ML20003D915
| ML20003D915 | |
| Person / Time | |
|---|---|
| Issue date: | 02/04/1981 |
| From: | Mcneill W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20003D902 | List: |
| References | |
| REF-QA-99900001 NUDOCS 8104010391 | |
| Download: ML20003D915 (7) | |
Text
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- O-U.5. NUCLEAR REGULATORY CCMMISSICN OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900001/81-01 Program No. 51500 Company
Babcock and Wilcox Comoany Nuclear Materials Division P. O. Box 1260 Lynchburg, Virginia 24505 Inspection Conducted: January 20-23, 1981 Inspector:
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W. M. McNeill, Contractor Inspector Date CcmponentsSection I Vendor Inspection Branch A; Y-' / A -
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II. E. Whitesell, Chief Oate ComponentsSection I Vendor Inspection Branch Summary Inspection on January 20-23, 1981 (99900001/81-01)
Areas Insoected:
Imolementation of 10 CFR 50, Appendix B, including control of special processes, handling, storage and shippings, fuel rod manufacture; periodic management meeting; and followup on previous inspection findings. The inspection involved twenty-six (25) inspector-nours on site by one (1) NRC inspector.
Results:
In the four (4) areas inspected, no apparent nonconformances or unresolved items were identified in t.iree (3) areas, one nonconformance was found in one (1) area.
Nonconformance:
Fuel Rod Manufacture - the metallographic procedure did not nave the same criteria as the specification (as required by the QA Manual and Criterion V of Appendix B (Notice of Nonconformance).
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2 DETAILS SECTION A.
Persons Contacted
- J. L. Brown, Data Evaluation, Sucervisor R. E. Davidson, Metallagraphic Supervisor "W. T. Engelke, Manufacturing Engineering Manager
- J. Ficor, Manager QC
- R. J. Flicker, Supervisor QC Engineer T. E. Ford, Manuf acturing Supervisor A. F. Garnier, Manufacturing Engineer
- L. T. Lee, Manufacturing Foreman
- J. R. Maycerry, Inspection Supervisor
- Denotes those attending the exit interview.
3.
Action on Previous Inscection Findinos (Closed) Follow Uo Item (Report No. 80-02):
Revision of the welder qualification procedure MA 198.
The welder qualification procedure now requires the same or a very similar weldment to be used to qualify.
C.
Control of Soecial Precesses 1.
Obiectives The objectives of this area of the inspection were to verify that special processes are properly qualified and controlled in accordance with Criterion IX, Appendix B,10 CFR 50 and the Quality Assurance Manual.
2.
Method of Accomolishment The preceding objectives were accomolished by:
a.
Review of the Commercial Nuclear Fuel Plant Quality Assurance Manual, Revision 10, Section 9, Control of Special Processes, which estaolished the general requirements for autoclave and corrosion testing.
b.
Review of the specifications pellet type, Zircaloy Clad Fuel Rod, 08-116-03; Zirconium Alloy Structural Tuoing, 08-1006-2, and Zirconium Alloy Tubing, 08-1214-05 wnich established the design requirements.
c.
Review of the procedures, Corrosion Testing Specification, QC-823, Revision 1; and Destructive Samoling of Zircaloy r
i 3
and Stainless Steel Welds, QC-907, Revision 5 which established the specific requirements.
d.
Inspection of the autoclave equipment, loading of samples, pressure gages, temperature charts, reports, visual standarcs, test coupons, and test samples.
Also, the ecuipment used for the water pH and resistivity measurements were inspected.
This verified the implementation of the above requirements and pro-cedures.
3.
Findings a
Nonconformances None.
b.
Unresolved Items None.
D.
Handlino, Storace and Shico'no 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Handling, storage and shipping operations are concucted in such a way as to give reasonaole assurance that damage or/
deterioration will not occur.
I b.
The manufacturer's system meets the requirements of Criterion l
XIII, 10 CFR 50, Appendix B.
2.
Method of Accomolishmant The preceding objectives were accomplished by:
Review of the Commercial Nuclear Fuel Plant Quality Assurance a.
Manual, Revision 10, Section 13, Handling, Cleanliness, Preser-vation, Packaging, Shipping and Storage which established the general requirements for handling, storage and snipping.
b.
Review of specifications Packaging, Shipping, anc Storage Criteria for the Mark B Series Fuel Assembly, Drive Guide, and Succort Plata Assemblies, and Core Control Components, 1185-1271 and Cleanli-ness, 08-1000100-03 and the Contract Information Sheets for a current contract which established the design requirements.
