IR 05000295/1979022
| ML19309B585 | |
| Person / Time | |
|---|---|
| Site: | Zion File:ZionSolutions icon.png |
| Issue date: | 02/14/1980 |
| From: | Danielson D, Key W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19309B576 | List: |
| References | |
| 50-295-79-22, 50-304-79-24, NUDOCS 8004040339 | |
| Download: ML19309B585 (19) | |
Text
_.
..
.-
U S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-295/79-22; 50-304/79-24 Docket No. 50-295; 50-304 License No. DPR-39; DPR-48 Licen: ice:
Commonwealth Edison Company P. O. Box 767 Chicago, Illinois 60690 Facility Name: Zion Station, Units 1 and 2 Inspection At: Zion Site, Zion, Illinois Inspection Conduc*ed: September 10, October 15-17, 19, 27, 29-31, November 1-2, C-n. 14-15, 20-21, 26-29, December 4-7, 11-14, 17-21, 26-28, 1979, and January 2-4, 1980 bukmv/it-Inspector:
W. J. Key
/
[0 mGa/L
'
Approved By:
D. H. Danielson, Chief J/14/fo Engineering Support Section 2 Inspection' Summary Inspections on September 10, October 15-17, 19, 27, 29, 31, November 1-2, 6-9, 14-15, 20-21, 26-29, December 4-7, 11-14, 17-21, 26-28, 1979, January 2-4, 1980 (Report No. 50-295/79-22; 50-304/79-24)
Areas Inspected:
Unit No. 1:
Review of ISI program, procedures, personnel and equipment qualifications, observation of work activities, and review of NDE examination documentation; Unit 1 and 2:
followup of licensee activities related to IE Bulletin 79-13, Cracking in Feedwater Piping
'
System, followup of licensee activities related to IE Bulletin 79-17, Pipe Cracking in Stagnant Borated Water Systems at Power Plants. The inspection involved a total of 323 irspector-hours on site by one NRC inspector.
Results:
No items of noncompliance or deviations were identified.
!
8004040 3 37
.
-
.
. -_..
-.
...
.
..
o-DETAILS Persons Contacted Commonwealth Edison Company (CECO)
N. E.. Wandke, Plant Superintendent
- L. Soth, Administration Supervisor
- B. Shannon, ISI Coordinator
- C.
Solich, Assistant ISI Coordinator E. Potter, Chief, Level-III Examiner
'
W. W. Witt, Level III Inspector T. Lukins, Quality Control Supervisor J. Booth, Quality Control Inspector
'
R. Tamminga, Engineer (SNED)
C. Hoerke, Engineer (SNED)
B.-Morevec, Engineer (Station Construction)
J. Hawkinson, Engineer (Station Construction)
B. Geier, Quality Control M. Stanish, Quality Assurance T. Spry, Quality Assurance Westinghouse Electric Corporation (W)
B. J. Lefebvre, ISI Supervisor J. Gilkerson, Welding Engineer E. Williams, Engineer J. Ellis, Engineer
. William A Pope Contruction Company (Pope)
J. Parrish, Project Manager J. Murphy, Qaulity Assurance Hartford Steam Boiler (Hartford)
J. Mislevy, Authorized Nuclear Inspector D. Stewart, Auditor Other personnel were also contacted during the course of this inspection.
- Denotes those attending the exit interview.
Funtional or Program Areas Inspected 1.
Inservice Inspection (ISI) Program Review - Unit 2 The following components and systems are to be examined during the refueling outage in accordance with plant. Technical Specification,
'
-
-2-
-.
-
- _. -
_
.
..
Section 4.2.1, and the requirements of IWB and IWC 2500 as referenced
in IWB and IWC 2600 of ASME Boiler and Pressure Vessel Code, 1974 Edition including Summer 1975 Addenda.
a.
Reactor Vessel b.
Pressurizer c.
Branch Connections d.
Valve Bonnet Bolting e.
f.
Excess Letdown Heat Exchanger g.
