IR 05000454/1985027

Insp Repts 50-454/85-27 & 50-455/85-19 on 850605-06.No Violation or Deviation Noted.Major Areas Inspected:Licensee Actions on Previous Insp Findings

ML20127P261
Person / Time
Site:	Byron
Issue date:	06/24/1985
From:	Gautam A, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20127P220	List: IR 05000454/1985027 ML20127P216
References
50-454-85-27, 50-455-85-19, NUDOCS 8507020362
Download: ML20127P261 (5)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION III

Report No. 50-454/85027(DRS);50-455/85019(DRS)

Docket No. 50-454; 50-455 License Nos. NPF-37; CPPR-131 Licensee: Commonwealth Edison Company P.O. Box 767 Chicago, IL 60690 Facility Name: Byron Station, Units 1 & 2 Inspection At: Byron Site, Byron, IL Inspection Conducted: June 5-6, 1985 Inspector: A. S. Gautam Reactor Inspector h Date h M d F4% %

Approved By: C. C. Williams, Section Chief 4/2//Br Plant Systems Section Date /

Inspection Summary Inspection on June 5-6, 1985 (Report Nos. 50 454/85027(DRS); 50-455/85019(DRS))

Areas Inspected: Routine, unannounced safety inspection by a regional inspector of licensee actions on previous inspection findings. The inspection involved a total of 15 inspector-hours onsite and two inspector-hours offsite by one NRC inspecto Results: Of the areas inspected no violations or deviations from NRC requirements were identifie PDR 0 ADOCK 05000454 PDR

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DETAILS 1. Persons Contacted Commonwealth Edison (CECO)

• R. B. Klingler, Project QC Supervisor J. O. Bender, Project Electrical Supervisor

• E. L. Martin, QA Superintendent J. Glowinski, 0AD Supervisor

• J. Bergner, QA Supervisor M. Dellabetta, QA Supervisor D. Kruger, System Test Engineer J. Schaefer, Staff Assistant L. Steen, Project Construction Engineer P. Wicyk, Construction Engineer - C&I Westinghouse - Nuclear Operations Division (WN0D)

Pane Miller, Process Control Engineer Hatfield Electric Company (HECo)

Dand Dehmlou, Quality Control Engineer

• Denotes those attending the exit meeting on June 6, 1985.

2. Licensee Action on Previous Inspection Finding (Closed) Unresolved Item (455/80011-5). This item referenced NRC concerns regarding significant amounts of rework being performed on safety-related equipment. Based on subsequent reviews this item is close (Closed) Open Item (455/84010-01). This item addressed the lack of qualifying documentation, onsite, for the interrupting capacity of circuit breakers in 480V substations in Units 1 and 2. Since this item has been previously addressed and closed for Unit 1, item 454/84-14-01 in Report Nos. 50-454/84-23; 50-455/84-16, and since the same equipment is installed in Unit 2, this item is close (Closed) Open item (455/84047-01). This item addressed concerns regarding deficiencies at plants utilizing Bunker Ramo Containment electrical penetration assemblies. These deficiencies were identified in I.E. Bulletin No. 82-04, and involved improper lug crimps, incorrect lug types, loose terminations at terminal blocks, cracked insulation in conductors and inadequate crimped butt splice l

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The NRC inspector reviewed the licensee's surveillance Report No. 6503, dated September 21, 1984, and a follow up surveillance report by the Plant Construction Department (PCD) dated October 26, 1984. The PCD report documented inspection results and corrective actions for the deficiencies found in the field. The inspector also reviewed HECo QC inspections on modifications made in the field on the (15) penetration assemblies on site. Modifications included replacing (15)

and rework of 6) (penetration modules lug crimps and with Conax lug type adapterbutt No inadequate assemblies,

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splices were found by the licensee. Based on the above review this item is close . Licensee Action on 10 CFR 50.55(e) Items (Closed) 50.55(e) (455/83006-EE). This item concerned misoperation of the Under Voltage (UV) trip on Westinghouse DS-416 breakers. The scope of this item involved deficiencies in a total of four under-voltage trip assemblies for two main breakers and two bypass breakers, one UV assembly per breaker in the Reactor Trip Switchgear (RTS).