4 c.
Review of procedures Fuel Assembly - Shipping Container Loading and Shipping Inspection, QC-815, Revision 2; Fuel Assembly Packing and Shipping, MA-470, Revision 12; NSC Fuel Assemoly Transfer, Handling and Storage, EH-FA-468, Revision 3; and Fuel Rod cladding, Subassembly and Assembly Handling and Storage, MA 456, Revision, which established specific require-ments.
d.
Inspection of fuel assembly packaging and rod handling and storage activities and verification that the above requirements and pro-cedures have been implemented.
3.
Findings a.
Nonconformances None.
b.
Unresolved Items E.
Fuel Rod Fabrication Controls 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
The fuel rod assemoly and quality control practices and procecures are sufficient to give 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 Accomolishment The preceding objectives were accomplished by:
a.
Review of the Commercial Nuclear Fuel Plant Quality Assurance Manual, Revision 10, Sections 5, " Instructions, Procedures, and Drawings;" 10; " Inspection;" 14, " Inspection Test and Operating Status," which established the general requirements for controls of fuel rod assemblies.
b.
Review of the specification Pellet Type, Zircaloy Clad Fuel Rod, 08-1116-03 and the Contract Information Sheets for a current project which established the design requirements.
5 c.
Review the following procedures which establish specific requirements:
Fuel Rod Inspection (In-Process & Final), QC-802, Revision 1; NSC Fuel Rod Weldment, MA451, Revision 31; NSC Fuel Rod Weldment Rework, MA-458, Revision 11; Welding Operator Qualification (End Cap and Pressure Welding),
MA-494, Revision 1; and Metallographic Examination of Zircaloy Welds, QC-900, Revision 3.
d.
Inspection of the fuel rod welding station, metallographic lab and final inspection station.
In order to verify the above requirements and procedures.
3.
Firidincs a.
Nonconformance See Notice of Nonconformance b.
Unresolved Items None.
c.
Comments The metallographic procedure QC-900 Addendum I states that internal defects within the " minimum wall" are to be evaluated.
The specification states that the defects between the outside diameter and inside diameter are to evaluated.
The difference between " minimum wall" and the inside diameter is 0.002.
How-ever this difference precludes the full weld joint from evalu-ation when one follows the procedure.
One sample #830-37-5, was evaluated by the NRC inspector which contained numerous indications.
These indications were not evaluated by the metalla-graphic lab because they were not in the area of intrest, defined by the outside wall and " minimum wall".
These indications were in the weld joint between the end plug anc the clad wall.
This is an area of high probability of indications and defects.
It was noted that the procedure had been submitted to Design for approval.
This approval was documented on CR-CS-200, Revision 4 This document did not specifically approve the waiver or cnange of a specification requirement.
6 d.
Follow Uo Item The fuel rod specification in section 3.1.2 requires a given level of impurities in the rod gas after pressurization.
Puncture type testing has reportedly been performed, however, time did not permit recovery of this record from the files.
F.
Periodic Management Meeting 1.
Obiectives The objectives of this meeting were to accomplish the following:
a.
To meet with the company management and those persons respons-ible for administrative of the Baccock and Wilcox Co., Inc.
QA program and to reestablish channels of communication.
b.
To redetermine the extent of the company's involvement in the commercial nuclear business, c.
To explain N9C direct inspection program including VIB organiza-tion, inspection methods and documentation.
2.
Method of Accomolishment The preceding objectives were accomplisned by a meeting with Mr.
C. J. Barock, General Manager.
The following is a summary of the meeting:
a.
The VIB organization was described and its relationship to NRC Region IV and the NRC Headquarters component of the Office of Inspection and Enforcement.
b.
The VIB was described including the reasons for i.s establithment, its objectives, its implementation structure.
c.
The conduct of VIB inspections was described and how our inspec-tions are documented including the report, responses to reports, how proprietary information is handled, the Public Document Room: and the White Book.
d.
The company's contribution to the nuclear industry and inspection history were discussed including current and projected activity.
e.
The company quality ascurance program was discussed.
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3.
Findinos No changes have occurred other than personnel since the last meeting.
G.
Exit Interview The inspector met with management representatives (denoted in paragraph A) at the conclusion of the inspection on January 23, 1981.
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.
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