Resioual Heat Exchanger h.
Seal Water Heat Exchanger i.
Non-regenerative Heat Exchanger J.
Regenerative Heat Exchanger k.
Seal Water Injection Filters 1.
Seal Water Return Filters m.
Circumferential Pipe Welds n.
Reactor Coolant Filters o.
Residual Heat Removal Pumps p.
Centrifugal Charging Pumps q.
Positive Displacement Charging Pumps r.
Valves s.
B Generator Feedwater Pump Flywheel 2.
ISI Examination Procedure Review - Unit 2 The following (W) ISI examination procedures and amendments to be used during this outage were reviewed:
a.
OPS-NSD-101, Revision 5 Preservice and Inservice Documentation b.
NSD-ISI-10, Revision 4 Preservice and Inservice Examination, Manual Ultrasonic Equipment Qualification c.
NSD-ISI-8, Revision 0 Visual Examination Procedure d.
NSD-ISI-11, Revision 9 tiquid Penetrant Examination Procedure e.
NSD-ISI-90, Revision 1 Manual Ultrasonic Procedure for Investigating for Presence of Intergranular Corrosion. Qualified September 25, 1979 at TMI.
.f.
NSD-ISI-15, Revision 6 Ultrasonic Examination of Studs, Bolts and Nuts 3-
.
.. _
_
..
..
g.
NSD-ISI-41, Revision 4 Manual Ultrasonic Testing of Reactor Coolant Pump Flywheel h.
NSD-ISI-47, Revision.2 Manual Ultrasonic Examination of Circumferential and Longitudinal Butt Welds in Ferritic Vessels of 2-1/2" Thick and Greater i.
NSD-ISI-70, Revision 0 Magnetic Particle. Examination Procedure J.
NSD-ISI-205, Revision 2 Manual Ultrasonic Examination of Full Penetration Circumferential and Longitudinal Butt Welds No items of noncompliance or deviations were identified.
3.
Personnel Qualification
,
The following qualification / certification records of (W) personnel were reviewed:
Name Method Level B. J. Lefebre UT III PT III MT III RT II(R)
VT III i
VT II(A)
RT II B. J. Aston UT II PT II J. S. Busby UT II PT II MT II J. Carson UT I
PT I
R. Curl UT I
PT I
J. L. Cannizzo UT III PT II VT II-4-i
_.-
,_
-. _ _
.. _.
_
.-
-..
.
_
._ _
.< *
J. Obermeyer UT I
PT I
No items of noncompliance or deviations were identified.
4.
Equipment Certification The following equipr.ent certification records were reviewed and the equipment examined for last calibration:
Ultrasonic Instruments:
Sonic-MK-1-S/N-755109 Sonic-MK-1-S/N-780603 Sonic-MK-1-S/N-784523
. Ultrasonic Couplant:
Sonotrace - Batch 7781 Ultragel - Batch E17960
-
Liquid Penetrant Materials:
Magnaflux. Cleaner SKC-NF Batch 78F097 SKC-S Batch 78B015 SKC-C Batch 52033 Magnaflux, Penetrant SKL-HF/SKL-S Batch SE067 SKL-HF/F Batch 6A035 Magnaflux, Developer SKD-S Batch SE052 SKD-S Batch 6D144 Ultrasonic Transducers:
Size Serial No.
Frequency
.50"x1.0" B06923 2.25
.50"x1.0" S780436 2.25
.750"
'J05821 2.25
.50" E08929 2.25
.50" L21730 2.25 l
.250" H07808 2.25
.50" 22244 5.0
.375" J05737 5.0
.250" A11608 5.0 No items of noncompliance or deviations were identified,
'
-5-
. -..
_
.,.
.
-
_
_
..
5.
Observation of Activities
The inspector witnessed examination of the following items:
a.
Magnetic particle examination of vessel closure studs, nuts and washers b.
Ultrasonic examination of circumferential pipe weld in the SIS and RHR system, Weld No. 4.
It was determined by the inspector that examination procedures were being followed.
