IR 05000454/1985026

Insp Repts 50-454/85-26 & 50-455/85-18 on 850603,19-20 & 24-25.No Violation or Deviation Noted.Major Areas Inspected: Steam Generator Shell Repairs,Welding of Reactor Vessel Internals & Record Review of safety-related Structures

ML20129B499
Person / Time
Site:	Byron
Issue date:	07/10/1985
From:	Danielson D, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20129B481	List: IR 05000454/1985026 ML20129B474
References
50-454-85-26, 50-455-85-18, NUDOCS 8507150530
Download: ML20129B499 (7)

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.U.S. NUCLEAR REGULATORY COMMISSION

REGION III

Reports No. 50-454/85026(DRS);50-455/85018(DRS)

Docket Nos. 50-454; 50-455 Licenses No. NPF-23; CPPR-131 Licensee: Commonwealth Edison Company

. Post Office Box 767 Chicago, Illinois 60690 Facility Name: Byron Station, Units 1 and 2-Inspection At: Byron Site, Byron, Illinois Inspection Conducted: June 3, 19-20, and 24-25, 1985 IN M 7/dYIl~

Inspector: K. D. Ward Date Approved By:

hNb N@ W M D. H. Danielson, Chief 7)/0)/f~

Materials and Processes Section Date Inspection Summary Inspection on June 3, 19-20, and 24-25, 1985 (Reports No. 50-454/85026(DRS);

50-455/85018(DRS))

Areas Inspected: Unannounced special safety inspection of steam generator shell repairs; welding of reactor vessel intervals; record review of safety-related structures; and review of radiographs and reports of field piping welds. The inspection involved a total of 36 inspector-hours by one NRC inspecto Results: No violations or deviations were identifie W h$$ f G

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DETAILS 1. Persons Contacted Commonwealth Edison Company (CECO)

• R. Klinger, QC Supervisor

• G. Briette, QA Engineer M. Lohmann, Assistant Construction Superintendent J. Wo ridge, QA Supervisor J. Porter, Construction Supervisor R. Moravec, Mechanical Supervisor W. Witt, Level 111 NDE Westinghouse Electric Corporation B. Humphries, Mechanical Engineer M. Monkelis, Coordinator Nuclear Installation Services Company (NISCo)

D. Stringer, QA/QC Manager Blount Brothers Corporation (BBC)

R. Bay, QA/QC Manager Nuclear Regulatory Commission (NRC)

J. Hinds, Jr., Senior Resident Inspector The inspector also contacted and interviewed other licensee and contractor employee * Denotes those attending the final exit interview June 25, 198 . Steam Generator Shell Repairs, Unit 2 An ultrasonic examination (UT) was performed on various indications in gerthweldsonUnit2steamgenerators(SG). These indications as reported in the preservice inspection (PSI) were rejectable by EBASCO to ASME Code Section XI requirements. Reexamination of these indications was performed by Ceco to confirm independently their location and the siz The following listing denotes the steam generator, weld and indication locatio S. G. N Weld N Indication Location 2095 SGC-02(tubesheet) 110" CCW 2096 SGC-05 (lower trans.) 212.75" CW 2097 SGC-02 107.25" CW 2097 SGC-06 (upper trans.) 139.25" CW 2098 SGC-06 40.625" CW

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All the indications except the one in SG 2095 were located on or very near to the I.D. surfac A radiographic review of the as built Unit 2 SG welds was made by Ceco in the presence of Westinghouse in Pittsburgh, Pennsylvania. All the radiographs and welds complied to ASME Section Ill. The indications were not of the sizes reported in the baseline UT. Radiographs were also taken for information only of the five areas in November 1983 and were subsequently reviewed by CECO, Westinghouse and the NRC inspector. No unacceptable indications were noted. There were three views of each indication taken, 6* up, 6' down and straight o Core holes, 21" diameter, were machined out of No.1 #095, Weld #SGC02 and No. 3, #2097, Weld #SGC02 and were analyzed by Westinghouse. The final report will be submitted to CECO in the near future. The NRC inspector was informed by CECO that the results revealed that the indications were not as large as the indications previously identified by U Westinghouse excavated only that amount of material necessary to remove the indications in an effort to maintain minimum wall thickness in No. 2,

