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VIItOINIA ELucritic ANi> I*ownie COMI%NY

nacnwonn.viuonn:A uG261

April 5, 1979

Mr. Harold R. Denton, Director Serial No. 099Office of Nuclear Reactor Regulation P0/KEB:scjAttn: Mr. A. Schwencer, Chief Docket Nos.: 50-280

Operating Reactors Branch No. 1 50-281Division of Operating Reactors License Nos.: DPR-32

U. S. Nuclear Regulatory Commission DPR-37Washington, D. C. 20555

Dear Mr. Denton:

Pursuant to Surry Power Station Technical Specification 6.6.3.aVirginia Electric and Power Company hereby submits its five year inserviceinspection report for Units 1 and 2.

Vepco is presently preparing submittals for updating the Surry Units 1and 2 inservice inspection programs for the final forty month periods of thefirst ten year intervals to the 1974 Edition of the ASME Section XI Code,with Addenda thru the Summer of 1975, as required by 10 CFR 50, Section50.55a(g).

Examination requirements per the ASME Code are being reviewed in lightof existing technology and requests for relief for those specific examinationsdetermined to be impractical will be submitted pursuant to 10 CFR 50,Section 50.55a(g)(6)(i).

Very truly yours,

h. b'), k$ C& Ly4C. M. Stallings

Vice President-Power Supplyand Production Operations

cc: Mr. James P. O'Reilly, DirectorOffice of Inspection and EnforcementRegion 11

S''\%97 9 0 4 0 9 01(c,I

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VIRGIMf A EI.ECTPIC A :D l'0WER CXiPANY

SURRY I'O'JER STATIOh

UNITS 162

FTVE YEAR INSERVICE IMSPECTION SUMMARY REPORT

Inservice inspections during the first five yeact of coime rc ial opera-

tien at Surry Po'rer Statiou Units I and 2 vere performed in accordance withthe Surry Technical Specifications with guidance provided by Section XI ofthe AStiE Boiler and Pressure Vescel Code, 1971 Edition with addenda thru the

summer of 1972.

The arrangeuent and detail of Surry Units 1 and 2 piping systems and

associated components were designed and f abricated before any of the examina--

tion requirements of Section XI of the Code were formalized. Consequently,

the performance of the examinations has been limited to the extent practical

due to accessibility, geometric configuration and metallurgical characteristics.

1:ach inspection outage is summarized herein along with exanination

limitations and results. Detailed reports of the inspections are availnble

at Surry Power Station.

The examinat ions performed during this period revealed no indications

which would af fect safe operation of the units. Typical indications re port ed

strikes, minor gouges, tust andwere damaged and nicked bolt threads, arc

corrosion. The af fected components were either repaired or scheduled forfuture maintenance depending on significance.

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SURRY UNIT I

ISI CONDUCTED FRO:1 FEBi;UARY ]1 THRU 13, 1974

An inservice inspection was performed by Ucst inghouse at Surry Unit 1over the period of February 11 thru February 13, 1974.

Visual and Ultraconic Inspections performed during this outage were onthe Loop "C" nain coolant punp flywheel, the bolt hole ligament areas, theinternal pressure boundary and the main coolcr.t pump bolt s. Inspection ofthe Loop "C" cold leg and hot leg stop valve studs and nuts was also accom-plished.

Tha visual inspections performed on the various items indicated thegeneral condition of all but one item to be satisfactory. One cold leg stopvalve stud, heat nunber 24097, has a circumferential sau-cut of approxumately

inch long by 1/8 inch deep. The notch was cut in an attempt to nake anoneultrasonic angle beam standard. This valve stud was replaced.

The ultrasonic inspections performed were in some cases limited to lessthan 100 percent of the item primarily due to gecaetric configuration. Theultrasonic inspection of the stop valve studs, both h,, and cold legs, wereinspected for approximately fifty percent of their total area utilizing astraight beam inspection frcm the head end of the studs. The center portionof the stud head is the only area where a back reflect ion f rom the oppositeend could be maintained due to the geometric configuration of the oppositestud end. An attempt to inspect the threaded area of the studs utilizing anangle beam inspection from the nonthreaded area of the item proved unsuccess-ful as the reflections from the stud threads were of such a high amplitude,as compared to the available notched standard, that th is inspection wouldnot be meaningful.

