ML20028G006
| ML20028G006 | |
| Person / Time | |
|---|---|
| Issue date: | 01/13/1983 |
| From: | Barnes I, Mcneill W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20028G001 | List: |
| References | |
| REF-QA-99900005 NUDOCS 8302070307 | |
| Download: ML20028G006 (7) | |
Text
ORGANIZATION: WESTZNGHOUSE ELECTRIC CORPORATION NUCLEAR FUEL DIVISION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION INSPECTION NO.:
99900005/82-02 DATES 11/16-18/82 ON-SITE HOURS:
22 CORRESPONDENCE ADDRESS: Westinghouse Electric Corporation Nuclear Fuel Division ATTN: Mr. W. M. Jacobi, General Manager P. O. Box 355 Pittsburgh, PA 15230 ORGANIZATIONAL CONTACT: Mr. R. R. Cost, Operations Product Assurance Manager TELEPHONE NUMBER:
(412) 373-5105 PRINCIPAL PRODUCT:
Nuclear fuel and steam generator tubing.
NUCLEAR INDUSTRY ACTIVITY:
Nuclehr fuel and steam generator tubing supplier for Westinghouse designed cores.
ASSIGNED INSPECTOR: # 8c-
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W. M. McNeill, Reactive and Component Program Date Section (R& CPS)
OTHER INSPECTORS:
APPROVED BY:
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/-,3-pr I. Barnes, Chief, R& CPS Date INSPECTIUN BASES AND SCOPE:
A.
BASES: Westinghouse Topical Report WCAP 7800/5A.
B.
SCOPE: Manufacturing process control; nonconformance and corrective action; and control of special processes.
PLANT SITE APPLICABILITY:
Not identified.
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( p L' i, i 8302070307 930118 PDR GA999 EMVWEST 99900005 PDR
ORGANIZAT10N: WESTINGHOUSE ELECTRlC CORPORATION NUCLEAR FUEL DIVlS10N BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION N0.:
99900005/82-02 RESULTS:
PAGE 2 of 4 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
1.
Contrary to Section 5 of the Topical Report and Specification No. NFP 31008, paragraph 3.3.1 and Table 1, there was no evidence of the submittal to and approval by the purchaser of the procedures for the outside surface finish process, inside surface finish process, chemical composition testing, and tensile testing.
s 2.
Contrary to Section 5 of the Topical Report and the Quality Procedure, QC-300, paragraph 2.1, manufacturing at the time of this inspection did not have the latest revision of Customer Specification No. NFP 31008 listed on the QCF-3003 form in reference to Order No. 548H20313.
3.
Contrary to Section 5 of the Topical Report and the Specification No. NFP 31008, paragraph 3.2, the identity of some material with respect to ingot melt number and lot number was not maintained at all stages of manufacture as evidenced by:
a.
Two tubes of lot No. F73 2266 were found to have been mixed with lot No. F73 2257 which is from a different ingot melt number and heat treat lot number. These two tubes had been reworkad on traveler card G 13448, and b.
In addition to the above, another tube in lot No. F73 2257 could not be accounted for by comparing inspection records with the actual piece count of the lot.
4.
Contrary to Section 5 of the Topical Report and the QA Program Manual, paragraph 5.2, the quality procedures did not include the practice and application of "T tags" which are used to make engineering dispositions of nonconforming material.
5.
Contrary to Section 5 of the Topical Report and the Quality Procedure, QC-103, paragraph 3.2.1, form QCF-1030 information has not been supplied by inspectors to their supervisors, although above normal reject rates have occurred.
C.
UNRESOLVED ITEMS:
None
~
dRGANIZATION: WESTINGHOUSE ELECTIRC CORPORATION NUCLEAR FUEL DIVISION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION NO.-
99900005/82-02 RESULTS:
PAGE 3 of 4 D.
OTHER FINDINGS OR COMMENTS:
1.
