Objectives: The objective of the work described in this paper was to provide the ability to efficiently process large amounts of data. These data were obtained from the videotaped visual NDE of the SONGS steam generator peripheral secondary-side lattice bar tube supports (eggcrates). Specifically, the project goals were to develop: 1) a scalable database capable of storing millions of independent, visually-assessed grades, with several different built-in sorting and filtering options for data analysis; 2) a user-friendly graphical-user interface which allowed for fast and accurate data input without the need for extensive application training; and 3) the capability to provide a real-time assessment of inspection status via the existing site Local Area Network. The end product is called the Eggcrate Lattice Visual Inspection System (ELVIS).

Methodologies: ELVIS was developed by a diverse team of utility personnel. The site Information Services group dedicated appropriate support to ensure that a quality product would be delivered in a timely manner. The programmers implemented large amounts of experienced-based input from the users. Several refinements were added as needs, features, and system limitations were determined and assessed by the team during the development of the application. This project was a good example of how utility in-house organizations can successfully work together for site improvements.

Conclusions: Significant cost savings have been realized through the use of ELVIS. During the NDE of the Unit 2 steam generators in January 1999, only two data analysts were utilized, with no support personnel required. In contrast, a similar-scope inspection of Unit 2 performed in January 1998 required the support of four analysts and two data entry personnel, and took longer to complete. This represents reductions of 50% of the analysts and 100% of the support personnel, with an improvement in the rate of data entry into the database. Similar savings were also realized in the inspections of the Unit 3 steam generators completed in April 1999.

In addition to reducing the manpower required to support this task, savings have also been made with the ability to more quickly collate and analyze the data, which allows for a quicker release of the inspection and tube plugging vendors who are on standby until the analysis is complete. Also, the development of ELVIS eliminated the two error-prone activities of data transcription and manual database entry, thereby reducing risk, saving database review time, and reducing analyst burnout.

The database has several features which make it an excellent tool for tracking the maintenance history of any heat exchanger or other tubed component. An expansion of ELVIS is being reviewed by the SONGS site engineering group as a replacement for the hard-copy files which currently track the maintenance histories of the site's 26 feedwater heaters. Other potential SONGS applications include the component cooling water heat exchangers, the turbine plant cooling water heat exchangers, the main condenser, the letdown heat exchangers, and the regenerative heat exchangers.