The inspector reviewed FCN No. CAEM-10783 and FCN No. CAEM-10749 for changes to these UV assemblies on the RTS breakers. The licensee is in the process of replacing the existing UV trip assemblies with new modified trip assemblies in accordance with with manufacturer's instructions. Reference W Dwgs 588C785,R.5 and 693C350,R2 which are part of above FCNs. Field changes include testing and documented inspections by QC inspector The inspector reviewed completion of this work in Unit 1 and physically examined UV attachments. The licensee is in the process of completing modifications in Unit 2. Based on the above review this item is close (Closed) 50.55(e) (455/83012-EE). This item identified a notification by the licensee regarding Over Load (0L) blocks in No. A200 series sizes 0, 1 and 2 Westinghouse Motor Control Center (WMCC) starters, tripping outside of their acceptable band specified by Westinghouse. The minimum trip value was found, after testing, to be too lo The licensee issued Nonconformance Reports Nos. 834 and F-900 which identified the problem and required replacing and/or recalibrating the deficient over load blocks as identified by station personnel.

' The inspector reviewed an S&L review dated May 20, 1983, on thermal over load relay sizing and their justification for the thermal relay sizing for valve actuator continuous duty motors fed from WMCCs at Byro S&L determined that OL sizes selected from W OL ~

Tieater application tables were wrong and would trip over load relays at current values less than motor full load currents in the conser-vative direction which was not desirable. Westinghouse concurred with S& . _- . -. .

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The inspector reviewed procedure BHP-4200-28, Revision 1, Thermal over load testing, performed by the Electrical Maintenance Departmen The' inspector also reviewed work request No. B04867 for Unit 1, documenting removal of the OL from MCC, testing and replacement with the correct size. A QC inspection was documented on the same work request. No OLs were reworked in Unit 2 where (261) out of (300)

OLs have been replace Based on the above review, this item is

. close (0 pen) 50.55(e) (454/82011-EE; 455/82011-EE). This item identified a notification by the licensee of a deficiency regarding the accuracy of Barton electronic instrument transmitters at the Byron Statio Barton Model 763 and 764 electronic transmitters delivered after July 1, 1979, had been found by Barton to exhibit thermal non-repeatibility and performance characteristics outside of Barton's specifications. Based on statistical analysis of 80 transmitters Westinghouse calculated expected error deviations of these instruments and determined that adequate margin existed in the setpoints of all Model 763 and 764 transmitters to absorb additional errors due to thermal non-repeatability at accident environment temperatures of 325 F and abnormal environment temperatures of 130 Westinghouse's evaluation had determined that the thermal non-repeatability was caused by current leakage through the potentiometers due to an incorrect manufacturing process and the methodology used during the temperature compensation procedure. Proposed corrective action by Westinghouse was to add an insulating washer to eliminate electrical leakage and to establish a revised temperature compensation procedure to make it possible for the calibration technique error to be corrected in the fiel In a December 15, 1983, letter to the NRC, the licensee declared that based on Westinghouse's statistical review and conclusions that adequate margins existed in the setpoints. Sufficient justification existed to defer any modifications or adjustments until all corrective actions could be implemented simultaneously. The Westinghouse statistical review was not available on site for review by the inspecto In a June 29, 1984, letter, (Reference CAW-7549, CBW-4716) to the licensee, Vestinghouse provided a " final resolution of Barton transmitter r oblems." In this letter Westinghouse concluded that

"the Barton transmitters for Byron and Braidwood do not require any replacement or modification to ensure that they would perform their intended safety function." The inspector found no justification for this conclusion. The June 29, 1984, letter further stated that based upon present Technical Specification limits, the DNBR margin was reduced equivalent to a 1% increase F delta H and many have a negative impact on the ability to compensate for future operability problem I

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The licensee was requested by the inspector to further clarify and make available the statistical review by Westinghouse (Reference December 15, 1983 letter to NRC);information as to whether the insulating washers had been added" whether a revised calibration procedure for temperature compensation had been implemented; Westinghouse's justification for its conclusions in its June 29, 1984, letter to the licensee, and the possible negative impact of the reduction in DNBR margin on the ability to compensate for future plant operability problem Pending review of the above requested information, this item remains ope . Exit Interview The inspector met with the licensee's representatives (denoted under Paragraph 1) on June 6,1985, and summarized the scope and findings of the inspection. The licensee acknowledged the information. The inspector also discussed the likely informational content of the inspection report with regard to documents or processes reviewed by the inspector during the inspection. The licensee did not identify any such documents / processes as proprietar