An ultrasonic angle beam inspection of the main coolant pump boltsupper four inches of the threaded area appeared to be a very useful inspec-tion. The calibration for this inspection was cccomplished using the bo ltnotched standard supplied by Vepco and a procedure for the optional anglebeam inspection. A straight beam inspection from the threaded end of thebolt was also performed to insure 100 per cent coverage of the bolt threadedarea.

The ultrasonic inspection of the main coolant pump ligament arcasbetween the bolt holes was perforned frca the flange face only. The supplemen-tary examination from the bore side of the pump casing was not performedbecause the pump casing was half full of primary coolant water.

The ultrasonic inspections performed indicated all items tested were insatisfactory condition.

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I SI C0!m0CTED ' RC:t t'0VE!!iW: 1 THRUDECE!H;ER 31, 1974 (lct REFil! l.l k . OUTAGIO

A suanary report of this inspection (Report No. ISI 75-3) was sent tothe NRC via lett er serial no. 409 dated liay 5, 1975.

ISI CONDUCTED FRO: F0VE:fiiER 4 TilRU 9, 1975(2nd REFUEll!L OUTAGE) '

A sumna ry re;iort of this inspection (Report No. ISL 75-0) was sent tothe NRC via letter serial no. 873 dated February 4, 1976.

ISI CONDUCTED FRO?! OCT0"ER 17, 1976 THRUJANUARY 21, 1977 (3rd IM. FUELING OUTAGE'

INTRODUCTION _

An inservice examination of the react or vessel, Class I conponents, certainauxiliary piping systens, sensitized stainless steel piping and designatedwelds of high energy lines was conducted at Surry Unit I fron October 17,1976 thru January 21, 1977. Examinations were performed in acordance withthe Examination Program for Refueling Outage Core III-IV.

Examinat ion precedures were approved prior to the examinations, and certifica-t ions relative to personnel, equipment and viat e rials we re reviewed anddetermined to be satisfactory. Examinations were witnessed by a CodeAuthorized inspector from The Hartford Steam Iloiler Inspection and InsuranceCompany.

RI: SUI.TS

Vepco examinations resulted in numerous indications of arc strikes, weldsplatter, rust and corrosion being found by visual methods en the low headSIS piping (T.S. Item 7.2) and the sensitized stainless stee' piping (T.S.Item 8.1.2). These indications were not judged to be seriou: enough forina.3diate corrective action; therefore were schedulc.d for remwal duringfuture maintenance.

West inghouse examinat ions resulted in a total of 52 reportabic indicationsbeing noted. The term " reportable indication", as applied to Westinghouseinservice inspection, is a broad term reference to which the followingclassification has been assigned to clarify usage.

Indications are classified as follows:

Class 1 - Flaw indication. Exceeds reportable requirements. This classifi-cation requires a repair.A total of 10 indications were in this classification and all were

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repaired to a no indication (NI) condit ion. Six were due todamaged threads on bolts and four were surface indications thatwere removed by light blending or grinding. Refer t o Table 1 for

details.

Class 2 - Flaw ind icat ion. Exceeds reportable requirements and is acceptable.This classification requires a disposit ica. A total of 38 indica-tions are in this classification and the dispositions have beensatisfied. Refer to Table 1 for details.

Class 3 - Flaw indication. Less than reportable requirements --noted for reference univ. This classificat ion is applied to note

flaw areas that might be of interest to future examiners. Thereis one indication in this classification. Refer to Table 1 fordetails.

Class 4 - Ccometric indication. Noted for reference only, this classifica-tion is applied to note geometric indication areas that mightcause interpretation difficulty for future examiners. There aretwo indications in this classification.

Both areas were detected ultrasonically with a 45* beam angle andinvestigated with 45* and 60* beam angles, and with 5 MHZ andwere

dual element high resolution straight be mq transducers to confirmthe lack of flaws.

The weld crown was removed from the indication area of weld 10 onthe 4" pressurizer spray line (T.S. iable 4.2-1, Item No. 8.1.1, UISO VPA044/S) to allow scanning across the weld and half nodeinvestigation.

The indication areas on weld 18 of Loop 2 main steam line (T.S.4.15, W ISO VpA102) produce sicultaneous reficctions from the I.D.and 0.D. with an apparent finw indication between these two.Finger damping of the weld crown affects both the 0.D. signal andthe apparent mid-wall flaw indication. The mid-wall signal iscaused by a mode conversion ( ard the resulting velocity change)due to the 1.D. surface configuration.

