ML19262C535
| ML19262C535 | |
| Person / Time | |
|---|---|
| Issue date: | 12/20/1979 |
| From: | Mcneill W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19262C533 | List: |
| References | |
| REF-QA-99900005 99900005-79-2, NUDOCS 8002140320 | |
| Download: ML19262C535 (9) | |
Text
.
U. S. NUCLEAR REGULATORY COT!ISSION OFFICE OF INSPECTION AND ENFORCEMEh7 REGION IV Report No.
99900005/79-02 Program No. 51500 Company:
Westinghouse Electric Corporation Nuclear Fuel Division Box 355 Pittsburgh, Pennsylvania 15230 Inspection at: Columbia, South Carolina Inspection Conducted:
November 26-30, 1979 Inspectors:
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O/ Y W. M. McNeill, Contractor Inspector Date ComponentsSection I Vendor Inspection Branch 7
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Approved:
D. E. Whitesell, Chief Date ComponentsSection I Vendor Inspection Branch Summary Inspection November 26-30, 1979 (99900005/79-02)
Areas Inspected:
Implementation of Topical Report and other applicable codes and standards, including document controls, enrichment and impurity controls, fuel rod manufacture controls, review of manufacturing activities, and action on previous inspection findings.
The inspection involved thirty (30) inspec-tor hours en site bv one NRC inspector.
Results:
In five (5) areas inspected, no apparent deviations or unresolved items were identified.
80 0214023 2 CD
2 DETAILS SECTION A.
Persons Contacted
- W. H. Britton, Chemical Operations Manager
- J. R. Bush, Quality Control Manager D. W. Campbell, Inspection Supervisor
- H. J. Corey, Inspection Manager
- R. R. Cost, Operations Product Assurance Manager R. Dereani, Manufacturing Supervisor G. S. Gantt, Chemist
- M. J. Jump, Analytical Services Manager
- L. P. Kays, Plant Operations Product Assurance Manager R. L. Kesterson, Q. C. Engineer F. Kulas, Inspection Supervisor A. M. Legrand, Chemist A. D. Parent, Q. C. Engineer J. R. Rosier, Maintenance Supervisor B. R. Stamper, Mechanical Drafting Manager
- C. E. Vogel, Q. C. Engineering Manager W. L. Wall, Q. C. Records Manager
- J. L. Werner, Q. C. Engineer H. V. Whitaker, Chemist
- R. J. Wiggins, Mechanical Operations Manager D. Yeo, Process Engineer
- Denotes those attending the Exit Interview.
B.
Actions on Previous Inspection Findings (Closed) Unresolved Item (Report No. 79-01):
An inconsistency exists on the pellet drying temperature range established by the process speci-fication, and the operating procedures.
The operating procedure 82-05-02-02 has been revised (Revision C) to be consistent with the process specification.
3 C.
Document Controls 1.
Objectives The objectives of this area of the inspection were to verify that:
The fuel manufacturer's document control system for design, a.
manufacturing, and quality assurance documents is consistent with Regulatory requirements.
b.
The document control system includes all drawings, specifi-cations, procedures, instructions, etc., which affect quality.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the Westinghouse NFD Topical Report WCAP-7800, a.
Revision 5-A, Section 6, Document Control, and Policy and Procedure P-007, Revision 1, Document Control.
b.
Review of Product Assurance Manual, Section 2.6.1, Document Control, Revision 3, and the Quality Control Manual, Section 6.1, Document Control, Revision 4, which established the specific requirements of document control.
Review of the following Quality Control Instructions (QCIs) c.
which established additional specific requirements of document control:
QCI-000105, Revision 7, Control and Distribution of Quality Control Instructions, QCI-000129, Revision 4, Specification Review and Approval, QCI-000117, Revision 4, Job Order and CQAR Review Acknow-ledgement and Implementation, QCI-000109, Revision 9, Engineering Change Notice (ECN) and Specification or Drawing Revisic; 51gn-off, QCI-000122, Revisica 5, Single Drawing Subverification and, QCI-000147, Revision 7, Control and Distribution of Quality Control Instructions.
d.
Review of the following Manufacturing Manual procedures which established additional specific requirements of document control:
4 MM-1, Revision 11, Engineering Design Drawing and Material /
Product Specification Control and, MM-13, Revision 9, Engineering Change Notice.
Observation of a sample of twenty-three (23) QCIs and e.
drawings.
These were found in the fuel assembly grid, fuel rod, and component inspection areas.
The sample was veri-fied to be properly issued, reviewed, distributed, and approved.
f.
Two (2) recer. changes to drawings and QCIs were followed to verify that procedures were followed.
3.
Findings a.
Deviations None b.
Unresolved Items None D.
Enrichment and Impurity Controls 1.
Objectives The objectives of the inspection were to verify that:
Material flow procedures and practices cover manufacturing a.
operations for all inputs of material in any form from UF6 tc completed pellets.
b.
Enriched material is controlled, inspected and checked at each stage during manufacturing and processing to prevent enrichment mixup or contamination.
Sufficient final enrichment checks and chemical analyses c.
are made on pellets or rods to detect any significant enrichment deviations or contamination, and to give assurance that the pellets and rods meet specifications and contractural requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
5 Review of the Westinghouse NFD Topical Report WCAP-7800, a.
Revision 5-A, Secti.on 5, Instructions, Procedures, and Drawings:
Section 11, Test Control; Section 14, Inspection. Test, and Operating Status which established the general requirements for enrichment and impurity controls.
b.
Review of the Product Assurance M:nual, Sections 2.5.1, Procedures and Instructions, Revision 1.
Review of the Quality Control Manual, Section 5.1, Instructions, Procedures and Drawings, Revision 6; Section 10.1, Inspection, Revision 4; Section 14.1, Inspection and Test Status, Revision 3; which established the specific requirements of enrichment and impurity controls.
c.
