IR 05000295/1987019

Insp Repts 50-295/87-19 & 50-304/87-08 on 870414-0812.No Violations or Deviations Noted.Major Areas Inspected: Inservice Insp Activities,Including Review of Program, Procedures,Observation of Work Activities & LERs

ML20237H252
Person / Time
Site:	Zion  File:ZionSolutions icon.png
Issue date:	08/19/1987
From:	Danielson D, Schapker J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20237H241	List: IR 05000295/1987019 ML20237H237
References
50-295-87-19, 50-304-87-08, NUDOCS 8708240409
Download: ML20237H252 (7)

Text

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i U.S. NUCLEAR REGULATORY-COMMISSION j REGION III I i

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Reports No. 50-295/87019(DRS); 50-304/87008(DRS)

Docket Nos. 50-295; 50-304 Licenses No. DPR-39; DPR-48 Licensee: Commonwealth Edison Company -

Post Office Box 767 Chicago, IL 6069 Facility Name: Zion Station, Units 1 and 2 Inspection At: Zion Site, Zion, Illinois Inspection Conducted: April 14-17, May 4-7, 17-21, July 7-10 and August 11-12, 1987 M

l Inspector: . F. Schapker (!#hJ Date

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Approved By: D. H. Danielson, Chief 8/MM7 Materials and Processes Section Date Inspection Summary Inspection on April 14-17, May 4-7, 17-21, July 7-10 and August 11-12, 1987 (Reports No. 50-295/87019(DRS); 50-304/87008(DRS))

Areas Inspected: Routine unannounced inspection of inservice inspection (ISI)

activities including review of program (73051), procedures (73052), observation of work activities (73753), and data review and evaluation (73755); review of Licensee Event Reports (LERs) (92700), training effectiveness as'it relates to the above modules (41400).

Results: No violations or deviations were identifie !

8708240409 B70819 PDR ADOCK 05000295'

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DETAILS  !

1. Persons Contacted Commonwealth Edison Company (CECO)

• Plim1,-Station Manager

• Schultz, Regulatory Assurance Supervisor

• Stone, Station QA Superintendent

• Madigan, ISI Coordinator

• Wulf, ISI Engineer

• L. Laspisa, Assistant Tech. Staff Supervisor

• R. Budowle, Assistant Superintendent Technical Services

• D. Felz, QA Ir.spector

• G. Olson, QA Engineer Westinghouse Electric Corporation (WEC)

N. Bollingno, ISI Inspector J. Bell, ISI Inspector J. Delbusso, ISI Inspector R. Matney, ISI Inspector U.S. Nuclear Regulatory Commission (USNRC)

• P. Eng, Resident Inspector

• Denotes those attending the exit meeting on August 12, 1987. Other station technical and administrative personnel were contacted during the course of the inspectio . Followup on Licensee Event Reports Through review of ISI records and applicable Technical Specifications, the following event report was reviewed to determine that deportability requirements were fulfilled and corrective actions are appropriate and adequate to prevent recurrenc (Closed) LER 87002-00: 1-D Steam Generator Reveals Greater Than 1% of Tubes Defectiv During the second outage of the first period of the second ten year plan, eddy current testing revealed that steam generator "1-D" fell into Category "C-3", as defined in the Zion Station Technical Specifications as greater than one percent of the tubes inspected had >/=40% through-wall indications. The safety significance is small because the Zion Station's Safety Analysis allows up to 10% tube plugging. The steam generator tubes were inspected 100% by eddy current this outage. During the next outage, the licensee will perform 100% eddy current examination of the Unit 1 steam generator tubes. Further corrective action taken by the licensee to prevent recurrence has been initiated by the Steam Generator Chemistry Program modeled after the EPRI Guideline _ _ _ _ _ - - _ _ - - - . - I