.

A review of the appropriate construction radiographa revealed noflaws in or near the areas producing these re flec tors .

Class 5 - Minor indications. Typical or characteristic. Condition isacceptable. This classification is applied to light surfacecorrosion or oxidation, light scratches or grinding marks, smallrounded dents, etc.There are no indications in this classification.

Class 6 - Indications outside of examination zone. Noted for assistanceonly. This classification is applied to indications outside of the1 "T" examination area that are noted or reported as aid orassistance to the construction contractor or owner. There was oneindication in this classification that was repaired to a noindication condition. Refer to Table 1 for details.

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1. IMITATIONS

Sone of the arrangement s and details of the piping cystem and componentsdesigned and fabricated before the acce - and examination requirementswere

of Section XI of the Code could he applied; consequently nome examinationsare limited or nct pract ical due to geor'etric configuration or accessibility.Generally these limitations exist at all fitting to fitting joints such aselbow to tee, elbou to valve, reducer to valve etc., where geometry andsometimes surface condition preclude ultrasonic coupling or access for therequired scan length.

'he limitations exist to a lesser degree at pipo to fitting assemblies,particularly where the weld is not ground flush with the pipe 0.D. surface.

At these joints examin.it ions can be conducted f rom the pipe side, however,the fitting again limits or precludou examination from the opposite side.When the weld surfacc is flat, the fitting side exanunation is replaced by acalibrated ntraight berm examination on the weld as allowed by the Code.

For the reactor coolant pump integrally welded supports visual and surfacee:: amination was substituted for the volumetric examination required by

Section Xi of the Code. This is allowable for Category K items as amplifiedon T.S. page 4.2-13 and Table 4.2-1, item no. 5.6.

For the angr.ented inspection of thee high energy line outs ide the containmentas required by T.S. 4.15, examination of three (3) main steam line welds wasnot perforced due to location within the wall penetration and determinationof inaccessability by inspection personnel.

EXAMINATIONS

Examinations were conducted to review as much of thee examinat ion zone aspract ical, within geouetrical, metallurgical and physical limitations.was

When 100% c,f the required examination could not be achieved, the examinationwas considered to be part ial (PAR) and so noted. Generally PAR's are notedet fitt ing-to-fitt ing acsemblies (as explained under LIMITATIONS) and inareas where integrally velded supports, lugs, or hangers, etc., precludeaccess to sorae part of the excmination area.

Ultrasonic examinations that produced greater than reference level sensitivity,from reflectors th a t are characteristic of metallurgical structure or th eI.D. and 0.D. surfaces of an item were acknowledged only. Examples of areasthat generally produce such geometric indications:

(1) I.D. weld prep or root and or the crown overlay or toe.(2) the I.D. radius of the tube sheet on the channel head to tube

sheet weld of steam generators, when examining from the tubesheetside.

(3) the metallurgical structure of the cast main coolant piping.(4) responses from the thread areas of bolt ing.

Geometric responses from these areas are charact eristic of the examinationand are not considered relevant for report ing lengt h or depth.

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TA3LE 1 -

T.S. TABLE 4.2-1'J CLASS />RCA EXAMII;ED ITEi! I;0. U ISO ITEM DESCRIPTIO!; CONDITIO!!S

1 Reactor vessel closure 1.11 VPA151 Marca clamp cssembly missing base r.etal

he.2d conoscal bolting

1 Steam generator manway 3.5 VPA154 bolts 32,B2,D27,C3 & C7 damnged threads,bolting nicks en chreads

and bolt heads

1 2" CVCS letdown piping 8.2.2 VPA59/S piece 18 1/8" linear indica-tion

1 8" containment spray 8.2.1 VPA74/S piece 32 are strike

ring #1

1 8" containment spray 8.2.1 VPA75/S piece 6B two linear indica-

ring #2 tiens

2 Reactor vessel closure 1.11 VPA151 jacking screw accecblu small nicks

head conoscal bolting

2 Pressurizer nanway bolting 2.6 VPA153 bolts 1-16 minor nicks andgoures on boltheads

2 Steam generator manway 3.5 VPA154 bolts A4,5,8,21,22,23, ninor nicks on

bolting 24,25,26;B4,5.6,25,26; threadsC2,4,5,6,18,20,22

3 Loop A 6" 6 2" SIS 8.2.2 VPA71/S piece 30 small hole in grind car

hot leg piping

6 Loop A 2" SIS cold leg 8.2.2 VPA68/S piece 54 are strike

piping

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S U R RY U N I_T _2._

ISI CO ! DUCTED FROM IUY 13 TllRU 15, 1974

It1SPECT10Il SUMMAhY_

An inservice inspection was performed by U:stinghous, at Surry Unit 2 overthe period of May 13, thru Ilay 15, 1974.

