IR 05000454/1993002
| ML20035D898 | |
| Person / Time | |
|---|---|
| Site: | Byron  |
| Issue date: | 04/08/1993 |
| From: | Jeffrey Jacobson, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20035D891 | List: |
| References | |
| 50-454-93-02, 50-454-93-2, NUDOCS 9304140096 | |
| Download: ML20035D898 (7) | |
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U. S. NUCLEAR REGULATORY COMMISSION
REGION III
Report No.:
50 -454/93002(DRS)
Docket No.:
50-454 License No. NPF-37 Licensee:
Commonwealth Edison Company
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Executive Towers West III 1400 Opus Place, Suite 300 Downers Grove, IL 60515 Facility Name:
Byron Station - Unit 1 Inspection At:
Byron Site, Byron, IL Inspection Conducted: January 29 through April 1,1993 Inspector:
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4-B-93
.'D! Ward /
Date Accompanied By:
B. Metrow, IDNS (January 29, February 2, 18-19, March 18, and April 1, 1993)
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Approved By:
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. i. Jaco Date Materials &pn, Chief Processes Section Inspection Summary I
Insoection on January 29. February 10-11. 23. March 9. 18. and April 1. 1993 (Report No. 50-454/93002(DRS))
Areas Insoected:
Routine, unannounced safety inspection of inservice inspection (ISI) activities including review of programs (73051), data (73755), procedures (73052), observation of work activities (73753), and review of the erosion / corrosion (E/C) program.
Results: No violations or deviations were identified.
Based on the results of the inspection, one open item regarding steam generator tube degradation was identified (Paragraph 2.c.(2)). The NRC inspector also noted the following:
The licensee adequately demonstrated the ability to properly implement
the E/C and ISI programs, including the eddy current examinations of the steam generator tubes.
Personnel involved in the E/C and ISI efforts appeared knowledgeable, i
well trained, and competent.
i 9304140096 930409 PDP ADOCK 05000454 g
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DETAILS 1.
Persons Contacted Commonwealth Edison Company (CECO)
- M. Burgess, Technical Superintendent
- T. Tulon, Operations Manager
- A. Javorik, Technical Staff Supervisor
- D. Prisby, QC Supervisor
- D. Brindle, Regulatory Assurance Supervisor
- J. Smith, ISI Group Leader
- P. Enge, NRC Coordinator
- C. Bontes, Site Quality Verification Engineer
- G. Hagermann, ISI Coordinator W. Frundmann, Station Quality Verification Superintendent P. O'Neil, Assistant Technical Staff Supervisor P. Reister, Technical Staff Engineer S. Kerr, Chemistry Engineer R. Colglagier, Compliance Engineer (Regulatory Assurance)
C. Moudt, Engineering Nuclear Construction A. Beihon, Engineering Nuclear Construction U. S. Nuclear Reaulatory Commission (NRC)
H. Peterson, Senior Resident Inspector
- C. Brown, Resident Inspector
- C. Osterholtz, Resident Inspector Illinois Department of Nuclear Safety (IDNS)
- B. Metrow, IDNS Inspector
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Conam Nuclear. Inc. (Conam)
J. Funanich, Level III Allen Nuclear Associates. Inc. (ANA)
C. Walton, Level III MOS Inspection. Inc. (MOS)
J. Bushevy, Lead ISI Babcock and Wilcox Company (B&W)
H. McBride, Level III Ebasco Services (Ebasco)
R. McBride, Level III I-w, w-v
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Letec. Inc. (Zetec)
e S. Merriam, level III Hartford Steam Boiler Inspection and Insurance Company (HSB)
J. Hendricks, ANII The NRC inspector also contacted and interviewed other licensee and contractor employees.
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- Denotes those present during the exit interview on April 1,1993.
2.
Inservice Inspection (ISI)
a.
Proaram Review (73051)
Personnel from B&W, Ebasco, Conam, MQS, ANA, Zetec and CECO performed the ISI in accordance with ASME Section XI, 1983 Edition, Summer 1983 Addenda. Audit No. 06-93-02 and surveillances of the ISI program activities performed by CECO were performed by qualified personnel and found to be acceptable.
Organizational staffing for the ISI program was found to be acceptable and the services of an Authorized Nuclear Inservice i
Inspector (ANII) were procured from the Hartford Steam Boiler Inspection and Insurance Company.
The qualifications and certifications of all inspection personnel performing ISI were reviewed to ensure conformance with SNT-TC-1A.
b.
Procedure Review (73052)
All applicable ISI procedures were approved by the ANII and were
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reviewed by the NRC inspector.
The ISI procedures were found to
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be acceptable and in accordance with ASME Section V,1983 Edition, Summer 1983 Addenda.
c.
Data Review (73755)
(1)
General The examination data was found to be in accordance with the applicable ISI procedures and ASME Code requirements.
The NRC inspector reviewed documents related to nondestructive
examination equipment, data, and evaluations.
(2)
Eddy Current Examination (ET)
Eddy current examinations were conducted on 100% of the tubes in each steam generator. Half of the tubes were examined full length and all others were examined through the U-bend to the top support plate on the cold leg side.
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The examinations were conducted utilizing the Zetec MIZ-18 multifrequency digital examination equipment with associated acquisition software and remote positioning devices.
The Zetec DDA-4 Digital Data Analysis System was used for the data evaluation.
Motorized rotating pancake coil (MRPC) examinations were utilized to supplement the bobbin coil examinations. The MRPC was used to further characterize manufacturing burnish marks and undefined indications.
The primary analysis of the data was performed using Zetec's Eddynet System. The secondary eddy current analysis was performed using an Automatic Data Screening Program that was integrated directly into the Eddynet System.
