ML19269E295

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{{#Wiki_filter:. O One First National Plaza. Chicac Commonwealth Edison Address Reply to: Post Office Box 767 Chicago III:nois 60690 June 20, 1979 Mr. A. Schwencer, Chief Operating Reactors Branch #1 Division of Operating Reactors U.S. Nuclear Regulatory Commission Washington, DC 20555

Subject:

Zion Station Units 1 and 2 Feedwater Nozzle Inspection and SteEm Generator Water Hammer Evaluation NRC Docket Nos. 50-295 and 50-304

Dear Mr. Schwencer:

As a result of the cracking observed in the feedwater lines at the D.C. Cook Units 1 and 2, Commonwealth Edison Company during a recent mini-outage inspected via radiographs the Zion Unit 1 feedwater nozzles. An examination of the Zion Unit 1 radiographs indicated a dark band at the intersection of the ramp and the counterbore of the nozzle. No other indications were observed. This dark band indicates a reduced section thickness which is most probably a groove resulting from the machining of these nozzles. The reduct. ion in section thickness is believed trivial in comparison to the loading on this member. Since the feedwater pipe cracking observed at other plants occurred at a similar location in the pipe weld preparation, it is important to resolve this apparent anomaly. As a result, Commonwealth Edison will obtain a satisfactory explanation from the fabricator or perform a boroscope examination during the Fall 1979 Unit refueling outage. The subject radiographs, together with D.C. Cook radiographs, have been viewed by NRC Region III inspectors. The Zion Unit 2 feedwater nozzles will be radiographed during the Spring 1980 refueling outage or at an earlier date if an unexpected cold shutdown outage occurs. It should be noted, however, that certain design differences between the Zion units and those with detectable flaws suggest that Zion is less prone to this type failure. The Zion nozzle and -pipe are Schedule 120 whereas the affected units have Schedule 60 or 80. r/av: 00I$ Y pfag S'ys 13 e Re e.v e s s iji ,nadvs 2t34 016 e e4 906270/77 /

Commonwealth Edison NRC Docket Nos. 50-295/304 Mr. A. Schwencer: June 20, 1979 Per recent discussions with you and members of your staf f, Commonwealth Edison has reviewed steam generator ater hammer experience at Zion station to ascertain what modifications are necessary to bnprove the reliability of the feedwater system piping of the Zion units. To date, certain steam generators have, experienced the majority of the water hammers at Cion Station. The steam generators involved are those with the longest pipe lengths at the same elevation as the nozzles. Steam Generator 2C was one of these steam generators and in March 1978 J-tubes were installed in this steam generator. Since installation, there have been no Unit 2 water hammers. Similarly, Unit 1 experience has indicated that J-tube installatici is merited primarily on the 1C Steam Generator and to a lesser extent 13 Steam Generator. Commonwealth Edison's curret.t outage plans includa installation of J-tubes on the 1C Steam Generator during the Fall 1979 refueling outage and on the 1D Steam Generator during the Fall 1980 refueling outage. In addition, Commonwealth Edison studies indicate that installation of J-tubes in the remaining five (5) steam generators would be beneficial, as a precautionary measure, to alleviate the severity and frequency of water hammers even though experience demonstrates that these steam generators are not prone to water hammers. Thus, Ccamonwealth Edison confirms the verbal commitment made to you on June 8, 1979 that J-tubes will be installed in all the Zion Station steam generators. However, the J-tubes will be installed at the rate of one steam generator per refueling outage to minimize installation costs and ALARA considerations, as outlined below. The cost of installation excluding lost generation is approximately $200,000 per steam generator. By coinciding installation with refuelings, the cost of lost generation is minimized. illustrates the financial impact associated with multiple steam generator modifications in a given outage. ote that if more than one steam generator is modified at each refueling outage, the financial impact increases by 12.5 to 67 times that associated with a single modification. In addition, an approximately 9 man-rem exposure is associated with each steam generator modification. Thus, multiple modifications may be limited by the availability of the skilled labor force necessary to perform the modifications primarily due to increases in annual worker exposures and/or other labor demands within the region. O 2134 017

Commonwealth Edison NRC Docket Nos. 50-295/304 Mr. A. Schwencer: June 20, 1979 Commonwealth Edison also feels that an accelerated schedule for installing J-tubes is not necessary for the following reasons. 1. Analyses of the Zion piping system inc.icate that the safety related portions of the feedwater piping can withstand the most intense credible water hammer. These analyses were previously transmitted to the NRC (see Feedwater System Transient Analysis, Zion Station, dated January 6, 1979 and Water Hammer Analysis For Main and Auxiliary Feedwater Systems, dated January 8, 1979 both by Sargent & Lundy Engineers.) 2. Although the Zion units have experienced several water hammers, no damzge to safety-related piping has occurred. Minor damage to snubber mountings has been observed in non-safety related portions of the feedwater piping located in the turbine building. The damage was most probably due to water hammer shocks transmitted out of the containntent building. 3. Water hammers do not appear to be a factor in the pipe cracking observed at other plants. This observation is based on information involving D.C. Cook Unit 2 in which pipe leaks were found in the feedwater to steam generator nozzle pipe connections. This unit, which has installed J-tubes, has e::perienced no water hammers. The recent 7 ion Unit 1 inspection showed no evidence of indications in tnis weld joint. Finally, with regard to raising the set-point for steam generator water level actuation, Commonwealth Edison is currently evaluating such a change in light of all plant operations and transient and accident conditions that could be affected by such a change. The results of this evaluation will be forwarded to you within thirty (30) days. Very truly yours, Cardell Reed Assistant Vice-President attachment 2134 018

ATTACIIMEl T 1 j Financial Impact Associated with Multiple Steam Generator Modifications Time Added to Cost of Cost Per Number Modified Refueling Outage Lost Power

  • SG Modification Por Refueling Outage (Mecks)

($) [1) 1 0 0 200,000 2 1 2,100,000 1,250,000 3 5 10,500,000 3,700,000 4 6 12,600,000 3,350,000

  • Assume Differential Fuel Cost ='$300,000/ day N

-p= O 4}}

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