No items of noncompliance or deviations were identified.
6.
ISI Examination Record Review, Unit 2
'he inspector reviewed the following ISI examination records for completeness and compliance to requirements:
a.
Steam Generators Ultrasonic Examination Program Items 1, 2, 3, and 4 ASME Section XI, Reference IWC 2600, C1.1 Sketch CWE-2-1100 Calibration Block CWE-35 Butt Weld, 1-3, lower shell to stud barrel Butt Weld, 2-10, upper head to shell Butt Weld, 3-6, upper shell to transition Butt Weld, 4-5, transition cone to lower shell b.
Seal Water Injection Filter Ultrasonic Examination Program Item No. 26 ASME Section XI, Reference IWC-2600, C1.1 Sketch CWE-2-21300 Calibration Block CWE-29 Head to shell weld 1-1 c.
Steam Generator Ultrasonic Examination Program Item No. 7 ASME Section XI, Reference, IWC 2600, C1.4 Sketch 2-1100 Pressure retaining bolting _4-1 thru 4-40
<
-6-i
_ _ _ _, _ _.
. - _ _ _
-. -.
,
-
..
.
...
d.
Excess Letdoyn Heat Exchanger
.
Ultrasonic examination Program Item No. 8-9-ASME Section XI, Reference IWC 2600, C1.1 Sketch CWE-2-1100
Weld 1, head to shell Weld 2, shell'to flange e.
Seal Water Heat Exchanger Liquid Penetrant Examination Program Item 19-20 ASME Section XI, Reference IWC 2600, C1.1 Sketch CWE 2-1130 Weld 1, Head to Shell Weld 2, Shell to Flange f.
Circumferential Pipe Welds Ultrasonic Examination Program Item 37 ASME Section XI, Reference IWC 2600, C2.1 Sketch CWE 2-2200 Calibration Block, CWE-32 Weld 2 Main Steam g.
Ultrasonic Examination Program Item 41 ASME Section XI, Reference IWC 2600, C2.1 Sketch CWE 2-2500 Weld 3 and 18 Recirculation SIS sump to RHR system h.
Ultrasonic Examination
'
Program Item 49 ASME Section XI, Refere-2 IWC 2600, C2.1 Sketch 2-2532 Calibration Block CWE-10 Weld 1, RilR Hot Leg i.
Reactor-Vessel Program Item 5 ASME Section XI, Reference IWB 26]O, Bl.8
'
Magnetic-Particle Examination and Visual Sketch 1-1400 Vessel Closure Studs and Nuts 19 thiu 36
-~7
-
,
.
-
_ _.,
-
-
--
.
.
J.
Pressurizer
,
Program Item 22 ASME Section XI, Reference IWB 2600, B4.5 Calibration Block CWE-10 Weld 27 8" RHR Cold Leg Loop 2 k.
-Ultrasonic Examination Program Item 26 ASHE Section XI, Reference IWB 2600, B4.5 Sketch 1-4207 Calibration Block CWE-18 Weld 31 thru 34 3" CVCS Letdown 1.
Reactor Vessel Ultrasonic Examination Program Item 4 ASME Section XI, Reference IWB 2600, Bl.6
,
Calibration Block CWE-1 Sketch CWE 1-4300 Weld 1-(DM)(1)
Nozzle to Safe End m.
Pressurizer Ultrasonic Examination ASME Section XI, Reference IVB 2600, B4.5 Sketch CWE 1-4304 Weld 14 thru 19, Loop 3 8" RHR Cold Leg n.
Ultrasonic Examination Program Item 17 ASME Section XI, Reference IWB 2600, B2.4 Sketch CWE-17 Weld 1(DM) - 6" Pressurizer Relief Line, Nozzle to Safe End No items of noncompliance or deviations were. identified.
7.
Ultrasonic Examination (1978 Refueling Outage) - Unit 1 During the 1978 refueling outage of Unit 1, Weld No. 27 of the pres-surizer 8" RER cold leg, Program Item No. 22, in this examination period, was ultrasonically examined.