Visual and Ultrasonic Inspections perforra:d during this outage were on th eLoop "C" nain coolant pump flywheel, th- bolt hole lig. ment areas, the

internal pressure boundary and the main coolant pump bolts. Inspection of

the Loop "C" cold leg and hot leg stop valve studs and nuts was also accom-plished.

The visual ins pect ions perforned on the various it e m indicated the generalcondition of all items to be sat is f ac tory.

The uttrasonic inspections performed were in some cases limited to less than100 percent of the item prinarily due to geometric configuration.

The ultrasonic inspection of the stop valve studs, both hot and cold legs,were inspected for approximately fifty percent of their total area utilizinga st raight bene innpoct ion f rom the head end of the ;tuds. The center

port ion of the stud head is the only area where a back reflection frca theopposite end could be maintained due to the geometric configuration of theoppos it e stud end.

An ultrasonic angle beam inspection of the main coolant pump bolts upperfour inches of th readed area was performed. The calibration for thisinspection was accenplished using the bolt notched standard supplied byVEPCO and the procedure for the opt ional cogle beam inspection. A straightbeam inspection from the threaded end o! the bolt was also performed toinsure 100 percent coverage of ths. bolt threaded area.

The ultrasonic inspection of the main coolant pump lignment areas betweenthe bolt holes was performed from the flange face only. The supplementaryexaminat ion f rom the bore side of the pump casing uas not performed because

the pump casing was half full of primary coolant water.

The ultrasonic inspections performed indicated all items tested were insatinfactory condition.

ISI CONDUCTED FROM SEPTEMBER, 1974 THRU JULY, 1975 (OUTAGE CORE I-II)

A summary report of this inspect ion (11eport No. ISI 75-7) was sent to theNRC via letter serial no. 813 dated December 18, 1975.

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ISI ComiUC'I ED FP.DM APRII, 21, 1976 THRUJU:H: 1, 1976 (CD FAG'; CORE II-I]I)

SUI' MARY

Inservice examinations were performed on Class I components, auxiliarypiping systen;, sancitized stainle: s ctcel pipinc., component supports andsupport structurer at Sorry Unit 2 from April 21, 1976 thru June 1, 1976.

Visual, sur f ace and volunatric nondest ruct ive testing methods were utilinedfor the component inspections.

Review and approval of examination procedures, personnel qualifications, UTinstruaunt and calibration, block certifications, couplant certifications,and liquid penetrant cert i fi cat ions , we re completed prior t o st art of theinservice inspection.

On the pressurizer spray line, ultrasonic examinat ions we re performed atreference sensitivity due to high noise level in this specinen. All otherultrasonic examinations were performed at a mininma of 2X sensitivity.

LIli1TATIONS

The piping syntens of the Surry Unit 2 plant contain welds and adjacent basematerial which are inaccessible f or 100'' exami na t ion. Componert configura-tions restricted angle Loam examination of weld and "lT" en each side asrequired by the Code. These weldc. were examined (except uhcre noted other-wise) by the following techniques: (1) 100'4 angle beam of the weld and ITfrom the pipe nide; (2) longitudinal wave inspection of the pipe side, weldmetal and cooponent areas where search unit contact is possible within th eone ucld thickness zone; and (3) part ial angle beam examination from thecomponent side, search unit contact permitting. This technique satisfiescode requiretants for inspection of the weld, but does not inspect baseraet al for IT on component side of the wm ld.

For the react or coolant pump integrally welded support s visual examinationsubstituted for the voltu etric exanination required by Section XI of thewas

Code. This is allowable for Category K items as emplified on T.S. page4.2-13 and Table 4.2-1, item no. 5.6.