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No violations or deviations were identifie . Inservice Inspection (ISI), Unit 2  ; General This is the second outage of the first period of the second ten year pla CECO contracted Conam Inspection to perform the eddy current examinations (ET) of the steam generator tubes. Westinghouse j Electric Corporation performed the ultrasonic (UT), liquid penetrant (PT), magnetic particle (MT), and visual (VT) examinations for the ISI, in accordance with the rules'and requirements of the ASME Section XI, 1980 Edition, Winter 1981 Addend The ultrasonic examinations were performed by Westinghouse Electric Corporation (WEC) using approved ultrasonic examination procedure The Westinghouse UT procedures were reviewed and approved by a CECO Level III that was EPRI qualifie Programs and Procedures

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The NRC inspector reviewed the following WEC nondestructive examination procedures:

Procedure Revision Title ISI-8 9 Visual Examination (VT)

ISI-11 10 Liquid Penetrant Examination (PT)

ISI-41 5 Ultrasonic Examination at RCP Flywheel ISI-47 4 Ultrasonic Examination of Vessel Welds ISI-70 2 Magnetic Particle Examination (MT)

151-206 1 Manual Ultrasonic Examination of Welds QA Trainino, Qualification and Certification of NDE Personnel NSD-ISI-10 6 Qualification of UT Manual Equipment OPS-NSD-101 5 Preservice and Inservice Documentation

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.s The NRC inspector also reviewed the licensee's inservice inspection i program for the second ten year interva Zion Station received a Technical Evaluation Report (TER) dated February 11, 1986, from l the NRC pertaining to Zion Station's second ten year Inservice Inspection Program. The TER contained the NRC's evaluations of specific relief request. The relief requests were granted, or granted if certain provisions were made with the exception of the following relief request:

Item No. 1 Relief Request IWB No. 5, Bolting and Studs, Reactor Vessel Closure Head, Category B-G-1, Items 86.20 and 86.3 Relief Request Relief is requested from volumetric examination of bolting and i studs on the reactor vessel closure hea NRC Review The Code requires both ultrasonic and surface examination when the '

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studs are removed. The licensee has provided no compelling reason to eliminate a Code requirement (volumetric examination).

Licensee Response During a conference call on June 4, 1986, Jan Norris, George Johnson, and Sam Lee of the NRC and Mike Madigan of Commonwealth Edison (Zion Station) discussed the relief request and its relationship to Code Cases N-216 and N-30 The NRC requested to review these Code Case A second conference call was held on June 5, 1986, with Jan Norris, George Johnson, and Mike Madigan. The NRC stated that they had reviewed both Code Cases and will reconsider Zion Station's relief request to perform surface and visual examinations if wet magnetic particle and visual examinations are performed as an alternative to volumetrically examining the reactor vessel closure head stud This alternative was acceptable to Commonwealth Ediso Item No. 2 I Relief Request IWB No. 8, Longitudinal Electroslag Welds and Cast-to-Cast Circumferential Welds, Category B-J Items B-J l Items 89.11 and B9.12 (Items 84.5 in 1974 Edition, Summer  !

1975 Addenda).

Relief Request i

Relief is requested from performing volumetric examination on l longitudinal electroslag welds and circumferential welds that ;

are cast-to-cas i I

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NRC Review Because ultrasonic testing of the subject welds is likely not to be practical and because the applicability of MINAC/Shrinkac examinations to them is uncertain, relief from the Code required volumetric examination would be appropriate. Because of the great variability of the current ultrasonic methods, the licensee should attempt UT on a 25% sample of these welds to demonstrate whether these methods are indeed impractical. The proposed visual and =

surface examinations will also add a measure of knowledge on the integrity of these component Licensee Response IWB-2412 of ASME Section XI, 1980 Edition, Winter 1981 Addenda defines a range of minimum and maximum percentage of performed examinations that may be credited within an inspection period. Since Zion's Unit 1 1986 and Unit 2 1987 refueling outages mark the end of the first inspection period of the second interval, examinations which satisfy the requirements of IWB-2412 will soon be complet Furthermore, based on recently developed ultrasonic testing -