Indications were noted and recorded.
,
-8-
...
.
At'that time the CECO Chief Level III examiner.committ'ed to replace-
.
ment of the weld during the 1979 refueling outage. Prior to this outage, the licensee contacted the RIII office requesting they be permitted to perform further examinations, using other non-destructive methods, including radiographic examination to evaluate the ultrasonic indications before removing this weld. The regional office had no objections to further examinations and evaluations being performed.
After shutdown for this refueling outage, the inspector met with licensee personnel on October 15, 1979.
Examinations performed to date, including preservice and inservice were discussed.
Radiographs taken during this outage, and the original installation radiographs, taken on February 2, 1972 were reviewed.
Both radio-graphs show the same slag inclusion at the location indicated by ultrasonic examination.
It does not appear that there has been any change in the indication since installation.
As a result of further examination and review, it was determined that this weld meets the acceptance criteria of ASME Section XI, 1974 Edition, including Summer 1975 Add
.
It was suggested that this weld be ultrasonically examined each out-age through the 1983 refueling outage with one radiographic examina-tion being performed during this period.
The licensee is to inform RIII office of their schedule for examin-ing this weld.
No items of noncompliance or deviations were identified.
8.
IE Bulletin 79-17, Pipe Cracking In Stagnant Borated Water Systems at Power Plants In accordance with Item 1 of the bulletin requirements, the licensee submitted a written response dated August 24, 1979, to the RIII office identifying safety related stainless steel piping systems and portions of systems containing stagnant oxygenated borated water.
Included was the extent and dates of nondestructive examination per-formed to date in accordance with ASME Section XI.
Also, a summary of the waste water chemistry of the identified systems and a table identitying welds in the systems that had received preservice non-destructive examinations required by design specifications. The licensee reported no experience of cracking in the identified systems.
The following systems and portions of systems were identified a.
and inspected in accordance with bulletin requirements:
.
-
-9-
.__ _
_
_ _
._. -
k-
. - -.
.
--
+
Reactor Cooling System (RCS)
-.
.
.
Accumulator Discharge (AD)
.
Residual Heat Removal (RilR)
.
.-
-Volume Control (VC)
,
Safety Injection (SI)
.
Spent Fuel (SF)
~
.
b.
The following' Unit i systems were identified and examined:
'
CWE SIZE No.
WELD NO.
SUMMARY NO.
SYSTEM IN.
WFLDS EXAMINED ALL 18" 12" 10"
~8" 4"
3" 1701 CS
20 1,2,3
3 1702 CS
20 7,8,9,10
4 1703 CS
20 1,2,3A
3 1704 CS
21 1705 RiiR
2
.
10 1,6,7
3 1706-RHR
27 4*5,7
3
.,
_1706 RliR -
8 28,28A
2
,
1707 Sl (Ril) -
1
14 4,5,9
3 4-1708-SI(CS)
2
,
'
21 20,21 2,
1709 VC
21 13,14,22,
23
4 1710 SI
26 1711-SI 4.
,
'
2
28 27,28
2
1713 SI
7 1714 SI(Ril)
.12
1A,3,4
3 1715 SI(Rll)
10
1
1716 SI(Ril)'
8
1
~ 1717
.SI
65
-
' 1718-.SI
27 1,2,3
3 1719 SI
24-1,2,13,14
4 1720f SI
29 2,3,9,10, 11,12,17, 18,24,25, 26,27
- 12
.
e
- 1721
_SF
4 3,4
,
2
>
10 -
-
.
, - -
-
w
,
e,,
-
e
,-v,
,-r.,
wr
,,r-g
, -,, -., -
~,-+--r
,em s~n
.
=,
.
. _....
.-..
..
.-
.
- .
'
,
L=.
- PT Only
2
.6-10 16 19
Totals 437
40 88 109 176
- 6
'
Percent Examined'
13%
'11% 15% 15% 11% 33%
Results: No evidence of I.G.S.CsC.
