ML20129F851

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Insp Rept 99990001/96-05 on 960830.No Violations or Deviations/Noncompliance Noted.Major Areas Inspected: Organization & Scope of Activities,Personnel Training & RP, Matl Inventory & Independent Measurements
ML20129F851
Person / Time
Issue date: 10/11/1996
From: Kinneman J, Oberg C
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20129F776 List:
References
REF-QA-99990001-961015 99990001-96-05, 99990001-96-5, NUDOCS 9610290224
Download: ML20129F851 (17)
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Text

.-. -.

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i U.S. NUCLEAR REGULATORY COMMISSION REGION I INSPECTION REPORT Report No. 999-90001/96-005 j

i Docket No. 999-9001 License No. General License Licensee:

No_rth American Refractories Co.

251 East Memorial Avenue Womelsdorf, Pennsylvania 19576-9603 Facility Name: North American Refractories Co.

Inspection At: Womelsdorf, Pennsylvania Inspection Conducted: August 30, 1996 N/A Inspector:

/v C. Thor Oberg, H

'Physjcist date" Approved By:

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Nuclear M terials Safety Branch 2

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Divisi of Nuclear Materials Safety Inspection Summary: Specias, Announced Inspection Conducted August 30, 1996, of activities performed pursuant to the general license in 10 CFR 40.22, and to review the status of disposition of source material in excess of 10 CFR i

40.22 limits (Inspection Report No. 999-90001/96-005).

j Areas Inspected: Organization and scope of activities; personnel training and radiation protection; material inventory; and independent measurements.

Results: No violations were identified. One non-cited violation was identified:

the licensee identified that they exceeded the possession limits for source material specified in the general license of 10 CFR 40.22, and began immediate corrective actions which were completed following the inspection. The licensee reduced the amount of source material on site by shipping the raw material, baddeleyite (zirconium dioxide), containing uranium and thorium to a licensed facility and to warehouses for distribution to customers (Sections 4. and 6.).

RETURN ORIGINAL TO REGION I 9610290224 963c.13 REC 1 GA999 E*******

99990001 PDR

$ v is v i o 7 z *l j

i DETAILS

1. Persons Contacted
  • George S. Robinson, Plant Manager
  • Mark R. Cauffman, Manager Training-Safety-Health Environmental Leider Kleinfelder, Union Representative Various plant workers
  • those present at the exit interview
2. Organization and Scope of Licensed Activities NARC 0 produces refractories from various metallic ores and oxides as raw i

materials. One of these is baddeleyite, a form of zirconium dioxide, that contains about 595 parts-per-million (ppm) of source material.

Baddeleyite is sintered (pressed and heated or " fired") to form zirconia (another form of zirconium dioxide) products as heat resistant items used in furnaces and smelting operations. The zirconia and products contain about 480 ppm of uranium (U) and thorium (Th).

These materials are possessed and used i

pursuant to the general license described in 10 CFR 40.22.

Mr. George Robinson is the Plant Manager for North American Refractories Co. (NARCO). Mr. Mark Cauffman, Manaoer of Training for Safety, Health, and the Environment, reports to Mr. Robinson and provides training for the NARC 0 workers.

No safety issues or violations were identified.

1 i

3. Personnel Training and Radiation Protection During June of 1995, Mr. Cauffman provided training to all of the hourly, and most of the salaried, employees. The training was entitled ZETTRAL INSTRUCTIONS AND PRECAUTIONS (see outline presented in EXHIBIT A) and provided information on the baddeleyite raw material, named ZETTRAL by the licensee. The training consisted of specifying that there is radioactivity in the baddeleyite on site, the types of radiation and that which w given off by the raw material, and the major hazards from this radioactive material (inhalation or ingestion of dust). Typical dust levels were discussed for air samples taken during press compacting operations.

For a breathing period of one year, 2000 hours0.0231 days <br />0.556 hours <br />0.00331 weeks <br />7.61e-4 months <br />, an individual could be exposed to about 25% of the Derived Air Concentration (DAC) or less depending on the time necessary for a given operation.