1. 2096, Weld #SGC05, No. 3 #2097, Weld #SGC06 and No. 4, #2098, Weld kSGC06, these activities were performed in accordance with the ASME Code, Section III,1971 Edition Sumer 1972 Addenda, and Westinghouse procedures and specification The NRC inspector visually exanined the excavated area inside the steam generator No. 4, #2098, found it blended smooth and acceptable. The other areas in the remaining steam generators were not accessible. The NRC inspector also visually examined the 21" diameter core holes in the SGs, threaded holes for the bolts, bolts for the flanges and the flanges and gaskets prior to installatio The NRC inspector reviewed documentation related to the steam generators repairs including Installation / Fabrication Sequence sheets; drawings; NDE records; procedures and specifications. All the indications found by UT were observed being removed in the excavation process. Inspections and audits of these activities were performed by the ANI, (Lumbermens Mutual Casualty Company), CECO, Westinghouse and the ASME Audit Tea The NRC inspector agreed with the actions taken by the licensee. No violations or deviations were identifie . Reactor _Ve_ssel In,ternals, Weldingx Units 1 and 2 Unit 1 The welding is comaleted and the unit is operating. The NRC inspector ascertained that tie weld identification records were established to permit cicar retrieval of accurate weld data in compliance with the ASME Code and licensce's procedure r

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The NRC inspector reviewed related documentation for the welding activities of installing dowel pins in the instrumentation butt columns S/N #07038, weld # E-ST and weld #E-5B, indication removal in instrumentation butt column S/N #07038 and split pin modification The documentation included process control sheets and checklists; NDE records; drawings; weld material requisitions; welders certifications; procedures; and audits by NISCo and CEC The NRC inspector determined that the above activities were performed in accordance with applicable procedure No violations or deviations were identifie Unit 2 The welding is completed and the NRC inspector ascertained that the weld identification records were established to permit clear retrieval of accurate weld data in compliance with the ASME Code and licensee's procedure The NRC inspector reviewed related documentation for the welding activities of replacement of guide tube support pins and clevises and installation of thermal sleeves. The documentation included process control sheets and checklists; weld material requisitions; welders certifications; procedures; NDE records; drawings; and audits by NISCo and CECO. The NRC inspector also observed the reactor vessel internals, visually examining items such as the support colunins, support ring, and guide tube assemblies. The NRC inspector determined that the above activities were performed in accordance with applicable procedure No violations or deviations were identifie . Safety-Related Structures , Weldis- Review o_fJuali_ty,a Re_co_rds ,,,U_n,i,t_2

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The NRC inspector reviewed records for knee brace #1855, #1880, #6AB531-N and #6HB526-R, flange, #6AB176N-4 and cover plate #6AB161 and determined that the records were in conforn'ance with established procedures and that the records reflected work accomplishn'ent consistent with NRC requirements and SAR commitments. The NRC inspector reviewed weld inspection records; NDE records; field changes; drawings; welders certifications; procedures and other related documentatio No violations or deviations were identifie . Review of Radiographs Unit 2 The NRC inspector reviewed radiographs and reports of the following field welds in accordance with the ASME Code, Section 111, 1974 Edition, Sunmer 1975 Addenda, The radiography for the following holds was perfornied by Pittsburgh Testing Laboratories (PTL) and all were found to be acceptable:

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System .Weld N Diameter Thickness Date RT RY-13-7 FW-175 4" 0.531" 11/15/83 RY-13-3 FW-177 4" 0.531" 11/15/83 RY-13-7 FW-176 4" 0.531" 11/15/83 RY-13-4 FW-179 6" 0.719" 07/11/83 RY-13-5 FW-180 6" 0.719" 01/18/84 RY-13-4 FW-178 6" 0.719" 07/11/83 RY-13 FW-113 4" 0.531"/0.521" 10/10/83 l RY-13 FW-123 4" 0.740"/0.531" 01/23/84 SX-42 FW-2693 16" 0.375" 07/15/81 SX-42 FW-2699 10" 0.386" 11/10/81 SX-42 FW-2698 14" 0.375" 08/03/81 SX-42 FW-2697 14" 0.375" 10/28/81 SX-42 FW-2696 14" 0.375" 08/03/81 SX-42 FW-2695 14" 0.375" 08/10/81 SX-42 FW-2694 14" 0.375" 08/05/81 j SX-42-6 FW-2700 10" 0.365" 11/09/81 l SI-37 FW-621 24" 0.688" 02/10/83

! SI-37 FW-622 24" 0.688" 02/24/83 l SI-37 FW-623 16" 0.500" 10/01/82 SI-37 FW-624 16" 0.525/0.500 12/09/82 WO-7 FW-647 10" 0.365" 08/25/81 WO-7 FW-648 10" 0.365" 09/11/81 WO-7 FW-649 10" 0.365" 10/12/81 RD-17E FW-10 12" 0.406" 04/30/80 RD-16E FW-9 12" 0.406" 04/21/80 RD-15E FW-8 12" 0.500" 04/15/80 t RD-13E FW-7 12" 0.406" 03/25/80 RD-12E FW-6 12" 0.406" 01/03/80 51-24 FW-796 4" 0.531" 12/21/82 SI-24 FW-793 4" 0.531" 12/30/82 S1-24 FW-794 4" 0.531" 12/28/82 SI-24 FW-795 4" 0.531" 12/16/82 OG-60 FW-492 3" 0.216" 06/29/82

, OG-60 FW-499 3" 0.216" 05/03/82 i OG-60 FW-491 3" 0.216" 04/26/82 CV-28-3 FW-3692 3" 0.438" 04/15/83 CV-28-3 FW-3694A 3" 0.438" 04/29/83 CV-28-3 FW-3696 3" 0.438" 04/15/83 CV-28-3 FW-3695A 3" 0.438" 06/26/83 CV-28-3 FW-3697A 3" 0.438" 04/21/83 CV-28-3 FW-3699 3" 0.438" 04/20/83 CS-17 FW-196 14" 0.375/0.471" 04/20/82 CS-17 FW-197 14" 0.375" 05/05/82 CS-17 FW-198 16" 0.525/0.375" 02/03/82 CS-17 FW-199 16" 0.525/0.375" 01/28/82 CS-17 FW-200 16" 0.525/0.375" 03/19/82 CS-17 FW-201 16" 0.375" 01/13/82 CC-33-1 FW-894 3" 0.216" 08/10/81 HCC-33-1 FW-893 3" 0.216" 10/01/81 HCC-33-1 FW-895 3" 0.216" 09/29/81 HCC-33-1 FW-896 6" 0.280/0.417" 09/21/81

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l System Weld No. Diameter Thickness Date RT

! HCC-33-2A FW-897 6" 0.419"/0.280" 08/20/81 l CC-33-2A FW-898 6" 0.280" 08/13/81 CS-18 FW-207 16" 0.375/0.525" 06/22/81 CS-18 FW-208 14" 0.375" 06/15/81 C5-18 FW-204 14" 0.375" 09/04/81 CS-18 FW-206 16" 0.375/0.525" 07/08/81 CS-18 FW-205 16" 0.375/0.525" 10/28/82 CS-18 FW-203 14" 0.375" 09/21/81 l CS-18 FW-202 14" 0.375" 09/25/81 l LV03E FW-12 12" 0.406" 12/13/79 LV02E FW-11 12" 0.406" 10/10/79 i LV01E FW-9A 12" 0.406" 02/03/81 l LV01E FW-9 12" 0.406" 11/30/79