'
~
c.
The following Unit 2 systems were identified and examined:
'COM SIZE-NO WELD NO.
SUMMARY s
I No. -SYSTEM'
IN.
WELDS EXAMINED ALL 18" 12" 10" 8"
4" 3"
1701 CS
20 2,3
2 1702 CS
20 2,3
2 1703 CS
12 0 2,3
2 1704 CS.
14 12,13
2 1705 RHR-10
10 11'
1 t1706 RHR
- 27 2,3,3A,4
4
'
7 26*,27*
2 1707 SI(RH)
14 6,7,8 3'
,
1708 SI-
2 24*
1
23 21,21A,22
3
,
1709 NCE
20 5,11,12,14 4
i
!
1710 SI
31 1711 SI 4-
'
2
...
2 30*
1
30 28,28A,29
3
'
.1713 SI
6 1714 SI
13 4,7A
2
1715 SI
10
1
1716-SI
9
1
'
1717 SI
56
',
1718 SI-
32 1,2,3,4 4.
1719 SI 4~
1,2,17
3 1720 SI
26 4,8*,9,11,
,
12,13,16,21*
22,24,26
11 1721 SF
4
1
]
- P/T Only' 53
6 10 16 18
Totals 433
40 80'110 178
r Percent Examined 12% 11% 15% 13% 15% 10% 17%
Results: No-evidence of I.G.S.C.C.
.,
- 11 -
l
-
,~~~-J
..,
.....,
-
...
. -. - -.. -,.. -. - -. -. -... - - - -. ~.
- -. - -
-
---,n
.
.
d.
.The following spent fuel systems welds were identified and examined:
.
SPENT FUEL SIZE NO.
WELD NOS.
SUMMARY SKETCli NO.
IN.
WELDS EXAMINED All 10" 8"
3
SF-01
14 18,23
2
20 12,17,30
3
10
1
SF-02
55 4,11,13,23,32 33,48,49,54
9 SF-03
2
21 8,9,19,20
4 SF-04
16 5,6,9 10,13
5 SF-05
22 4,15,16
3 SF-06
24 2,14,15
3 SF-07
19 5,6,15,16
4 SF-08
3
1
8
7,8,25
3 SF-09
16 3,10,12,13
4 Totals 247
12 10 20 51 66 130 Percent Examined 17% 24% 15% 15%
Results: No evidence of I.G.S.C.C.
WALL I.S.I LINE NUMBER DESCRIPTION SIZE SCHEDULE MATERIAL THICKNESS PERFORMED q
OSF001-10"AA Spent Fuel Cooling 10" 40S A312-Tp 304
.365" No l
OSF012-3"AA Spent Fuel Cooling 3"
40S
.216" No
"
ISF001-8"AA Spent Fuel Cooling 8"
40S
.322 No
"
ISF001 - 10 AA Spent Fuel Cooling 10" 40S
.365 No
"
ISF002-8"AA'
Spent Fuel Cooling _ 8" 40S
.322 No
"
ISF00Z-10"AA Spent Fuel Cooling 10" 40S
.365 No
"
SF003-10"AA~
Spent Fuel Cooling 10" 40S
.365 No
"
ISF007-3"AA Spent Fuel Cooling 3"
40S
.216 No
"
SF015-3"AA Spent Fuel Cooling 3"
40S
"
.216 No SF022-3"AA Spent Fuel Cooling 3"
40S
.216 No
"
SFu01-10"AA Spent Fuel Cooling 10" 40S
.365 No
"
SF001-8"AA Spent Fuel Cooling 8"
40S
.322 No
"
SF002-10"AA Spent Fue1 Cooling 10" 40S
.365 No
"
SF002-8"AA Spent Fuel Cooling 8"
40S
.322 No
"
SF003-10"AA Spent Fuel Cooling 10" 40S
.365 No
"
SF007-3"AA Spent Fuel Cooling 3"
40S
.216 Ns
"
SF015-3"AA Spent Fuel Cooling 3"
40S
.216 N.