Any discrepancies between the primary and secondary analysis
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were resolved by the onsite Level III analyst.
The following tubes were plugged as a result of this examination:
Steam Generator No. lA
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New Indications Plugged this Outage:
123 Total Tubes Plugged:
186
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Steam Generator No. IB f
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New Indications Plugged this Outage:
216
Total Tubes Plugged:
299 i
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Steam Generator No. 1C
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New Indications Plugged this Outage:
180 Total Tubes Plugged:
243 Steam Generator No. 1D New Indications Plugged this Outage:
Total Tubes Plugged:
119 During this outage, 530 tubes in the tube support plate areas were plugged due to outer diameter stress corrosion cracking, and 49 tubes in the tube sheet areas were plugged due to primary water stress corrosion cracking.
There were also 31 tubes plugged because of annulus vibraticn burnishing wear and other reasons.
CECO will be continue to explore the cause of the increased tube degradation.
This is considered an open item (50-454/93002-01(DRS)).
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(3)
Evaluation of Flaw Indications in 1 A Steam Generator Two previously detected flaws were reinspected and sized by ultrasonic examinations (UT) this outage (reference NRC inspection report No. 50-454/91025(DRS)) on the Unit 1 "A" steam generator. One flaw was located at the tube sheet to channel head weld and the other was located at the tube sheet to the stub barrel weld.
Both indications were determined to be weld related fabrication flaws in the weld metal to the base material fusion zone.
The flaws were
acceptable without repair. The indications were reinspected this outage in accordance with ASME Section XI, IWB-2420(b).
The indications were also UT'd with the P Scan Ultrasonic System. The flaw dimensions remained essentially unchanged for three successive inspection periods.
In accordance with ASME Section XI, IWB-2420(c), the examination schedule will revert to the original schedule of examinations for this i
component using the manual UT and P Scan UT System.
The Office of Nuclear Reactor Regulations (NRR) agreed with the above evaluation and examinations.
d.
Observations of Work Activitier (73753)
The NRC and IDNS inspectors observed work activities and had discussions with personnel during the ISI activities.
These
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observations included the following:
(1)
EBASCo personnel performing ultrasonic examinations (UT) on
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pipe welds No. C3 and No. C4 in the safety injection system.
The IDNS inspector observed EBASCo personnel performing UT on pipe welds No. RHEC-01, No. CIAL, No. RHX-01 and RHXN-02 in the RHR system.
He also observed UT on pipe weld No.
J11, in the RCS system, and on pipe weld No. SGC-02 in the MS system.
(2)
EBASCo personnel performing liquid penetrant examinations
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l (PT) on pipe welds No. W3, W8, and W9 in the safety injection system.
The IDNS inspector observed EBASCo personnel performing PT on pipe welds No. W-4, No. W-7, No. W-8, No. Jll, No. J12, No. W-22, No. W-25, and No. W-28 in the RCS system.
(3)
B&W personnel performing eddy current examinations on the tubes in the steam generators and B&W, Conam, Zetec and ANA personnel evaluating eddy current examination data.
(4)
CECO personnel performing visual examinations of the reactor vessel internals using an underwater TV camera in conjunction with the use of videotape recorders.
The tapes
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of the following examinations were reviewed in part by the
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NRC inspector:
(a)
Reactor flange I
(b)
Core barrel (c)
Lower core support plates (d)
Guide pins (e) Underside of reactor head No violations or deviations were identified.
3.
Erosion / Corrosion Activities (49001)
Commonwealth Edison Company began their erosion / corrosion (E/C) program at Byron in 1983.
In 1987, CECO established a formalized procedure and administrative controls to ensure continued long-term implementation of j
the E/C monitoring program for piping and components (reference NRC inspection report No. 50-455/92005(DRS)).
For this refueling outage, CECO selected an inspection sample of approximately 49 components, utilizing the EPRI Chec, Checmate computer program. Of the components examined, two were unccceptable. One 16" diameter, carbon steel regulating valve, was replaced in the feedwater system with a Cr-Mo regulating valve, and one 24" diameter tee was repaired in the extraction steam system this outage. The NRC inspector reviewed the E/C program, procedures, NDE certifications, data from previous inspections, and observed MQS personnel performing ultrasonic thickness examinations on piping components in the extraction and feedwater systems.
To date, several components and pipe sections have been repaired and/or replaced as a result of the E/C program. The previous carbon steel piping between the high pressure turbine and high pressure feedwater heaters had experienced E/C. During the last outage, sections of this line were replaced and repaired.
Numerous other components on the line were predicted to require replacement during the next two outages.
Ceco decided to replace the entire line this outage to eliminate future replacement costs. This consisted of approximately 10' of 12" diameter pipe, 70' of 14" diameter pipe, and 130' of 20" diameter piping including elbows, tees and reducers. The material chosen for the change was carbon steel pipe with a stainless steel cladding. The NRC inspector observed the William A. Pope personnel performing cutting, fitting, and welding operations, and visually examined the completed welds.
The NRC inspector also reviewed work requests, drawings, weld data i
sheets and other related documentation.
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4.
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.
An open item i
disclosed during the inspection is discussed in Paragraph 2.c.(2) of
this report.
5.
Exit Interview
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The NRC inspector met with licensee representatives (denoted in Paragraph 1) at the conclusion of the inspection.
The NRC inspector summarized the scope and findings of the inspection activities.
The licensee acknowledged the inspection findings. The NRC inspector also discussed the likely informational content of the inspection report with regard to documents or processes reviewed by the NRC inspector during the inspection. The licensee did not identify any such documents / processes as proprietary.
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