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Insp Rept 50-455/85-31 on 851015-25 & 28-1107.No Violation Noted.Major Areas inspected:safety-related Piping Weldments Fabricated to ASME Code,Section Iii,Classes 1 & 2
	ML20138L086
Person / Time
Site:	Byron
Issue date:	11/26/1985
From:	Harris R, Kerch H, Lodewyk A, Wiggins J; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:	;
Shared Package
ML20138L083	List: IR 05000455/1985031; ML20138L081;
References
	50-455-85-31, NUDOCS 8512190163
	Download: ML20138L086 (26)
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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

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Report No. 50-455/85-31 Docket No.

50-455 License No.

CpPR-131 Priority Category A

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Licensee: Commonwealth Edison P.O. Box 767 Chicago, Illinois 60690 Facility Name: Byron Station Unit 2 Inspe:: tion At: Byron, Illinois Inspection Conducted: October 15-25 and October 28 - November 7, 1985 Inspectors:

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Approved by:

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6!/5 Jamel 'T. Wiggggg), Chief Date Matei1als and W ocesses Section Inspection Summary:

Inspection on October 15-25 at Region I office and October 28 - November 7,1985 at Byron site (Report No. 50-455/85-31)

Areas Inspected: A routine, announced NRC independent measurements inspection was conducted using the NRC Mobile Non-destructive Examination (NDE) labora-tory. Selected safety related piping weldments fabricated to ASME Code, Sec-tion III, Classes 1 and 2 were inspected. Three region-based inspection per-sonnel assisted by two NRC NDE contracted personnel were utilized during this inspection.

_The inspection involved 462 onsite hours and 104 offsite hours.

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Results: No violations were identified.

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DETAILS 1.

Persons Contacted Commonwealth Edison

R. Tuetken Startup Superintendent

V. I. Schosser Project Manager

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L. Martin, QA Superintendent

J. L. Woldridge QA Supervisor

G. Sorensen Project Construction Manager

B. E. Harl Staff Assistant QA

J. T. Porter Construction Supervisor R. Friedel PCD

R. J. Moravec Project Mechanic'al Supervisor E. Wolber QA Inspector M. V. Della Betta QA Supervisor R. B. Klingler Project QA Supervisor EBASCO

J. Sengenberger PSI /ISI Site Supervisor Pittsburgh' Test Lab. (PTL)

J. Becker Site Manager G. Schmolze Assistant Manager

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U.S. NRC J. M. Hinds Senior Resident Inspector

K. D. Ward Reactor Inspector

P. G. Brochman Resident Inspector

Attended exit meeting.

2. 0 Independent Measurements - NRC Nondestructive Examination and Quality Records Review of Safety Related Systems:

During the period of October 15 - 25, 1985 quality records received from Byron Nuclear Power Plant, Unit 2 were reviewed in the Region I office for completeness and for compliance to the licensee's FSAR commitments to ap-plicable codes, standards and specifications.

Subsequently, an onsite independent verification inspection was conducted during the weeks of October 28 through November 7, 1985 using the NRC Mobile Nondestructive Examination (NDE) laboratory. This inspection was

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performed by NRC Region I personnel in conjunction with NRC contracted NDE personnel.

The purpose of this examination was to verify the adequacy of the licen-see's welding Quality Control program.

This was accomplished by dupli-cating those examinations required of the licensee by regulations and codes, and evaluating the results.

In addition to those examinations, several other confirmatory examinations designed to verify conformance with material specifications were performed and compared to quality as-surance records.

'The NRC inspectors performed the examination on randomly selected weld-ments representing samples of piping systems, components, pipe sizes, shop and field weldments fabricated to ASME,Section III Code.

The items selected were previously inspected and accepted by the licensee, as indicated by vendor shop and onsite QA/QC records.

2.1 Quality Documents Review Forty-seven safety related piping systems documentation packages, covering the items shown in Attachment #3, were reviewed. The review also included other documents which provided background information and acceptance criteria necessary for the conduct of the inspection.

The following documents were reviewed:

Document Attributes Reviewed Material Certifications (CMTRS)

Material chemical and phys-(Base)

ical (Base) properties were compared to standards and code requirements.