"
SF022-3"AA Spent Fuel Cooling. 3" 40S
.216 No
"
.
- 12 -
..
,
..
9.
IE Bulletin 79-17 Procedure Review-
_..
The inspector-reviewed the following procedures, approved for examinations:
a.
ISI-11, Revision 9 Liquid Penetrant Examination Procedure b.
NSD-ISI-90, Revision 1 Manual Ultrasonic Procedure for Investigating for Presence of Intergranular Corrosion.
-No items of noncompliance or deviations were identfied.
10.
IE Bulletin 79-17~ Personnel Qualifications Examinations fo the identified systems were performed by Westinghouse personnel identified under the ISI section of this report.
11.
Reactor Water Storage Tank (RWST) - Unit 1 During the investigations conducted in accordance with IE Bulletin 79-17, boric acid crystal build-up was observed on Containment 1 Spray Pump Suction Line-ICS003-14-R1-R. /7 inspection of Unit 2 revealed a similar deposit on the RHR return line 2S1003-8"-L-R.
A further inspection was conducted on August 31, 1979, by the licensee by' sending a diver into each tank with a television camera which identified welds in the liner plate as being the cause of the leakage.
The deposits were removed and the lines observed for leakage for r
several days with no leakage noted.
Because there was no leakoff in the sight glass, the licensee concluded that the leak was no longer active.
Video tapes of the liner plate welds and the pipe ID's were reviewed by an NRC inspector on September 10, 1979.
On September 4, 1979, the licensee reported their actions to the NRC resident inspector, which is documen+.e; in IE Report No. 50-295/79-18, 50-304/79-17.
On September 5,1979, the licensee and RIII staff held a conference call, at whien time the licensee informed the staff of their actions to date, and their' justification for remaining on line until the next refueling outage of'each unit. At that time, each tank would be drained, examined and repaired.
\\
s
'
.e n
13 -
-
.
_.
_ -.
. -
,, _
-
_
-
-
..
-_
..
.'
The RIII staff concluded that the licensee's actions were acceptable and created no health or safety hazard.
On August 21-22 1979, following drainage of Unit 1 RWST visual and PT examination of the liner plate welds revealed 2 slag pockets and other pinhold indications. No indications were roted in the 1A and 1C containment spray lines.
From August 26 through August 31, 1979, repair of the noted indications was completed by welding. The effected areas were visually and PT examined and found acceptable.
It is believed by the licensee that leakage was due to poor weld quality during construction and not IGSCC. The repair actions taken by the licensee closes the open item in IE Report 50-295/79-18; 50-304/79-17.
No items of noncompliance or deviations were identified.
12.
IE Bulletin 79-17 Record Review The inspector reviewed documentation of examinations completed as required by Item 2(a) and 2(b) of IE Bulletin 79-17.
No evidence of intergranular stress corrosion cracking was reported.
No items of noncompliance or deviations were identified.
13.
IE Bulletin 79-13, Cracking In Feedwater System Piping a.
General After shutdown of Unit No. 1 on October 6, 1979, for refueling, the licensee performed radiographic examination of the steam generator feedwater nozzle to pipe welds in accordance with bulletin requirements.
The results of this examination revealed crack-like indications present in all four steam generator pipe to nozzle welds. On October 26, 1979, Unit No. 2 was shutdown to examine the welds on that unit. As with Unit No. 1, the Unit No. 2 weld examina-
>
tions revealed crack-like indications. On October 16 and October 30, 1979, the licensee completed Item 4 of the bulletin by notifying the RIII office of these indications. The welds that cracking was identified in are as follows:
.
Weld No. FW-430, nozzle to elbow Steam Generator IB
.
Weld No. FW-458, nozzle to elbow
- 14 -
,
l
._
..
-* -
.
Steam Generator 1C-Weld No. FW-439, nozzle to pipe-Steam' Generator ID
.
Weld No. FW-448, nozzle to pipe The remaining welds out to the first support on all feedwater lines were examined and reviewed. No indications of cracking were present.
b.
