) 339-2381 COMPLETE ONE LINE FOR EACH COMPONENT FAILURE DESCRIBED IN THIS REPORT (13)

CAUSE

SYSTEM COMPONENT MANUFACTURER REPORTABLE

CAUSE

SYSTEM COMPONENT MANUFACTURER REPORTABLE TONPRDS TONPRDS SUPPLEMENTAL REPORT EXPECTED (14)

EXPECTED MONTH DAY YEAR IYES xjNO SUBMISSION (If yes, complete EXPECTED SUBMISSION DATE).

DATE (15) xx xx xx ABSTRACT (Limit to 1400 spaces, i.e., approximately 15 single-spaced typewritten lines) (16)

During a review of prior outage test data to support estimations of Steam Generator (S/G) tube indication growth rates, eight tubes were identified to have exceeded the Salem Technical Specification plugging criteria of 40% of tube wall as specified in the acceptance criteria of the surveillance requirements of Section 4.4.5.4. Contrary to the Limiting Condition for Operations, Section 3.4.5, the unit was operated in modes 1 through 4 with steam generators that did not meet the operability requirements described in Section 4.4.5.4.

The root cause of this event was the lack of contractor oversight in the area of eddy current testing.

Based on the results of inspections performed, PSE&G changed out the steam generators with Model F steam generators from Seabrook. As of August 1996 all testing and analysis of the scrapped steam generator tubes was suspended. As the steam generators completed cycle 11, there were no safety consequences to this event.

This is reportable per 10CFR50.73(a)(2)(i)(B), a condition prohibited by the plant's Technical Specifications.

9801130418 971230 PDR ADOCK 05000272 S

PDR

~

I (4-95)

.S. NUCLEAR REGULATORY COMMISSION FACILITY NAME (1)

LICENSEE EVENT REPORT (LER)

TEXT CONTINUATION DOCKET NUMBER (2)

LER NUMBER (61 YEAR I SEQUENTIAL I RE\\l1SION NUMBER NUMlER PAGE (3)

SALEM UNIT 1 05000272 95 --

023 --

01 2

OF 5

TEXT (If more space is required, use additional copies of NRC Form 366A) (17)

PLANT AND SYSTEM IDENTIFICATION

Westinghouse - Pressurized Water Reactor Reactor Coolant System/Steam Generator (AB/SG)*

• Energy Industry Identification System (EllS) codes and component function identifier codes appear in the text as (SS/CCC).

IDENTIFICATION OF OCCURRENCE Missed Eddy Current Testing (ECT) indications during the 1993 Salem Unit #1 Refueling Outage (1 R11) steam generator tube evaluations.

Event Date: January 6, 1994.

Discovery Date: September 26, 1995.

Report Date: November xx, 1997.

CONDITIONS PRIOR TO OCCURRENCE Defueled - Reactor Power 0%

DESCRIPTION OF OCCURRENCE To determine the growth rate of indications during the operating period between past outage 1 R11 I and current outage 1R12, a review of 1993 ECT data was performed. During this review, on September 26, 1995, bobbin probe indications with depths which exceed the Technical Specification plugging criteria of 40% of tube wall specified in section 4.4.5.4 were identified for I eight tubes (seven tubes with one indication each and the remaining tube with two indications) which were not plugged.

.. (4-95)

U.S. NUCLEAR REGULATORY COMMISSION FACILITY NAME (1)

SALEM UNIT 1 LICENSEE EVENT REPORT (LER)

TEXT CONTINUATION DOCKET NUMBER (2)

LER NUMBER (6)

YEAR I SEQUENTIAL I RE\\llSICX'l NUMBER NUM3ER 05000272 95 --

023 --

01 TEXT (If more space is required, use additional copies of NRC Form 366A) (17)

APPARENT CAUSE OF OCCURRENCE PAGE (3) 3 OF 5

Four conditions adverse to quality (CAQs) lead to the undetected eddy current indications. These CAQs are causal factors which collectively point to the lack of contractor oversight during eddy current testing. The CAQs were: (1) There was no requirement for an eddy current data analyst performance demonstration program; (2) There was a lack of assurance of the independence of the primary and secondary analysts. The data was sent to only one location, where both primary and secondary data analysts worked. The work was performed in the same room with work stations set up for each data analyst. With both primary and secondary analysts working in the same room, total independence could not be ensured; (3) All analysis was performed by contractors with no PSE&G Level Ill oversight. Oversight by PSE&G may have reduced non-conservative calls; and (4) Only the lead analyst was required to be a Qualified Data Analyst (QDA). QDA is an EPRI qualification program for nondestructive examination personnel specifically for the analysis of eddy current data from steam generator tubing. The American Society for Nondestructive Testing (ASNT) sets the minimum standards for eddy current testing personnel. The EPRI QDA program focuses on the degradation mechanisms specific to steam generators. At the time of the inspections, the EPRI qualification program was new and the contractor had only sent some of their people for qualification.

