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U.S. NUCLEAR REGULATORY COMMISSION

REGION III

Report No. 50-295/85025(DRS);50-304/85026(DRS)

Docket No. 50-295; 50-304 License No. DRP-39; DPR-48

Licensee: Commonwealth Edison CompanyP.O. Box 767

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Chicago, IL 60690

Facility Name:. Zion Nuclear Power Station, Units 1 & 2

Inspection At: Zion site, Zion, IL

Inspection Conducted: July 16 and 17, 1985

Inspector: W [/ fDate'

Mwb h !Approved By: D. H. Danielson, ChiefMaterials and Processes Section Date

Inspection Summary

Inspection on July 16 and 17 1985 (Report No. 50-295/85025(DRSh50-304/85026(DRS))Areas Inspected: Unannounced safety inspection to review the inserviceinspection program, procedures, and examination documentation from the lastrefueling outages of Units 1 and 2. This inspection involved a total of 14inspector-hours onsite by one NRC inspector.Results: No violations or deviations were identified.

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DETAILS

1. Persons Contacted

Commonwealth Edison Company (CECO)

*C., Schultz, Assistant Technical Staff Supervisor*B. Cascarano, Technical Staff Supervisor*T. Rieck, Superintendent-Services*M. Madigan, Technical Staff Engineer, ISI*M. A. Hansen, Quality Control*W. Stone, Station QA Supervisor

* Denotes those attending either the exit / entrance meetings or both.

2. Inservice Inspection (ISI), Unit 1

a. ISI Program

The inservice inspection for this first period, first outage of thesecond interval started on January 1,1965 and extended throughJune 10, 1985.

The program was developed in accordance with Plant TechnicalSpecifications Section 4.3 and is based on Section XI of the 1980Edition of the ASME B&PV Code including the Winter 1981 Addenda,

b. Procedures

Examinations were performed by Westinghouse Electric Corporation (W)in accordance with the following approved (W) procedures:

OPS-NSD-101, Revision 5.

Preservice/ Inservice Inspection Documentation

NSD-ISI-10, Revision 6.

Qualification of Manual Ultrasonic Equipment

ISI-11, Revision 10.

Liquid Penetrant Examination

ISI-41, Revision 5.

Manual Ultrasoni: Examination of Reactor Coolant Pump Flywheels

ISI-47, Revision 4.

Manual Ultrasonic Examination of Welds in Vessels

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151-70, Revision 2..

Magnetic Particle Examination4

ISI-206, Revision 1.

Manual Ultrasonic Examination of Welds

c. Qualification Records

The inspector reviewed certification records for the NDE examinationpersonnel listed below.

Name Method / Level'

UT PT VT MT4

N. A. Bolling II II II II

J. R. DeMailo II II II"

S. A. Sabo I I I,

| R. R. Sebacher II II II

T. R. Swartz I II IT. L. Stephens II II II

K. E. Ciampa II II IIR

d. Equipment and Material Certification

The certification records of the examination equipment listed belowwere reviewed by the inspector:

(1) UT Instruments

Mfg. Model S/N

Sonic MK-1 08018ESonic MK-1 08078ESonic MK-1 11222ESonic MK-I 05940E

(2) Transducers

Mfg. Size Frequency S/N

Aerotech .5" 2.25 Mhz 40749Aerotech .5x1.0" 2.25 Mhz E24459Aerotech .25" 2.25 Mhz F28232 .

Aerotech 1.0" 2.25 Mhz G07310A,^

Aerotech 1.0" 1.0 Mhz K31339Aerotech 1.0" 2.25 Mhz H04305Panametrics .5" 2.25 Mhz 56757Panametrics .5"x5" 2.25 Mhz 56761.

Panametrics 1.0" 2.25 Mhz H04316'

Panametrics .5"x1.0" 2.25 Mhz J08331'

Panametrics .5" 2.25 Mhz J22943Panametrics 1.0" .5 Mhz P57939

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(3) Ut Couplant

Sonotrace 40 Batch Nos 8337/8448

(4) UT Calibration Blocks (licensee supplied)

I[[ Heat No. Size / Schedule

CWE-3 42794 18" sch. 40CWE-7 D61232 10" sch. 160CWE-10 2876-1-1 8" sch. 140CWE-12 M0937 8" sch. 40CWE-16 M9290 4" sch. 160CWE-28 121707 5 3/4"x7" bolt

(5) Penetrant (PT) Materials (Magnaflux)

Cleaner - Batch No. 84B019/84D024Penetrant - Batch No. 82G111/83F041Developer - Batch No. 83J057/84B091

(6) Magnetic (MT) Materials (Magnaflux)

Magnaflux Power 8A (Red) Batch No. 83H002Magnaflux AC Yoke, Model Y6, S/N-WNSD-002

e. Examination Records

The inspector reviewed the reports identified below of examinationsi performed during this refueling outage in accordance with the ISI

program.,

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Report / Sketch f:o. Weld No.

CWE-1-3100 4.1 S/G.

CWE-1-4100 5, 6, 7, 9, 10, 17, 18, 20.

Reactor Coolant System Piping

CWE-1-4101 1.

CWE-1-4103 3,4,5,6,7,8.

CWE-1-4104 16, 17, 18, 23, 24, 25, 26.

CWE-1-4111 1&2.

CWE-1-4302 41 & 42.

-CWE-1-4502 1.

CWE-2-1100 - 3-9.