Review of Product Specification, Uranium Dioxide Pellets, NFP-31029, Revision 14, and Process Specification, Manu-facture of Uranium Dioxide Pellets, NPS-80030XL, Revision 22, which established the design requirements.
d.
Review of the following Quality Control Instructions (QCIs) and Chem Lab Procedures (C0CLs) which established additional specific requirements of enrichment and impurity controls:
QCI-910211, Revision 16, UO, Pellet Chemistry and Isotopic
- Sampling, C0CL-1, Revision 5, Direct Reading Emission Spectremetry Determinations of Metallic Impurities in Uranium Compounds, C0CL-2, Revision 1, Nitrogen in UO Using a Nitrogen Deter-2
- minator, C0CL-5, Revision 6, Spectrochemical Determination of Rare Earth in Uranium, COCL-11, Revision 5, Determination of Carbon in Uranium Qxides, C0CL-15, Revision 6, Determination of Uranium and Oxgen-Uranium Ratio in Uranium Oxides (ignition method),
C0CL-17, Revision 5, Determination of Isotopic Composition of Uranium by Thermal Emission Mass Spectrometry, and C0CL-19, Revision 4, Determination of Flouride in Uranium Qxides by Specific Ion Electrode.
6 Witness the testing and review of log books of testing and e.
calibration / standardization for the above tests and verified compliance to procedures for four (4) recent lots of pellets.
f.
Review the records of testing for a recent region of fuel and verified compliance to the procedures.
3.
Findings a.
Deviations None b.
Unresolved Items None E.
Fuel Rod Fabrication Controls 1.
Objectives The objectives of this area of the inspection were to verify that:
The fuel rod assembly and quality control practices and a.
procedures are sufficient to give reasonable assurance that manufactured fuel rods meet specifications and contractual requirements.
b.
The manufacturer's system is capable of producing quality fuel rods.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the Westinghouse NFD Topical Report WCAP-7800, a.
Revision 5-A. Section 5, Instructions, Procedures, and Drawings: Section 10, Inspection; Section 11, Test Control; Section 14, Inspection Test, and Operating Status which established the general requirements for fuel rod manu-facture controls.
b.
Review of the Product Assurance Manual, Section 2.5.1, Procedures and Instructions, Revision 1.
Review of the Quality Control Manual, Section 5.1, Instructions, Procedures, and Drawings, Revision 6; Section 10.1, Inspection, Revision 4; Section 14.1, Inspection and Test Status, Revision 3; which established the specific requirements of fuel rod manufacture.
7 Review of Product Specification, Fuel Rod Assemblies, c.
NFP-31036, Revision 12, and Process Specification, Fab-rication of Uranium Dioxide Fuel Rod Assemblies, NPS-80314GA, Revision 15, which established the design requirements.
d.
Review of the following Quality Control Instructions (QCIs) and Operating Instructions (SOIs) which established add -
tional specific requirements of fuel rod manufacture controls:
QCI-927101, Revision 20, Fuel Rod Process Control.
QCI-924101, Revision 39, Fuel Rod Dimensional and Visual Inspection, S0I-R-0294, Revision A, SOI-R-0328, Revision A, S0I-R-0330, Revision A, and S0I-R-0331, Revision A.
Observation of fuel rod fabrication on four (4) of five (5) e.
fabrication lines and verification of compliance to the above procedures on loading, plugging and welding.
f.
Observation of the QC inprocess and visual and dimensional inspections of fuel rods and verification of compliance to the above procedures.
3.
Findings a.
Deviations None b.
Unresolved Items None.
F.
Review of Manufacturing Activities 1.
Objectives The objectives of this area of the inspection were to review the work load in terms of existing capacity, identification of principal contracts and unique dif.2rences between contracts in fuel assembly design, manufacture, and QC/QA requirements In addition, the objectives were to identify any systematic or
8 generic problems with fuel fabricated by the manufacturer.
- And, the objectives were to identify anticipated changes in fuel manu-facturing and processing or in scope of supply.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Discussion with management and technical personnel on the a.
above subjects.
b.
Observation of shop manufacturing activities on the above subjects.
3.
Findings a.
Deviations None b.
Unresolved Items None c.
Comments 1.
No significant changes have occurred in the workload nor are any changes anticipated in the scope of supply.
2.
Two problems were discussed via conference call with NFD Engineering (E.A. Bassler, R. A. Nadler, J. R. Schettig).
Westinghouse has experienced a high rate of failure of the RCC fingers at the Salem site.
The failuro appears to be stress corrosion cracking at the end of the finger.
It was reported that the stress corrosion was a result of two factors.
A tight tolerance on thread run out of the RCC finger.
The control rods thread into the fingers.
The failures were cracked at the end of the finger allowing the rod to separate from the RCC spider.
In addition to the tight tolerance which caused frequent rework of the threads a lubri-cant was being used in the final assembly of RCCs which was s
9 halogenated.
The failures were also limited to two received lots of fingers.
The tolerance had been opened some time ago and more recently the lubricant has been removed from use.
An engineering review of this pro-bleia by NFD established no safety significance to the problem.
3.
The second problem discussed was the grid damage incurred during handling at Salem site.
In moving of fuel during reload, damage was incurred due to grid-to-grid interference.
It appears that this problem is related to handling vari-ables in speed of movements, etc.
NFD has changed its Field Specifications on speeds, load cell set points, etc.
Like the finger problem discussed above an NFD Engineering review established no safety significance to this problem.
G.
Exit Interview The inspector met with management representatives (denoted in para-graph A) at the conclusion of the inspection on November 30, 1979.
The inspector summarized the scope and findings of the inspection.
The management representatives had no comment in response to each item discussed by the inspector.