) RF-5C FW-13 3" 0.216" 02/10/83 l RF-SC-2 FW-16 3" 0.216" 02/09/83 l RF-5A FW-10 3" 0.216" 06/11/82

RF-5C-2 FW-17 3" 0.216" 02/09/83 H-FSK-318-12 FW-3401 3" 0.216" 09/15/82 H-FSK-318-11 FW-3400 3" 0.216" 09/09/82 H-FSK-318-5 FW-3395 3" 0.216" 04/12/83 H-FSK-318-5 FW-3396 3" 0.216" 09/10/82 H-FSK-318-6 FW-3397 3" 0.216" 09/13/82 H-FSK-318-6 FW-3398 3" 0.216" 09/24/82 H-FSK-318-6 FW-3399 3" 0.216" 09/13/82 H-FSK-318-4 FW-3391 3" 0.216" 09/02/82 H-FSK-318-5 FW-3392 3" 0.216" 09/10/82 H-FSK-318-5 FW-3393 3" 0.216" 03/17/83 H-FSK-318-5 FW-3394 3" 0.216" 09/10/82 S-CV-100-229 FW-3194 2" 0.344" 11/09/82 l S-CV-100-229 FW-3194A 2" 0.344" 12/03/82 l S-CV-100-229 FW-3334 2" 0.344" 12/08/82 i S-CV-100-229 FW-3424 2" 0.344" 11/23/82 S-CV-100-218A FW-3030 2" 0.344" 01/31/83

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S-CV-100-218A FW-3020 2" 0.344" 05/24/83 S-CV-100-218A FW-3021 2" 0.344" 05/02/83 S-CV-100-218A FW-3022 2" 0.344" 04/28/83 S-CV-100-218A FW-3023 2" 0.344" 05/05/83 S-CV-100-218A FW-3024 2" 0.344" 06/17/83 1C-19E FW-3 12" 0.406" 01/03/80 RC-15-1 FW-431 3" 0.438" 06/08/83 RC-15-2 FW-433 3" 0.438" 10/13/81 RC-15-2 FW-432 3" 0.438" 10/13/81 RC-15-2 FW-435 3" 0.438" 10/13/81 RC-15-2 FW-434 3" 0.438" 07/03/83 RC-15 FW-429 3" 0.438" 07/08/83 RC-15 FW-427A 3" 0.645/0.438" 05/24/84 VP-01E FW-5 12" 0.406" 01/07/79 VP-02E FW-8 12" 0.406" 05/09/80 l VP-03E FW-6 12" 0.406" 10/02/79 VP-04E FW-7 12" 0.406" 12/20/79

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o The radiography for the following welds was perfonned by Peabody Testing on the following welds:

System Weld N Diameter Thickness Date RT CS-11 FW-29 6" 0.280" 07/19/77 CS-11 FW-30 6" 0.322" 07/14/77 CS-11 FW-31 6" 0.280" 07/12/77 CS-11 FW-32 6" 0.280" 07/11/77 CS-11 FW-33 6" 0.280" 06/30/77 CS-11 FW-34 6" 0.280" 07/13/77 CS-11 FW-35 6" 0.280" 07/19/77 CS-11 FW-36 6" 0.280" 07/18/77 The NRC inspector also reviewed radiographs and reports of the following field pipe welds in accordance with ANSI B-31.1. These radiographs were performed by PT System Weld N Diameter Thickness Date RT-MS-35 FW-22 32" 1.344" 02/05/82 MS-35 FW-23 32" 1.344" 01/12/82 MS-35 FW-24 32" 1.344" 10/06/81 MS-35 FW-25 32" 1.344" 10/15/81 MS-35 FW-26 32" 1.344" 01/25/82 MS-35 FW-11 41" 1.688" 05/30/80 MS-35 FW-10 41" 1.672" 05/23/80 MS-35 FW-9 41" 1.688" 07/31/81 No violations or deviations were identifie . Exit Interview The inspector met with site representatives (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 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