IR 05000455/1986018
| ML20207G432 | |
| Person / Time | |
|---|---|
| Site: | Byron  |
| Issue date: | 07/18/1986 |
| From: | Danielson D, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20207G409 | List: |
| References | |
| 50-455-86-18, NUDOCS 8607230072 | |
| Download: ML20207G432 (7) | |
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U.S. NUCLEAR REGULATORY COPNISSION
REGION III
i Report No. 50-455/86018(DRS)
Docket No. 50-455 License No. CPPR-131 i
Licensee: Consonwealth Edison Cortpany Post Office Box 767 Chicago, IL 60690 Facility Narre: Byron Station, Unit 2 Inspection At: Byron Site, Byron, IL Inspection Conducted: June 18-19, 24-25, 30, July 1 and 10, 1986
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7 /f!/Z Inspector:
. D. Ward wn Approved By:
D. H. Danielson, Chief 7//f/I4
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Materials and Processes Date Section
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_ Inspection Summary
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Inspection on June 18-19 24-25, 30, July 1 and 1_0_,1986 (Repor_t
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No. 5 ~ Inspected: Unannounced, routine safety inspection of radiographs of
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shop and fwd welds and resolution of previous inspection findings.
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Results: No violations or deviations were identified.
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i DETAILS 1.
P_ersons Contacted Commo nwe al _th_ Ed i s o n__C ompa ny__( C E C o )
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- R. Klingler, Project QC Supervisor R. Moravec, Project Mechanical Supervisor E. Martin, QA Superintendent J. Woldridge, QA Supervisor J. Porter, Construction Supervisor
~A. Rosenback, QA Supervisor W. Witt, NDE Supervisor E, Briette, QA Engineer E. Wolber, QA Inspector i
EBASCO Service _s, In_corpo_ rated _, (E_ BAS _C0J
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T. Pederson, Level III, NDE
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Nuclear Regulatory,CommissionJRCl
J. Hinds, Jr., Senior Resident Inspector i
P. Brochman, Resident Inspector J. Malloy, Resident Inspector The inspector also contacted and interviewed other licensee and contractor employees.
- Denotes individual attending the final exit interview on July 10, 1986.
Personnel Attending the June 26 1986 Meeting at the Braidwood Station
'C~. Milito, System MateiTaWXsa'Iysis Naiiager,TECo R. Gaitonde, Supervisor, Staff Engineer, CECO i
W. Witt, NDE Supervisor, CECO
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D. Christiana, Mechanical Engineer, CECO j
D. Rupert, Welding Engineer, CECO
R. Schofield, Project Construction Engineer, CECO
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D. Zebrauskas, ISI Engineer, CECO
.I B. Wilson, NDE Level III, CECO T. Haaker, NDE Level III, CECO
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T. Green, NDE Level II, CECO
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A. Adamiec, NDE Level II, CECO D. Chrzanowski, PSI /ISI Coordinator, CECO M. Sears, PSI /ISI Technical Staff, CECO K. Franczak, NDE Level II, PTL/ Ceco W. Caldwell, ANII, Hartford Steam Boiler Inspection and Insurance Company 1-i E. Sullivan, Materials Engineer, NRC/NRR G. Johnson, Materials Engineer, NRC/NRR S. Lee, Materials, NRC/NRR B. Brown, Sr., Engineer, NDE, EG8G/INEL (NRC Consultant)
K. Ward, Reactor Inspector, NRC/RIII
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Licensee Ac_ tion on Prev _io_us Insp_ection Items (Closed) Unresolved Item (455/85031-01): Data reports for Weld No.
2RC03AD271J12 did not clearly reflect the extent of the weld joint volume which had been ultrasonically examined.
Further review of the licensees'
ultrasonic data by the NRC NDE van personnel revealed that the cast
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stainless steel elbows in the primary piping system were not scheduled for complete ultrasonic examinations.