NDE Records Examinations were verified to meet codes and standard re-quirements, licensee proced-ures and other commitments.

Personnel were verified to be properly qualified. Appro-priate examinations were performed.

Fabrication Records A review of fabricators, traveler and fabrication rec-

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ords was conducted and

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these records were compared against other corresponding records and sign off sheets.

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Drawings (Isometrics)

Drawings were reviewed for design of weldments, lo-cation and classification.

Procedures Procedures were reviewed for completeness, and to verify the implementation of the licensee's commitments to code requirements.

Welding Material Material certifications for welding materials were reviewed to determine if physical and chemical prop-erties were as required by licensee's commitments to codes and industry standards.

Results: No violations were identified.

2.2 Nondestructive Examination Nondestructive examinations were performed using NRC procedures with addenda written specifically to comply with the licensee's PSAR commitment.to the ASME B&PV Code. The intent of these examinations was to duplicate, to the extent practicable, the techniques and methods of the original examinations.

The following nondestructive examinations were performed:

Radiographic Examinations Thirty-six (36) safety related pipe weldments were radiographed using an-Iridium 192 source. The technique and procedure'were in accord-ance with NRC procedure, NDE-5, Rev. O and addendum BR-2-5-1, Rev. O.

The weldments examined were ASME Class I and 2.

The resulting ra-diographs were evaluated per applicable code requirements and com-pared to the licensee's corresponding radiographs.

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During a field walkdown of Southwest Fabrication and Welding Co.

spool piece RH-14-1 the inspector noted two (2) weldments on the spool piece identified as weld W2 by the weld stamps. The Inspector then reviewed the documentation packages for these two welds and found that there were, in fact, two separate packages, each labeled as weld W2. However based on a review of the data in these packages, the inspector determined that correlation between each weld package and its associated weld was possible.

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The inspector. then reviewed the Southwest Fabrication and Welding Co's drawings for this spool piece and found that a pipe modifica-tion had been made and new identification numbers had been assigned to the above identified spool piece.

Weld W2.on the manufacturers records sheet for spool piece Q6050 RH-60RR (R4-14-1) was reassigned and replaced with weld W7. On November 7, 1985 the licensee issued letters to Hunter Corp. and Ebasco Services Inc. which directed changes to be made to the site drawings to reflect actual conditions found on spool piece. This item is considered unresolved pending completion of drawing changes and NRC verification (50-455/85-31-01).

Results:

No violations were identified.

Liquid Penetrant Twenty-six (26) safety related pipe weldments and adjacent base ma-terial (h" either side of weld) were examined using color contrast

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liquid penetrant techniques per NRC procedure NDE-9, Rev. O and ad-

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dendum BR-2-9-1, Rev. O.

Samples included ASME Class 1 and 2 stain-less steel type-316 and 304.

Results: No violations were identified.

Thickness Measurements Twenty-two (22) pipe weldments and adjacent base materials were ex-amined for wall thickness using a NOVA-D 100 digital thickness

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gage.

Examinations were performed per NRC procedure NDE-11, Rev. O.

Minimum wall thickness was determined by use of ASTM standard pipe size and nominal thickness chart.

Results:

No violations were identified.

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Ferrite Measurements:

Eleven (11) safety related pipe weldments were checked for delta ferrite content using a Type II ferrite indicator (Severn Gauge).

This test was intended to verify that welding filler metal composi-tion had achieved adequate as-deposited microstructure with delta ferrite content adequate to eliminate possible hot cracking.

Results:

No violations were identified.

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Visual Examination:

Forty-nine (49) safety related pipe weldments were visually examined per NRC procedure NDE-14, Rev. O.

The examinations were performed using visual aids such as lights, mirrors and English welding gages.

Examinations were performed to determine the general condition of the. piping weldment and the adjacent surfaces specifically checking for reinforcement, cracks, misalignment or other rejectable visual indications.

Results: No violations were identified.

Ultrasonic Examination:

Two (2) safety related pipe weldments were examined ultrasonically using a Sonic Mark I ultrasonic flaw detector per NRC procedure NDE-1 Rev. O and Ebasco Ultrasonic data sheets UT-A-23 and UT-A-33.