Repair Program and Procedures The licensee developed a repair program and procedures in accordance with ASME Section XI, and Section III, which were reviewed by the ANI and NRC inspector.
(1.) RP-FW-02-Z, Revision 2 Feedwater Piping Replacement (2.) Zion Steam Generator Nozzle Interior Examination and Investigation Procedure (3.) RP-FW-Al-Z1, Revision 0 Steam Generator Feedwater Nozzle Repair (4.) RP-FW-B2-Z, Revision 2 FWP, Replacement (5.) RP-FW-B1-Z1, Revision 0 Steam Generator Nozzle Repair (6.) RP-FW-CI-Z1, Revision 0 FWP Replacement (7.) RP-FW-Cl-21, Revision 0 Steam Generator Nozzle Repair (8.) RP-FW-D2-Z1, Revision 0 FWP Replacement (9.) RP-FW-DI-Zi, Revision 0 Steam Generator Nozzle Repair (10.)W. A. Pope Feedwater Repair Welding Procedures m
GT-SM 1.3C.1-PH (GTAW-SMAW, P1 to P3), Rev. O GT-SM 1.1C1.1-PH (GTAW-SMAW, P1) Rev. O SM3.3 BR-PH, Rev. O GT 3.3 BR-PH (PWilT), Rev. O GT-SM 1.1 or PH (PWHT), Rev. O PWIIT-1-(Postweld) (Weld Repair of Nozzle ID), Rev. O
- 15 -
i
.
.
.
. -..
PWHT-2 (Postweld - Nozzle to Piping), Rev. O
~
.
PWHT-3 (Postweld - El Piping), Rev. O Preheat - 1 (Intermediate build up nozzle),-Rev. O Preheat - 1 (Intermediate Nozzle to Piping), Rev. O GT-1.1 BR-Pil-(GTAW, P1 to P1), Rev. O SM-1.1 BR-Pil (SMAW, P1 to P1), Rev. O QAP-4, Rev. O, Weld Filler Material and Weld Rod.
Oven Calibration Control QAP-3, Rev. O, Material Receiving Inspection NDT-A&A3, Revision 7, Rediographic Examination Procedure c.
Personnel Certifications.
,
Commonwealth Edison Company (CECO)
NAME RT UT PT VT NT T. Lukens II II II II J. L. Booth II II II B. Wilson II C. Solich II II II II II W. Witt II II II II II E. Potter III III III III III Conam Inspection Division (CONAM)
NAME RT UT PT VT MT J. J. Tetrev II G. Foster II II II II M. Sippel I
II II T. Randle II II II R. Guentens-berger II.
II II II
L. Kalkofen II Superior Industrial X-Ray (SIX)
.
III III S. Turner II II II A. D' Antonio II II I
R. Ilurter~
II II II
- 16 -
. - -.
_
_. - -. -
_
_, - _ _ _, _
. __-,_.. ~
-
- -*..
Welder Qualifications (P0PE)
-
NAME STAMP NO.
P. Pelkonen
W. Kohl
E. Causey
R. Demichelo
M. Keane
R. Burgess
W. Pacura
J. Harrod
M. Koveikis
R. Defauw.
A. Jacob
D. Adamson
E. Williams
C. Settles
S. Lorch
J. Gass
M. Magdaleno
C. Lundgran
d.
Materials and Equipment Certification The following equipment used during feedwater pipe replacement was observed and examined for proper certifications:
16" Schedule 120 Pipe, Heat No. 59080 4, 90 Carbon Steel Elbows, Heat Code No. WPBU42 3/32", E7018, Welding Electrode, Heat No. 401J1571 1/8", E7018, Welding Electrode, Heat No. 412H6561 3/32", E70s-2, Bare Filler Wire, Heat No..065118 12, E70s-2, Inserts, 1/16"x3/16"x16", Heat No. 659A315 12, E70s-2, Inserts, 1/8"x3/16"x16", Heat No. 628065 Exo-lec, system 2D, Heating System, Transformer SN-1017-171, Model 14T79B Heating Controller, 2B, S/N-73708 Heating Controller, C-10R, S/N-1173-38 Thermometer, (Weksler Mercury) S/N-TT-1 Pyrometer, Alnor Model 400-A, S/N-3 Temperature Tester, Robinair Mcdel 12860, S/N-6 Volt-amp Meter, Model 003, S/N-3C286HF Gamma Plugs, Heat No. 793SR6579 e.