Manufacturing Process Control - A review was made of the Westinghouse Nuclear Fuel Division (W-NFD) Topical Report, Specialty Metals Plant QA Program Manual, inspection procedures, General Order Nos. 548H20313 and 548H20321, Specification No. NFP 31008, Drawing No.1683C8C, and Process Outline No. PEF-3564.
It was noted that the Water Reactor Division's Topical Report WCAP-8370, " Quality Assurance Plan," more fully describes the Specialty Metals Plant than the W-NFD Topical Report WCAP-7800. The Specialty Metals Plant recently was incorporated into W-NFD after being a separate Water Reactor Division.
It would appear that a revision of WCAP-7800 is needed to reflect the current organizations.
One requirement (paragraph 3.3.4 pertaining to end conditioning of tubes) of Specification No. NFP 31008 was deleted in Revision 16 and then reintroduced in Revision 17 without apparent approval by an Engineering Change Notice.
In addition, requirements for cobalt, manganese, and uranium 235 were rer.oved from Revision 17 also without apparent approval by an Engineering Change Notice. This will be further reviewed at the W-NFD Coh:mbia Plant. The purchaser (Columbia Plant) reportedly has begun to revise NFD 31008 to correct these and other errors.
The failure to submit and obtain approval of some procedures was identified as a nonconformance (see B.1 above).
The requirement for procedural submittals and approval was initially instituted in regard to inside surface finish and tensile testing in Revision 17 of the specification. Procedure submittal with respect to tensile testing appears to have been an error.
It was noted that Revision 17 had been issued October 11, 1982; however, at the time of the inspection, it had not been officially identified on the shop floor.
This was identified as a nonconformance (see B.2 above).
The file for lot No. F73 2266 which was recently processed through the last inspection operations was reviewed. The traveler or follower cards, DA tags, and rework tags associated with the lot were inspected.
It was noted that 2 of the 176 tubes were mixed into another lot (F73 2257), and review of that lot established that not all of the 431 tubes had supporting inspection records.
This was identified as a nonconformance (see B.3 above).
In addition, the ultrasonic (UT) nondestructive examination records were reviewed for lot No. F73 2266, and all tubes were found to be accepted.
The use of current procedures, approved visual standards, and calibrated equipment was verified. The documentation of inspection i
on follower cards, use of proper acceptance criteria, sampling l
frequencies, and compliance with the process outline were verified.
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0'GANIZATION: WESTINGHOUSE ELECTRIC CORPORATION R
NUCLEAR FUEL DIVISION BLAIRSVILLE, PENNSYLVANIA REPORT INSPECTION NO.:
99900005/82-02 RESULTS:
PAGE 4 of 4 2.
Nonconformance and Corrective Action - Topical Report WCAP-7800 and the quality procedures were reviewed. The control of noncon-forming and reworked materials was observed on the shop floor.
The computer reports of trend analysis for the past 3 months were reviewed.
It was noted that during early September 1982,end squareness and sonic inspection of the "C" type fuel tube had excessive reject rates, but an above normal reject / scrap investigation report form QCF-1030 was not issued in either case.
This was identified as a nonconformance (see B.5 above).
The corrective action procedure appears to be in need of revision and clarification, in that corrective action is undertaken when three conditions occur; i.e., quality cost input, reject rate investigation, and returned material.
It is not clear how the trend analysis data is used or how inspectors determine above normal reject rates.
"T tags" are used to enable materials to be reinspected and scrapped.
Also, "I tags" are used to accept material identified as nonconforming by an inspector. A review of the inspection procedures found that the dispositioning of material by "T tags" was not addressed in procedures except for a procedure for one station. The tags could be used at a number of stations. This was identified as a nonconformance (see B.4 above).
3.
Control of Special Processes - The ultrasonic flaw and dimensional inspection was witnessed and conformance to the process specification and procedure verified. The certificatica of the personnel and standards used was verified.
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Coltans:
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Drawing 5.
Purchas Drifer 1.
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Spectfication 6.
Internal ifemo 2.
Type of Document-3.
procedure 7.
l.etter 3.
Date of Document 4.
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Revision (If appilcalile) l
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