The weldments identified were 2RH01AB-12" J3 and 2RH01AB-12" J35 as indicated on UT data sheets.

Instrument calibration was performed using NRC procedure NDE-2, In-strument linearity verification. Distance Amplitude Correction (DAC)

was constructed using Ebasco Calibration Block 12-A-316-1.08-1.

In-strument settings and search unit (transducer) were matched as closely as possible to those indicated by UT data sheets in an at-tempt to duplicate the original examination.

During the ultrasonic examination and review of the ultrasonic data reports it was noted that the associated data did not reflect the proper contour, or thickness of the area for the actual welds tested.

Also during this review, the data reports referenced a Delta tech-nique which had been used to determine the ultrasonic beam angle within the material. An inquiry was made to see if there was an approved procedure that referenced the use of this delta technique.

The licensee was unable to furnish any procedure or other reference to this technique.

The inspector expressed concern over these two findings to the

~1icensee. The licensee agreed to review these concerns.

Results: This area is considered unresolved pending completion of the licensee's review of the above described NRC concerns.(50-455/

31-03).

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Alloy Analyzer:

Four (4) safety related pipe weldments and adjacent base material were examined using a Texas Alloy Analyzer. The Alloy Analyzer is

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capable of making selected qualitative and quantitative nondestruc-tive analysis of metal alloys and verification of material types.

Results: No violations were identified.

Hardness Measurements:

Eleven (11) safety related pipe weldments and adjacent base material were tested using the Equo-tip hardness tester per NRC procedure NDE-12, Rev. O.

Measurement values taken from the impact device are processed into "L" values as a digital read out; the numbers ("L" values) are then converted to Brinell hardness values and approximate tensile strength by means of a conversion table.

Results: No violations were identified.

Magnetic Particle Examination:

Six (6) safety related pipe weldments and adjacent base materials were examined by the magnetic particle method per NRC procedure NDE-6, Rev. O and addendum BS-2-6-1.

Samples examined were ASME Code Class 2.

Results: No violations were identified.

3.0 Review of'NDE Procedures The following NDE procedures were reviewed to verify their technical

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adequacy and conformance to code requirements:

Pittsburgh Testing Lab (PTL)

Magnetic Particle Examination QC-MT-2 Rev. 5 Liquid Penetrant Testing QC-PT-1 Rev. 9 Radiographic Examination QC-RT-1 Rev. 11 Southwest Fab.

Magnetic Particle Examination MT-3 Rev. O Liquid Penetrant PT-3 Rev. O Radiographic Examination RT-74-2 Rev. O Results: No violations were identified.

4.0 Radiographic Review A sampling of the licensee's radiographs was reviewed. The inspector reviewed radiographs for twenty shop welds and one hundred and six field welds to verify compliance with ASME III code requirements, accuracy of radiographic film interpretation and the adequacy of the licensee's ra-

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diographic program. Twenty-six of the welds were re-radiographed by the NRC during this inspection and the NRC film was compared to site file film to independently verify that correct radiographic file film was on hand (see Attachment #2, line items with asterisk).

During review of radio-graphic films for welds 2H-FSK-57-7 FW54R1 and 2HFSK-57-8 FW55, the in-spector noted that each film contained an apparent indication which was not properly documented on the licensee's radiographic reader sheet.

In response to these findings the licensee and NRC performed an ID surface check to resolve the indications. The welds were found to contain ID mismatches which should have been documented on the radiographic inspec-tion reports. The inspector determined, however, that the actual welds were acceptable to code requirements. The NRC had no further concerns.

Results: No violations were identified.

5.0 Preservice Inspection (PSI) Program The inspector reviewed various PSI ultrasonic data reports. Data reports for weld 2RC03AD27hJ12 did not clearly reflect the extent of the weld joint volume which had oeen ultrasonically examined. The weld joint data sketch illustrated the volume required to be examined by the ASME code.

However a thorough review of the data by the inspector revealed that 25%

of the ASME code required volume had not been examined for this weld.

Discussions with the ISI vendor personnel indicated that he had known the exact extent of the volume which had been examined. To avoid confusion, the licensee should consider methods to more clearly show the extent of the weld examined.