Several instructional items were specified to reduce possible radiation exposure to source material, such as not to sweep or use compressed air to clean up ZETTRAL, vacuum cleaning should be used instead. Mr. Kleifelder stated that personnel do not always vacuum clean the presses but use compressed air to remove residual ZETTRAL.

Some additional training has been provided as necessary since June 1995.

Inspection Report No. 999-90001/96-005

__ Mr. Cauffman has worked with a consultant from Penn State University who assisted with the training and air sampling, and who has conducted some radiation surveys in the plant.

No safety issues or violations were identified.

4. Material Inventory In a letter to Region I dated July 14, 1995, Mr. Cauffman stated that the source material contained in raw material on hand at the NARCO, Womelsdorf, PA, site was in excess of the limit specified in Part 40 of the NRC regulations because of a misunderstanding of 10 CFR 40.22. To meet the regulatory requirements and avoid the need for an NRC Source Material License, NARC 0 began to dispose of the material containing the source material to other licensed facilities.

On August 30, 1996, an NRC Region I inspector conducted an inspection at the NARCO plant. The inspector toured the plant, accompanied by NARC 0 personnel, Messrs. Cauffman and Kleinfelder, and observed both baddeleyite and zirconia products staged at various locations throughout the plant.

According to the accounting by Mr. Cauffman, on the day of the inspection the material on site included 28.5 tons of baddeleyite, containing 34 pounds of source material, to be shipped to a licensed facility, and more than 15 tons of zirconia proc'ucts, containing 14 pounds of U and Th, that would be shipped to the licensed facility and to two warehouse locations for storage / staging and distribution to customers.

In a letter dated September 10, 1996, (EXHIBIT B) NARCO submitted to NRC Region I an inventory of baddeleyite and source material as of August 30, 1996.

The letter also contained information on the baddeleyite, and U and Th, shipped to a facility licensed to receive and possess this form of source material, and to warehouses for subsequent distribution to customers. On September 4 and 5,1996, a total of 72114 pounds (36.06 tons) of baddeleyite, containing 34.61 pounds of source material, were shipped to ZIRC0A, Inc., Solon, Ohio, a facility licensed to receive and possess source material. On September 4, 1996, 5.97 tons of baddeleyite finished product (zirconia) containing 5.73 pounds of U and Th were shipped to a warehouse in Birmingham, AL. On September 6,1996, 0.55 tons of zirconia as Nozzle Inserts, containing 0.52 pounds of U and Th, were shipped to Curwensville, PA, for storage and distribution.

Thus, as of September 7,1996, a total of 13.87 pounds of U and Th remained on site at the NARC 0 plant in Womelsdorf, PA.

One non-cited violation was identified, failure to maintain source material within the limit authorized by 10 CFR 44.22(a).

However, the licensee identified the violation and has taken appropriate corrective action. No response to the violation is required.

Inspection Report No. 999-90001/96-005

_ _. _ _ _ _ _ _. _. 5. Independent Measurements During the inspection on August 30, 1996, the inspector conducted radiation i

surveys using a Ludlum Measurements, Inc., Model 19, Micro R Meter (NRC No.

33512, calibrated March 14,1996), throughout the NARC 0 plant. This included many locations at which palletized, 55 gallon drums of baddeleyite and zirconia were staged.

Staged pallets containing stacked I

finished products and packaged products, including bricks, rings, flow gates, nozzles, etc., were also surveyed as well as waste material in the form of " batts" and " furniture". A batt is material that is not usable and is pressed into blocks and fired in the plant kiln or furnace. The furniture is unusable products that are employed as seats and weights for new products during the firing or heating process.

The general background activity level in the plant was determined to be 5 to 10 micro R per hour ( R/hr).

Survey measurements obtained from I

palletized drums of raw material, between stacked pallets at about 4 inches i

from the drum surfaces on either side of the meter, were about 340 R/hr.