PRIOR SIMILAR OCCURRENCES There is no prior similar occurrence at Salem of the identification of an ECT indication which should have been called at a previous inspection. A review of events previously reported to the NRC by other plants indicates that missed bobbin coil probe pluggable indications have been experienced at Sequoyah Unit 1, ANO Unit 2, North Anna Unit 1, Ginna, Yankee Rowe, and Maine Yankee.

tSSESSMENT OF SAFETY CONSEQUENCES AND POTENTIAL IMPLICATIONS Based on the number of indications observed during the inspections performed during 1 R12, the amount of tubes required to be plugged would have challenged the analyzed plugging limit. As a result PSE&G changed out the Unit 1 steam generators with unused model F steam generators obtained from Seabrook. As of August 1996 PSE&G suspended all activities associated with the scrapped steam generator tube inspections, analysis, or testing. Therefore, a planned structural integrity assessment was never performed.

As the steam generators completed cycle 11 without any measurable tube leakage, there were no safety consequences to this event.

Based on the above, the Health and Safety of the public was not affected. (4-95)

.S. NUCLEAR REGULATORY COMMISSION FACILITY NAME (1)

LICENSEE EVENT REPORT (LER)

TEXT CONTINUATION DOCKET NUMBER (2)

LER NUMBER (6)

YEAR I SEQUENTIAL I REVISION NUMBER NUM3ER PAGE (3)

SALEM UNIT 1 05000272 95 --

023 --

01 4

OF 5

TEXT (If more space is required, use additional copies of NRC Form 366A) (17)

CORRECTIVE ACTIONS

Salem Unit #1

1. As of August 1996 PSE&G suspended all activities associated with the scrapped steam generator tube inspections, analysis, or testing. Given PSE&G's decision to replace the generators, further financial expenditures and additional man-rem burden on site personnel resulting from the canceled activities was no longer warranted. Therefore, a planned structural integrity assessment was never performed.

2. A number of corrective actions were taken including:

a. An independent assessment of the training and qualification of analysts involved in the 1993 and 1995 analyses of Salem Unit 1 ECT data has been performed. This assessment indicates that there are no apparent procedural or regulatory violations. However, specific areas where the program for training and qualification of analysts could be improved were noted. Each of these areas has been discussed with the contractor.

b. Analyst guidelines specific to Salem Units 1 and 2 and a performance demonstration program were developed. PSE&G contracted a L:evel 3 analyst to oversee eddy current activities. A steam generator examination engineering organization was developed.

c. A 100% bobbin coil inspection of all unplugged tubes in 11-14 steam generators was performed.

Two separate inservice inspection organizations performed primary and secondary data analysis. PSE&G provided Level Ill oversight of all eddy current activities. The Motorized Rotating Pancake Coil (MRPC) inspections were r.at completed. Based on the number of indications observed during the MRPC inspections, the amount of tubes required to be plugged would have challenged the analyzed plugging limit. PSE&G decided to change out the steam generators to Model F unused steam generators obtained from Seabrook. As a result, only the bobbin coil data and applicable MRPC +point data could be utilized to determine if additional tubes were mis-called during the 1993 eddy current inspection. Based on this review, no additional tubes were identified during the data analysis process. Due to the change in unit schedule priority associated with the decision to change out the Unit 1 steam generators, this task was not completed by March 29, 1996.

d. All bobbin coil inspection data already taken was not reanalyzed as planned. In lieu of this, the inspection described in "c" above was performed.

~ (4-95)

U.S. NUCLEAR REGULATORY COMMISSION FACILITY NAME (1)

LICENSEE EVENT REPORT (LER)

TEXT CONTINUATION DOCKET NUMBER (2)

LER NUMBER (6)

YEAR I SEQUENTIAL I REVISlON NUMBER NUM3ER PAGE (3)

SALEM UNIT 1 05000272 95 -- 023 --

01 5

OF 5

TEXT (If more space is required, use additional copies of NRC Form 366A) (17) e. Given the decision to replace the Unit 1 steam generators, no tube plugging occurred.

Salem Unit #2

3. The corrective action described in item 2b above for site specific training and testing was implemented prior to performing ECT on Salem Unit #2.

4. The scope of the Unit 2 eddy current inspection program performed during its outage was:

- 100% full length bobbin coil inspection of each steam generator.

- 100% +point MRPC inspection of all (1 through 7) hot leg tube support plate intersections in each steam generator.

- 100% + point MRPC inspection of all hot leg top of tube sheet transition locations in each steam generator.

- 100% + point MRPC inspection of all row 2 U-bends in each steam generator.

- 100% + point MRPC inspection of one steam generator (22 steam generator) cold leg tube support plate intersections ( 1 through 7).

- 100% + point MRPC inspection of one steam generator (22 steam generator) cold leg top of tube sheet transition locations.

Based on the results of the inspections and the review of previous refueling outage eddy current data, where applicable, there were no obvious or reported missed eddy current indications.