Pipe Pemoval After determining that cracking was present in the nozzle welds, the licensee removed the elbow on steam generator 1A nozzle by
- 17 -
_,
_
.. _,
,
o cutting through the nozzle weld No. FW-430 and Weld SWB (FW-430).
After removal sections of this elbow were sent to Westinghouse Electric Corporation (W) and the licensee's laboratory for metallurgical analysis.
f.
Nozzle Indication Removal Following removal of the elbows and pipe spools from the generator nozzles they were visually examined and buffed to bright metal, liquid penetrant examined, and indications
.
removed by grinding until cleared.
All grindouts were map-ped and the depths recorded.
Sections of suspected thermal sleeves were removed to examine the nozzle ID surface between the sleeve.
No indications were noted.
g.
Generator Nozzle ID Repair As nozzle ID indications were removed and examined, heating elements were installed prior to welding for preheating. The nozzles were then built up with weld metal, machined and ground to drawing dimensions. Stress concentrations were removed by radiusing as directed by (W) engineers.
Preheat temperatures were maintained between 300 F and 600 F during repair welding. Stress relief was at 1125 F.
All nozzle repair welds were NDE examined prior to pipe in-stallation.
h.
Elbow and Pipe Spool Installation Replacement elbows _and pipe spool sections were examined and the weld preparations machined in the Pope fabrication shop.
After transportation to the containment, they were fit to the generator nozzles and feedwater piping and tack welded in
-
accordance with approved welding procedures.
Preheat tempera-tures were maintained during all welding activities.
After completion of welding, the welded joints were post-weld heat treated at ll25F and permitted to cool to room temperature in still air.
Completed welds were radiographically and liquid penetrant examined.
Following acceptance of NDE examination results, weld surfaces were prepared for. ultrasonic examination to' establish a base 18 -
-
.
,
l j
line for inservice inspections.
Ultrasonic examinations were performed by (W) and licensee personnel in accordance with ex-amination procedure NSD-ISI-205,-Revision 2.
i.
Observation of Activities The RIII inspector observed all activities related to the feedwater pipe replacement. Reviewed material and personnel certifications, fit-up and welding activities, and reviewed all radiographs.
No~ items of noncompliance or deviations were identified.
14.
Pressurizer Nozzle Examination On December 14, 1979, Westinghouse Electric Corporation, via memo-randum,-notified all owners of (W) plants of cracking detected in the PORV nozzle safe end welds.
Westinghouse has recommended that all operating plants should, at their earliest convenient time, perform a liquid penetrant (PT)
examination of the pressurizer nozzle safe-end areas that have not been examined during the past 12 months.
Since both Units 1 and 2 of Zion Station are shut down for repair, the licensee examined the records identifying the nozzles that had not been examined and performed PT examination on both units as follows:
Unit No. 1 Component Dwg. No.
Weld No.
a.
Pressurizer Surge Line CWE-1-4500 1DM b.
IRC-141-4" CWE-1-4505 IDM c.
IRC-157-6" CWE-1-4504 IDM d.
IRC-156-6" CWE-1-4503 IDM Unit No. 2 Component Dwg. No.
Weld No.
a.
2RC-142-4" COM-1-4506 19DM b.
2RC-140-14" COM-1-4500 9DM No items of noncompliance or deviations were identified.
15.
Exit Interview The inspector conducted informal exits during the course of this inspection, discussed repair activities and the scope of the ISI examinations. A final exit interview was conducted on -January 4, 1980.
- 19 -
<
-. -.