Measurements at about 4 to 6 inches from packaged and palletized finished i

products, ready for shipment to warehouses, were 350 R/hr.

This was the highest measurement obtained during the inspection.

Measurements made at 24 inches from the finished products were about 100 R/hr and at 12 inches l

from the palletized drums, were about 160 R/hr.

Measurements made at a i

l meter from various staged baddeleyite and zirconia materials and items were l

between 75 and 125 R/hr.

No residual radiation levels were identified in the vicinity of presses and other machines in which these materials were i

previously used.

No safety issues or violations were identified

6. Exit Interview The inspector conducted an exit interview with the licensee personnel indicated in Section 1 of this report.

The inspector presented his findings stating that the radiation levels encountered did not present a i

significant hazard but, as discussed in the training outline, employees should not inhale or ingest any dust created from the baddeleyite or zirconia. The licensee should reinforce control of the use of compressed air to clean baddeleyite and/or zirconia residues from and about machinery after use.

Mr. Cauffman assured the inspector that the baddeleyite and zirconia shipments would leave the plant for shipment to a licensed facility and to warehouses by September 7, 1996. The licensee committed to submit to-the NRC Region I Staff an inventory of baddeleyite and zirconia on site prior to the shipment on August 30, 1996.

In addition, the licensee agreed to submit an invoice inventory of each shipment of these materials from the plant.

Inspection Report No. 999-90001/96-005

8,s 1

.2 North American Refractories Co.

T[L:(610) 589 2535

  • FAX:4610) Sil9-4772 ADDRESS REPLY TO:

WOMELSDORf PLANT 251 EAST MEMORIAL AVE.

WOML L SDORf, PA 19567-960.1 Ms. Betsy Ullrich September 10,1996 Division of Nuclear Materials Safety Nuclear Regulatory Commission, Region i 475 Allendale Road King of Prussia, PA 19401-1415 RE: Report of Source Material On Hand

Dear Ms. Ullrich:

During his visit, Mr. T. Oberg requested that we send an inventory of Source Material as of August 30,1996 along with a copy of the bi!!s of lading for the material shipped. These two items are enclosed along with the inventory taken on September 6, 1996.

The inventory of 9/6/96 showed that 13.86 pounds were on site. An additional shipment was sent to Curwensville on 9/9/96 reducing the material on hand to 10.43 pounds.

The small press, which Mr. Oberg saw, will be removed and shipped out in the next few weeks as the Nozzle business is being transferred to Zircoa who is licensed.

This plant will temporarily continue to keep the capability to make larger shapes, however the total business is lower volume than the Nozzles and we will stay under the 15 pound limit and the 150 pound yearly limit. A system is being developed to account for the material on hand. This also should be working in a few weeks, at the present time, I am keeping the totalin a cruder form.

Please contact me if you have any comments or questions.

Sin

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M. R. Cauff Mgr. Plant ronmental cc: G. S. Robinson RETURN ORIGINAL TO K. A. Nelson - Curwensville REGION I A Memberofihr thdorr Gnmp EXECUllVE Of rlCES: 300 HALLE BUILDING 1228 EUCLID AVENUE CL EVE LAND, OHK) 44115-1809 (216)621-5200

- ~... -

ZETTRAL INVEt#0RY I

ZETTRAL INVENTORY I 30-AugW TOTAL TOTAL TO_NS TOTAL GREEN fi5ED AMOUTLMRg{ @jQ JSM_ TONS FIRED TO TONS ppm U,Th ppm U,Th S/G PRESS ROOM POUNOS POUNDS PROD BATS SHIP 595 480 1

MATL TO BE PRESSED

  1. U, Th

_D. RUM. S @ 750#.EACH __

6 4500 2.3 2j8 DRUM @ $00# FROM ZlRCOA 12.5 6250A 3.1 3.72 BLUE DRUMS @ 250 # EA 14 35004 1.8 2.08 PALLETS PRESSED NOZZLES