CECO and NRC _Mee_tig
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i A meeting was held June 26, 1986, at the Braidwood Station between CECO and the NRC (See Paragraph I for attendees) to address the ultrasonic examination
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of cast stainless steel component welds. There was a brief description of the procedure qualification program for the following items:
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Calibration Blocks Mock up Transducers Equipment Owner's Group Samples Personnel Training Status of Inspection at Byron Unit 2 and Braidwood Unit 1 Schedule for Remaining PSI
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Cast stainless steel elbows were available at the cancelled Marble Hill
j plant. CECO personnel visited Marble Hill on January 7,1986, and examined nine statically cast elbows. One 31 inch to 29 inch reducing elbow was
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j selected as having comparable attenuation to that of the Byron /Braidwood castings. This elbow had the greatest variation of attenuation and had an
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area that had the highest attenuation of all the elbows examined. This elbow was purchased from Marble Hill for processing into calibration standards. Four calibration standard blocks were machined from this elbow; two from the 29 inch diameter end (2.34 inch thickness) which had lower overall attenuation and two from the 31 inch diameter end (2.83 inch thickness) which had higher attenuation. Both axial an circumferen-tial side drilled holes (S.D.H.) and inner diameter notches were machined into each block. The S.D.H.'s were 3/16 inch diameter and were located at 1/4,1/2 and 3/4T locations. The inner diameter notches were machined to 10%, 25% and 50% through wall depths. The first set of calibration standards (one from the 29 inch end and the other from the 31-inch end)
were sent to Krautkramer Branson (KBA) and the second set was shipped to
Harrisonics Labs approximately three weeks later.
KBA and Harrisonics Labs were requested to build search units producing optimum results on the 10% and 25% deep inner diameter notches. Available EPRI reconvrendations on the design of the search units were also supplied to the manufacturers.
KBA made a set (consisting of one unit for the axial scan and one for the circumferential scan) of search units for each block.
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l Each search unit consisted of two 1.0" dia X 1.0 MHZ, Alpha series flat-faced i
transducers mounted on contoured, removable wedges that produce an approxi-mate 40 to 45, dual, refracted longitudinal wave focused near the block
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inner diameter surface. Harrisonics Labs optimum search unit design was very similar to KBA's, but had cylindrically focused transducers mounted i
on wedges that produce an approximate 40, refracted L-wave.
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Using KBA supplied search units, examinations were conducted by CECO on both calibration blocks using several different UT instruments. The UT instruments available were: Nortec 131, Sonic Mark 1, Krautkramer USIP 11 and Panametrics EPOCH 2022. The EPOCH 2022 machine produced the best signal-to-noise ratios (at 0.5 MHZ filter) on the 10% and 25% inner diameter notches. The USIP 11 and Mark 1 were adequate, but not as good as EPOCH 2022. The Nortec 131 was found to be inadequate for angle beam examination.
With regard to the search units, several interesting observations were made.
The search units optimized for the 29 inch diameter calibration block (lower attenuation) also produced optimum results on the 31 inch diameter calibration block (higher attenuation). The second observation was that despite attenuation differences between the two blocks, approximately the same results were obtained regarding the background noise (10% to 20%
screen height at the reference sensitivity) and the signal-to-noise ratio.
Partial examinations were conducted by CECO at Braidwood Unit 2 on 9 welds of loop No. 1 using the EPOCH 2022 and the KBA transducers.
These prelim-inary examinations showed strong, but intermittent and sometimes continuous signals at the inner diameter. These signals, attributed to grain structure and/or inner diameter geometry, were similar to the ones obtained from the 10% inner diameter notch.
Based on this developmental work and the preliminary examination of some welds on Braidwood Unit 2, a procedure was written for the preservice examination of weldments in the cast stainless steel components and fittings at Byron Unit 2 and Braidwood Units 1 and 2.
This procedure was used to examine only the cast side (s) of the reactor coolant systems welds. The welds examined were categorized as follows:
Forged reactor nozzle safe-end - to - cast elbow welds Steam generator nozzle - to - cast elbow welds Forged pipe - to - cast elbow, pump or valve welds Cast elbow - to - cast pump or valve welds There are approximately 50 welds of these types in each reactor coolant system at Byron Units 1 and 2 and Braidwood Units 1 and 2.