CWE-2-2522 62 & 69.

CWE-1-4106 valve IRC 8073A (Bolts).

CWE-1-4112/U52 RCValveIRC8035(studs & nuts).

CWE-1-2100 (Pressurized) 10.

No violations or deviations were identified.

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3. Inservice Inspection, Unit 2

This interval 1, period 3, outage 3 started on March 30, 1984 andextended through July 2, 1984. Class 1 and 2 Components and Piping wereexamined and addy current examination was performed on approximately 900steam generator tubes 100% through the u-bend from the hot leg.

a. ISI Program

The inservice inspection for this refueling outage was performed inaccordance with Plant Technical Specification, Section 4.3 and wasbased on ASME B&PV Code Section XI, 1974 Edition including the i

Summer 1975 Addenda. ,

The program included examinations of welds in the components andpiping listed below:

Class-1

Reactor Vessel.

Pressurizer.

Steam Generators.

Pumps / Valves.

Class-2

Pressure Vessels.

Piping Systems.

Pumps / Valves.i

b. Procedures

The licensee approved Westinghouse examination procedures listedbelow were reviewed by the inspector:

NSD-ISI-10, Revision 4.

Preservice & Inservice Examination Manual UltrasonicEquipment Qualification

ISI-8, Revision 7.

Visual Examination Procedure

ISI-11, Revision 9.

Liquid Penetrant Examination Procedure

ISI-15, Revision 6.

Ultrasonic Examination of Studs, Nuts, and Bolts

ISI-47, Revision 2.

Manual Ultrasonic Examination of Circumferential and LongitudinalButt Welds in Ferritic Vessels of 2 1/2" Thickness and Greater

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151-70, Revision 1.

Magnetic Particle Examination'

ISI-203, Revision 2.

Manual Ultrasonic Examination of Full Penetration Circumferentialand Longitudinal Butt Welds

RV-ISI-01, Revision 1.

Reactor Vessel Inspection Program Preparation and DocumentationI

c. Qualification and Certifications

Certification records of the examination personnel and equipmentlisted below were reviewed by the inspector for conformance to thereferenced codes, standards, and NRC requirements:

(1) Personnel Certifications,

Name Level / Method

UT PT MT VT

R. W. Anderson II II II II i'

M. W. Blew II II II II

M. J. Kemp III III III III'

P. W. Michelson II II II II

S. A. Sabo T T T T

T. R. Swartz I I T T

W. Harris II

J. White II

C. Lindstrom II

J. Taylor II

J. Yost II,

R. Summers II

(2) Equipment and Materials

Ultrasonic Instryments

i Mfg. Model S/N

Sonic MK-1 06208ESonic MK-1 06209E

i Sonic MK-1 07965ESonic MK-1 08683E

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Ultrasonic Transducers

Mfg. Frequency Size S/N

| Aerotech 2.25 Mhz 5"x1.0" D25338.

Aerotech 2.25 Mhz 1.0" G07313A

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+v 4 --- -~ .- ,, n,,, ,-,,,-.r.,,--- , - - - - - , - - ,,-v.- ,, ,--,,,,-a- -,e --w, -- , - , , - , - , ,. - - - - - .,-

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Aerotech 1.0 Mhz 1.0" H25353Aerotech 1.0 Mhz 1.0" K31336Panametric 2.25 Mhz 1.0" P54790Aerotech 2.25 Mhz .500" 40399Panametric 2.25 Mhz .5"x1.0" 49300Panametric 2.25 Mhz .5"x1.0" 49301Panametric 5.0 Mhz .500" 59694Panametric 5.0 Mhz .500" P49773Aerotech 2.25 Mhz .250" F28240Panametric 2.25 Mhz .500" P47183

Ultrasonic Couplant

Sonotrace - Batch No. 8337

Liquid Penetrant Materials (Magnaflux)

Cleaner - Batch No. 81L119/830003Penetrant - Batch No. 82G111/82K019/83F041Developer - Batch No. 820013/83J057

d. Examination Documentation

The reports of examinations performed identified below were reviewedby the inspector:

Sketch No. Com-1-1100 (Reactor Vessel) Weld No. 6.

Ligaments 8-16, 26-30, 42-48.

Sketch No. Com-1-1300 (RV. Closure Head) Welds 1,2,3,4,5,6.

Sketch No. Com-1-1300 (RV Studs & Nuts) 37-54.

Reactor Coolant Piping Welds

SketchNo.Com-1-1400(Loop-1) Welds,16DM,21,22.

Sketch No. Com-1-4200 (Loop-1) Welds, 16DM, 21, 22.

Sketch No. Com-1-4402 (Loop-4) Weld 1 (BC).

Sketch No. Com-2-1310 (RC Filter) Weld 2WS, 3WS.

No violations or deviations were identified.

4. Conclusions

The inspector determined from his review of ISI documentation forthe last Unit 1 & 2 outages, that the examinations performed were inaccordance with the approved inspection program and met the require-ments of the referenced codes, standards, and NRC requirements.

5. Exit Interview

The inspector met with licensee site representatives (denoted in PersonsContacted paragraph) at the conclusion of the inspection on July 17, 1985.The inspector summarized the scope and findings of the inspection notedin this report. The inspector also discussed the likely informationalcontent of the report with regard to documents or processes reviewedduring the inspection. The licensee did not identify any such documents /

l processes as proprietary.7

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