~525pCS X 2.25 # EiACH 0

0A 0.0 0.00 COOKIES, PRESSED. 3#

882 264.6 0.1 0.16 GREEN.. BATS IN BAGS PRESSED BATS, DRUM 0

0.0 0.0 0.00 TOTAL 7.3 8.64

{

KILN AREA DRUMS OF GREEN 0-0 00 0.00 0.00 DRUMS TO BE SET 0.3 210 0.1 0.11 0.12 GREEN RINGS 124 458.8 0.2 0.23 0.27 COOKIES, BOX @ 270 PER BOX 2

162.0 0.1 0.10

~

TOTAL GREEN 9.13 i

CATlilAREA DRUMS BURNED BATS - 1100#

14 15400 7.7 7.70 7.39 FIRED RINGS 177 938.1 0.5 0.47 0.45

~ FIRED S/G's, 9.5#,PCS i

PALLET = 4 X 10 X 10 His400 0

0 0

0.00

. BOXES, PIECES @ 2.25# en 1716 3432 1.7 1.7 1.72 1,65 i

FIRED BRICK 18 12600 6.3 6.30 6.05

[PRODUCTg 2.25# es 0.0 0.0 0.0 0.00 0.00

^

FIRED BRICK 30918 30918A 15 5 1546 14.84 l

~5500UCT, NOZZ,1.08 0.0 0,0 0.0 0.00 0.00 i

KILN DEPT FIRED COOKlES - 1100*/DM 0

0 0.0 0.00 0.00 i

RINGS FIRED 0

0 0.0 0.00 0.00

\\

DRUMS FIRED 0

0 0.0 0.00 0.00 l

l

. CASING AREA j

FIRED NOZZLE & INSERTS 3.05*

3'14'11 0

0 00 0.0!

0.00 0.00 j,

1 i

Page1 A

+

. -.... ~ - - -...... ~ _ -. _... _ _.. _.

ZETTRAL INVENTORY ZETTRAL INVENTORY 30Aug46 FIRED TOTAL TOTAL TONS TOTAL GREEN AMOUNT GREEN FIRED TONS TONS FIRED TO TONS ppm U,Th ppm U,Th i

SIG PRESS ROOM POUNDS POUNDS PROD BATS SHIP 595 480 65 PCS 0

0.0 0.0 00 0.00 0.00 16 BOX _@ 12 EA Oi 0.0 0.0 0.0 0.00 0.00

__400 PCS_ PALLETS, STOCK 0

0.0 0.0 0.0 0.00 0.00 26 BOX g 12 RETURN O

0.0 0.0 0.0 0.00 0.00 OUTER SHE_LLS, 2.47# Z-65 11*14*7.5 Hi 0

0.0 0.0 0.0 0.00 0.00

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BOXFIR$D B TQ2f00 0

_0 00 0100 0,00 5 MALL NOZZUES INSERTS 1289 747.62 0.4 0.4 0.37 0.36 i

RAW M5' ERIALS T

GROUND BATS FOR USE 7150 3.6 3.00 3 43 SWPING AREA

{

DWUMS, FIRED

-4 4400 0.0 2.2 2.20 2.11

~

1 FNSHED GOODS PALLET 2Y 19400 0.0 9.7 9.70 9.31 TdTAL. POUNDS 58863.4 27667.7 31.5 21.1 35.4 54.72 TOTAL. TONS

~294 13 8 OT0i 0.0 43.3 Page 2

ZETTR AL SHIPMENTS SHIPMENTS TO PLANTS - Zt:i i K AL j

T6TAL TOTAL TONS TOTAL GREEN FIRED AMOUNf U_RER. EEER I_QNji TONS PlEED TC TONS ppm U.Th ppm U,Th POUNDS POUNDS PROD BATS SHIP 595 480 g