CECO conducted a plant tour for the meeting attendees pointing out welds on an elbow to steam generator nozzle, a pump to elbow, a pump to pipe and a valve to elbow that would be ultrasonically examined. CECO also performed UT on a valve to pipe weld and a pump to pipe weld. These examinations were conducted in accordance with ASME Section XI, 1977 Edition, Summer 1978 Addenda, Paragraph IWA-2240 and CECO Procedure NDT-C-38 Revision 0.
The ultrasonic technicians are trained on calibration blocks and a mock-up of a pipe weld using an EPOCH 2022 instrument and CECO's NDE Procedure NDT-C-38, Revision 0, prior to performing UT on the component welds in the-system. The NRC inspector observed some of the training conducted at Byron.
CECO plans to start ultrasonicly examining the welds en Byron Unit I during the next outage.
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_0bservation_ o_f_JJ1trasoni_c E_xami_ nations (UT)
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The NRC inspector observed UT on a forged safe end to cast elbow weld, (Line No. 2RC03AB-27.5," Weld No. J12) and a forged pipe to cast elbow weld (Line No. 2RC03AB-27.5," Weld No. J11). The calibration and the recording was also observed. The NRC inspector also reviewed the program,
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procedure, data, material and personnel certifications.
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Two of CECO's Level III's, an EBASCO Level III and the NRC inspector reviewed several radiographs of welds in which UT indications were.
observed. The NRC inspectors review of the radiographs and the UT results for these welds, concluded that the welds met applicable ASME Code requirements. The actions taken by the licensee were acceptable.
No violations or deviations were identified.
4.
Radiographic Review
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j The NRC inspector reviewed radiographs and reports of the following welds:
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Contractor Component /_Sys_ tem Shop Weld Thickness Date of RT PDM Reactor Pool Seams 105M2 3/16" 6/29/79 PDM Reactor Pool Seams 105M4 3/16" 6/29/79 PDM Reactor Pool Seams 105M3 3/16" 6/29/79 PDM Reactor Pool Seams 286M5 3/16" 11/28/78 PDM Reactor Pool Plug
3/16" 6/12/78 PDM Reactor Pool Seam
3/16" 6/12/78 PDM Reactor Pool Plug
3/16" 5/30/78 PDM Reactor Pool Seam SM 3/16" 6/28/79
PDM Reactor Pool Seam 288M3 3/16" 2/15/79 PDM Reactor Pool Seam 288M1.
3/16" 8/24/78 PDM Reactor Pool Seam 288M2R 3/16" 8/24/78
PDM Reactor Pool Seam 288M2L 3/16" 8/24/78 PDM Reactor Pool Seam
3/16" 5/17/78
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PDM Reactor Pool Seam
3/16" 5/17/78 PDM Reactor Pool Seam
3/16" 5/17/78
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PDM Reactor Pool Seam
3/16" 5/17/78 PDM Reactor Pool Seam
3/16" 5/17/78 PDM FW-76-1 Pipe W-2 2.75" 6/30/80 i
PDM FW-76-1 Pipe
2.75" 6/30/80
PDM FW-76-1 Pipe
2.75" 6/30/80
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PDM FW-76-1 Pipe
2.75" 6/30/80 l
PDM FW-76-1 Pipe
2.75" 6/30/80 PDM FW-76-1 Pipe
2.75" 6/30/80 Taylor Forge L/R 90 ELL
0.480" 1/2/75
Taylor Forge L/R 90 ELL
0.480" 8/26/77
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l Taylor Forge L/R 90 ELL
0.480" 8/26/77 l
Taylor Forge L/R 90 ELL
0.480" 8/26/77
.i Taylor Forge L/R 90 ELL
0.480" -
8/26/77 i
Tay1or Forge L/R 90 ELL
0.480" 8/26/77
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Taylor Forge L/R 90 ELL
0.450" 9/9/77 i
Taylor Forge L/R 90 ELL 12-6-40 0.450" 9/9/77 Taylor Forge L/R 90 ELL 12-6-41 0.450" 9/9/77 Taylor Forge L/R 90 ELL 12-6-42 0.450" 9/9/77-l Taylor Forge L/R 90 ELL 12-6-44 0.450" 9/9/77 Taylor Forge L/R 90 ELL 12-6-45 0.450" 9/9/77 Taylor Forge L/R 90 ELL 12-6-46 0.450" 9/9/77
Taylor Forge L/R 90* ELL 12-7-49 0.450" 9/9/77 Taylor Forge L/R 90* ELL 12-7-55 0.450" 9/9/77
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Taylor Forge L/R 90 ELL 12-8-57 0.450" 9/9/77 Taylor Forge L/R 90 ELL 12-8-59 0.450" 9/9/77 Taylor Forge L/R 90' ELL 12-8-60 0.450" 9/9/77 Taylor Forge L/R 90 ELL 12-8-61 0.450" 9/9/77
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Graver Tank Spray Additive Tank 1Al-1 1/2" 7/20/77
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Graver Tank Spray Additive Tank 2Al-1 1/2" 7/20/77 i
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Southwest Fab.