INDICATIONS

Visual exaninations resulted in the following report able indications:

Stean Generator "A"Hot and cold nanway bolting inspected revealed thirteen (13) bolts withnicks on threads.

Steara Gene rat or "B"Hot and cold manway holting inspected revealed two (2) bolts with nickson threads.

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Ste.- Cenerat n "C"llot and cold . w ray bolt ing inspected revealed nine (9) bolts w i t. hnicks on th readt .

" chased" and cleaned up and bolts w re re-examinc.1 andThe threads weredet erni end acceptable.

Surface ex mai nat ion s resulted in the following, report able indication:

1. cop "C" Hot Lee liigh !!ead ';IS

Liquid penetreat c ..ca i.na t i c a revealed a tepartable indication on weld#4. Thia indicatian was later r,round, re examined and deteritinedaccept:ble.

Ult ra.4onic examinations resulted in no re po rt :1b l e indicalions.

ISI CONDUCTED FPret SEPTEMBER 13, 1977 THRUOC10HER 8, 1977 (OUTAC) C0!m III -l V )

I MTRf, DUCT IO.N-

An innervice examinat ion of the reactor vessel, Class I components, certainsenqitized st ainlesc steel piping and desinnatedauxiliary piping c ya tt : ,,

weldr. of high energy 1 inns was conducted at Surry Unit 2 from september 13,1977 thru October 8, 1977. Examinat ions were performed in accordance withthe Exaninat ion Progran for Refueling Outage Cote III-IV.

E; amination procedures were approved prior to the examinations, and certifica-tionn relative to personnel, equipu:nt and r:m.c r i a l s were reviewed and

witnet<;cd by a Codedetermined to be satisfactory. Exrninations r re

Aut hor ized Innpector f rom The llart ford Stean Boiler Inspection and Insurance

Company.

RESULTS

The only indicationr, reported within the areas examined during thin outagewere on non-code itens, examined by plant personnel in accordance with th eTech. Spec. Table 4.2-1, Item 7.2.

The indications were detected by visual examinationn and were all evaluatedas being minor and not requiring ircediate correction.

LIMITATIO.NS

So.ne of the arrangements and details of the piping sys tera and componentswere denigned and fabricated before the access and exanination requirementsof Section XI of the Code could be applied; consequently some examinationsare limited or not practical due to geonetric configuration or accessibility.Generally these limitations exist at all fitt ing t o fitting joints such aselbow to tee , cibow to valve, reducer, to valve etc., where geometry andsometimes surface condition preclud" ultrasonic coupline or accesc for therequired scan length.

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Tb- limit at inns exist to a lesser degree at pipe to litting asseublies,part icularly where the w"1d is a<er ground flu ;h with the pipe O.D. curface.At these joints examinutions can he c ondu c t e <' from the pipe side, h o'.m ve r ,the f i t t i n; a- iin lim ts o r p r e e l t N r. examin.ition from the opposite c. i d e .

When the veld su,-face is flat, the fitting side exain; tion is repinced by acalibrated 4trai@ t bcr > excmination on the weld as allowed by the Code.

E X AMIN AT ION _S_

finminations ucre conducted to revi u as much of the cyamination zone as was

prac tical, uith i n gem e t rical, net.il lurgical cod physical liuitations. b'h e n

10fC of the rec uired examinalion ccmid not be achieved, the examination wasi

considered to be pa rt i el (P.\R) and ro noted. Gen" rally PAR's are noted atf i t t ing-t o-f it t ing as sembliec (as explained under LIMITATIOUS) and in areaswhere inter, rally ucided supporte, luna, or hange rs , etc., preclude access tos er..e part of the exanination area.

Ultrasonic exnuinations that produced greater th an re fe rence level sensitivity,frou reflectors that are characteristic of metallurgical structure or the1.D. and or O.D. surfaces of an iten were ackno.iledged only. Examples ofareas that penerclly pro 1uce such geometric indications:

(1) I.D. weld prep or root and or the croan overlay or toe.(2) the 1.D. radiur. of the tche sheet on the channel head to tube

sheet weld of stean generators, vben examining from the tubesheetside.

(3) the retallurgical structure of the cast aain coolant piping.(4) responses f rou the head

Geometric responses fren these areas are charact eristic of the examinationand are not considered relevant for reporting leny,th or depth.

Illtrasonic examinations resulted in no reportable indications.

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