SHIPPING MANIFESTS CURWENSVILLE A6ZZLE INSERTS & J-65,9/5/96-~

1885 1093.3 0.5' O.55 0.52 ZiRCOA ETTRAL SCIf P,9/4/96 43173 43173 21.6 21.59 20.72 ZETTRAL SCRAP,915/97 28941 28941 14.5 14.47 13.89

~

BI55ilNGHAM WHSE FIMSHED PRODUCT. 9/4/96

'11943}

i 11943 6.01 5.97 5.73

.-... -.. -.- -. - - ~ ~ - - -

-_. - ~

ZETTRAL INVEffrORY 9/6/96 INVENTORY 9NW96 NOON ZETTRAL INVENTORY 9MM TOTAL fOTAL TONS TOTAL GREEN FIRED AMO_UNT_ _GREg_F TR}_ TONS FIRED TO TONS ppm U,Th ppm u,Th M

POUNDS POUNDS PROD BATS SHIP 595 480 CAT lil BURNED f6IGS 177 918 0.44

_ BURNED NOZZLES 882 2205 1.0S BURNED STUMPS 1716 3432 1.65 FINISHED GOODS NOZZLE,600 600 330 0.16 CAT ll ZlRCOA, DRUMS 8

4000 2.38 0.00 GREY DRUMS, 3.75 2812.5 1,67 BLUE DRUMS 11 2750 1,64

~

d'ASING. INSERTS 0

i SHIPPING 1

DRUM,-48M 1500 1500 0.72

]

BAGS,14MXD 113 5650 2.71 1

li!Lti.ABE8 GREEN NOZZLES 391.44 782.88 0.47

_ GREEN NOZZLES 96 192 0.11 GREEN RINGS 116 754 0.45 COOICES 540 162 0.10 BATS GREEN, DRUM 0.25 250 0.15 1

BURNED COOKIES, BOX,270 4

324 0.16 i

TOTALS 6.96 6.89 GRAND TOTAL 1386

North American R fractories Co.

04WOrcE3 WWOICE3 CUSTOpG BEL Of TERRf10fua 4 N,-ber of the nac, crw, cleveland. ohio 44t ts-i809 moppgg retDas DATE OF SHIPRENT

  1. 0R 5)ELNE!tY 6AreFE69 f0VNSEst WOMELSDORF 09/05/96 ASAP 20-4786 on, emiri a o nar*

REMARKS:

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ADDRESS SOLON, OH 44139 C

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ZETTRAL BATS 25 28,921 7-36"X48" DF PALLETS @77f EA.

539 25 29,460 B/L NO. APPLYING ON ABOVE:

960020-09-035 i

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8H!PPING MANIFEST North Americao R1fracton=es Ca*

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20-4781 REMARKS:

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solo To ZIRCOA. INC.

cun 31501 SOLON ROAD, DOCK #1 "fde'*'5""

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in mten ADDRESS SOLON. OH 44139 C

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960020-09-016 i

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SHIPPING MANIFEST N:rth American Refract: ries Co.

aeveland* ofu*oT4/15-1809 A Member of ne Diner Group 9

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WOMELSDORF 09/04/96

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WOMELSDORF REMARKS:

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NUMBE, OYeTa. NO.

EntFPED pgges WEDGHT FIECE S* EQlW-RELEASE #:

CUST. REQ #:

BOL S:

THRut 01280010 01.00.01-050174-0020-0020 NONE 900 1620 ZETTRAL 95S NOZZLE MODEL 56098 15.5MM BORE AMERICAN STEEL BALDWIN 273733 - LINES 2, 3 & 4 36" X 48" - DOUBLE FACE 3

231 01200010 32.00.01-053229-0020-0020 NONE 2060 3996 ZETTRAL 95S NOZZLE MODEL 56098 15.1MM BORE AMERICAN STEEL BALDWIN 262226 LINES 4, 5,,6, 7&8 36" X 48" - DOUBLE FACE 5