FW-71-6
.W-2 0.438" 12/17/79 Southwest Fab.
FW-71-6 W-3 0.438" 12/17/79 Southwest Fab.
FW-71-6 W-4 0.438" 12/17/79 Southwest Fab.
FW-71-6 W-5 0.438" 12/17/79 i
Southwest Fab.
51-34-6 W-2 0.906" 6/17/80 i
Southwest Fab.
SI-34-6 W-3 0.906" 6/17/80 Southwest Fab.
51-34-6 W-4 0.906" 6/17/80 Southwest Fab.
SI-34-6 W-7 0.906" 6/17/80 Southwest Fab.
FW-74-7 W-2 0.300" 6/18/80 Southwest Fab.
FW-74-7 W-3 0.300" 6/18/80
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Southwest Fab.
FW-74-7 W-4 0.300" 6/18/80 Southwest Fab.
FW-74-7 W-5 0.300" 6/18/80
PTL S-CV-100-2198 FW-3057 0.344" 12/19/82 PTL S-CV-100-219B FW-3058 0.344" 1/30/84 PTL S-CV-100-219B FK-3059 0.344" 7/29/83 PTL S-CV-100-219B FW-3060 0.344" 7/29/83 PTL S-CV-100-229 FW-3185 0.344" 11/4/82
PTL S-CV-100-229 FW-3183 0.344" 1/31/83 PTL S-CV-100-229 FW-3183A 0.344" 2/11/83 i
PTL S-CV-100-229 FW-3184 0.344" 4/16/82
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PTL FW-24 FW-67 1.812" 9/2/81
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PTL FW-24 FW-174 1.812" 10/1/80 PTL FW-24 FW-172 1.812" 10/3/80
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PTL FW-24 FW-68 1.812" 10/27/81 PTL FW-24 FW-66 1.812"
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PTL FW-24 FW-65 1.812" 9/9/81 PTL CS-15 FW-85 0.345" 9/29/81 PTL CS-15 FW-83 0.345" 4/29/83 PTL CS-15 FW-248 0.365" 7/18/81 PTL CS-15 FW-86 0.365" 8/11/81 PTL CS-15-7 FW-247 0.365" 11/24/81 PTL CS-15-8 FW-424 0.345" 2/16/83 PTL CS-15-9 FW-425 0.345" 11/10/81
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PTL AF-24 FW-249 0.438" 1/8/82 PTL AF-23 FW-260 0.438" 2/8/82 PTL AF-21 FW-273 0.438" 10/30/81 PTL AF-22 FW-311 0.438" 12/10/81 PTL AF-23 FW-255 0.438" 2/2/82 No violations or deviations were identified.
5.
Exit Meeting The inspector met with site representative (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 inspector report with regard to documents or processes reviewed by the inspector during the inspection. The licensee did not identify any such documents /
processes as proprietary.
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