Further review of the licensee ultrasonic data revealed that the cast stainless steel elbows in the primary piping system were not scheduled for complete ultrasonic examinations (see Attachment #4 for listing of welds and extent of examinations). A meeting was conducted on November 5, 1985, with the licensee regarding the cast stainless steel elbow ultrasonic examinations and Steam Generator ID girth indications. This meeting did not resolve these issues. On November 7, 1985, the inspector held a phone conversation with a representative of NRR: MTEB regarding the examinations of the primary loop elbows. The outcome of this conversation was NRR's intent that the licensee perform the required ASME code examinations for each of the cast stainless steel elbow welds and subsequently report the examination results.

Results: The NRC concerns regarding clarification of the PSI records and the examination of the cast stainless steel elbow welds remain unresolved pending licensee's evaluation and subsequent NRC review (50-455/85-31-02).

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6.0 Attachments Attchment No. 1 is a tabulation of the specific items examined and the results achieved. Attachment No. 2 is a list of specific radiographs reviewed. Attachment No. 3 is a list of specific document packages reviewed. Attachment No. 4 is a list of welds and extent of examination.

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Attachment #5 is a list of attendees to a meeting to discuss cast elbow examinations.

7.0 Unresolved Unresolved items are those for which more information is necessary for the NRC to determine whether the items are acceptable, violations or deviations. Unresolved items are contained in paragraph 2.2, and 5.0.

8.0 Exit Interview An exit interview was held on November 7, 1985 with members of the licen-see's staff. The inspector summarized the scope and findings of this inspection. No written material was provided to the licensee during this inspection.

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ATTACHMENT 4 Page 1 of 2 CAST STAINLESS ELBOW AREA DESCRIPTION EXTENT OF VOLUMETRIC EXAMINATION Loop A 27h" 2-Pipe to Elbows Pipe Side only 29" 1-Steam Generator to Elbow SG side only 2-Elbow to Valve No Volumetric 31" 1-Steam Generator to Elbow SG side only 4-Pipe to Elbow Pipe side only 1-Elbow to Pump No volumetrics

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ATTACHMENT 4 Page 2 of 2 Lcop C

_31" 1-Steam Generator to Elbow SG side only 4-Pipe to Elbow Pipe side only 1-Elbow to Pump No volumetrics Loop D 27h" 2-Pipe'to Elbow Pipe side only 29" 1-Steam Generator to Elbow SG side only 1-Elbow to Valve No volumetric

31" 1-Steam Generator to Elbow SG side only 4-Pipe to Elbow Pipe side only 1-Elbow to. Pump No volumetrics Material Elbows Cast Stainless Steel SA-351-CF8A

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ATTACHMENT 4 Page 2 of 2 Loop C 31"'

1-Steam Generator to Elbow SG side only 4-Pipe to Elbow Pipe side only 1-Elbow to Pump No volumetrics Loop D 27h" 2-Pipe'to Elbow Pipe side only 29" 1-Steam Generator to Elbow SG side only 1-Elbow to Valve No volumetric

31" 1-Steam Generator to Elbow SG side only 4-Pipe to Elbow Pipe side only 1-Elbow to Pump No volumetrics

' Material Elbows Cast Stainless Steel SA-351-CF8A

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ATTACHMENT 5 BYRON PROJECT CONSTRUCTION / NUCLEAR REGULATORY COMMISSION MEETING OF NOVEMBER 5, 1985 Attendance Name Title Organization R. P. Tuetken Start-Up Superintendent Ceco. Byron Station Ram Gaitonde Supervising Staff Engineer Ceco. System Material Analysis Department W. W. Witt-General Supervisor NDE Ceco. System Material Analysis Department R. Moravec Lead Mechanical Engineer Ceco. Project Construction Department D.'Christiana Mechanical Engineer Ceco. Project Engineering Department J. Porter Construction Supervisor Ceco. Project Engineering Department H. Kerch Lead Reactor Engineer USNRC RI K. Ward Lead Reactor Engineer USNRC RIII

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IR 05000455/1985031

Text

REGION I

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