techniques, Commonwealth Edison is currently conducting a feasibility study on inspectability of the Reactor Coolant system longitudinal electroslag welds and cast-to-cast circumferential welds at Zion Station. During the Unit 2 1987 refueling outage, Zion Station will attempt to perform a demonstration inspection on calibration blocks of representative material from the actual pipe to validate the ultrasonic test results. However, depending upon the demonstration inspection results, relief may be requested from ultrasonicly testing the longitudinal electroslag and cast-to-cast circumferential welds during the second and perhaps third periods of the second interval. As substitute examinations, surface and visual examinations may be performed on the longitudinal electroslag and cast-to-cast circumferential welds and in addition, other welds in the Reactor Coolant system or other B-J category welds may be chosen for inspection to satisfy the requirements of IWB-2412. In any event, it is realized that the intent of the Code is to evenly distribute i examinations among the various types of welds within a system, but l

until a volumetric examination method is capable of producing l reliable data results on the longitudinal electroslag and cast-to-cast circumferential welds at Zion Station, substitute examinations on the Reactor Coolant system and other B-J piping welds will be examined to satisfy the requirements of ASME Section XI. Thus, the NRC staff is

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requested to reevaluate this relief request utilizing the above l informatio The NRC inspector verified that the licensee has initiated a volumetric 'inspectability study of the Item 2 welds. Visual examinations and dimensioning of the subject welds has been completed on Unit 2 Reactor Coolant Loop 1 piping. These atypical joint designs are being evaluated by the licensees' System Materials Analysis Department (SMAD) to determine feasibility of U _ _ _ - _ _ _ _

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The licensee has also engaged the services of WEC to manufacture demonstration samples of the referenced welds, utilizing metallurgically similar materials and weld procedures. These samples will be further processed by SMAD and evaluated for attenuation values of the inspection media to further evaluate the inspectability utilizing U l l

The resolution of the above items is considered to be an open item pending further action by the licensee and review by the NRC (295/87019-01(DRS); 304/87008-01(DRS)).  ;

c. Review of Material, Equipment, and Personnel Certifications, Audits and Data j l

The NRC inspector reviewed documents relating to the following: l

• Ultrasonic instruments, calibration blocks, transducers, and UT couplant certificatio I

• Certification of liquid penetrant and magnetic particle l material !

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• Eddy current (ET) equipment calibratio l

• NDE personnel certifications in accordance with SNT-TC-1 * Audits and surveillanc * NDE reports for ISI performed this outag * Data from the last Unit 2 outage and this outag * ET data reports including the plugging of the following:

Steam Generator Plugged Sleeved Previous Plugged

"A" 23 0 13

"B" 2 0 11

"C" 2 0 7

"D" 0 0 9 d. Observation of Work Activities The NRC inspector observed ISI work activities in progress. These observations included calibration, performance, certification of personnel and materials, and documentation of the following NDE:

• Ultrasonic examinations of reactor coolant loop piping weld * Ultrasonic examination of reactor vessel head wel _ _ _ _ _ _ _ _ _ _ _ _

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• ' Ultrasonic = examination of RHR hot leg piping weld * Liquid penetrant examination of reactor coolant loop l' valve and piping weld * Visual / magnetic particle examination of reactor vessel studs.

l The NRC inspector visually examined the following weld preparatio surfaces.for UT/MT/or P * Loop 1, RC hot' leg welds (UT and PT)

• - RV head weld (UT and PT)

• Loop 1 RC loop' piping. welds (UT and PT)

• . RV head studs (MT)

• RV nozzle safe end weld (UT)

The NRC inspector also performed visual inspection of.the-following:

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• Reactor vessel outlet nozzle inside radius'and accessible '

reactor internals via Minirover MKI vehicle remote TV camer * 'RHR piping supports

• Steam Generator manway studs No violations or deviations were identifie . Open Items Open' Items are matters which have been discussed with the licensee which will be reviewed'further by the NRC inspector and which involve some  !

action on the part of the NRC or licensee or both. One open Item was disclosed during this inspection which is discussed in Paragraph 3 . Exit Interview .

The inspector met with site representatives (denoted in Persons Contacted paragraph) at the conclusion of the inspection. The inspector summarized the scope and findings of the inspection noted in this report. The inspector also discussed the likely informational content of the inspection report with regard to' documents or processes reviewed by the inspector during the inspectio The licensee did not identify any such documents / processes as proprietar i 7  !

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