385 01280010 03.00.01-053552-0020-0020 NONE 800 1448 ZETTRAL 95S NOZZLE MODEL 5748 16.5MM BORE AMERICAN STEEL CHARLOTTE 269636 LINE 7 PACKAGED 1 @ 300 / 1 6 500 36" X 48" - DOUBLE FACE 2

154 01280010 04.00.01-073518-0020-0020 NONE 180 360 ZETTRAL 95S NOZZLE MODEL 5748 /16.7mm AMERICAN STEEL CHARLOTTE

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RELEASE 4:

CUST. REQ #:

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77 01280010 05.00.01-090007-0020-0020 NONE 1200 1992 ZETTRAL 95S NOZZLE MODEL 56098 14.5fiti BORE (.571")

AMERICAN STEEL BALDWIN 267047 LINES 2, 3, 4&5 t

3s" X 48" - DOUBLE FACE 4

388 01280010 06.00.01-060949-0020-0020 NONE 500 945 ZETTRAL 95S NOZZLE F10 DEL 5748 15.BMN t.625) BORE hMERICAN STEEL CHART!.OTTE 269636 LINE 5 36" X 48" - DOUBLE FACE 1

77 01280010 07.00.01-060948-0020-0020 NONE 500 945 ZETTRAL 95S NOZZLE MODEL 5748.15.5tT1 (.610 ) BORE AMERICAN STEEL CHARLOTTE 269636 LIN31 & 2-36'~ X 48" - DOUBLE FACE 2

154 01280010 08.00.01-049734-0020-0020 NONE 360 637 ZETTRAL 95S NOZZLE

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REMARKS:

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MODEL 5748 14.0MH C.55")

AMERICAN STEEL KNOXVILLE 258675 LINE 1 36" X 48" - DOUBLE FACE 1

77 NOTES:

TOTAL 9 IN EQUtU:

.0 TOTAL QTY:

6500 TD4S:

5.97 L TOTAL PALLET WT. (LB):

1463 TOT M_ TARE WT.

(LB):

0 B/L NO. APPLYING,0N ABOVE:

960020-09-0)Sg 0\\q h

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SHIPPING MANIFEST North American Refractrries Co.

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RELEASE 4:

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D1200170 D1.00.01-050069-0020-0020 NONE 536 1592 JUSTAL 65S/95S TUNDISH NOZZLE t

93-039/15.0 NETER NOZZLE ASSY CONSISTS OF ITEN 536 050063 NONE 1.00 536.00 ZETTRAL 65S TutOISH NOZZLE i

93-039-1 ZIRCON OUTER SHELL CONSISTS OF ITEN 536 050066 NONE 1.00 536.00 ZETTRAL 95S NOZZLE 93-039-2/15.0 INSERT 36" X 48" - DOUBLE FACE 2

154 01280170

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~

36" X 48" - DCUBLE FACE 1

77 01280170 U3.00.01-069696-0020-0020 NOME 124 64 ZETTRAL 95S NOZZLE-93-039-2/17.5 INSERT 01280170 04.00.01-068030-0020-0020 NONE 97 52 ZETTRAL 95S NOZZLE 93-039-2/16.5 INSERT 01280170 35.00.01-050068-0020-0020 NONE 927 2707 JUSTAL 65S/95S TUNDISH NOZZLE 93-039/14.5 NETER NOZZLE ASSY 1

blPhND MANIFEST PAGE 2 5'ects imma:

cus s es eat w met -

ruome Ndrth American Refractories C,o.-

Cleveland, Ohio 44115-1809 A Member of The Didier Group GG sa.ene rnou an:E OF 3HiPMmT FOR DEtJYERY

. ANFE;.;T 8etiMBFA 0020070543ST WOMELSDDRF 09/06/96 ASAP

oar, WOMELSDORF REMARKS:

'"'",7 W

" " " " * ^ ' ^

,ous NORTH AMERICAN REFRACTORIES'CO SOLD TO c,..

NTr,. -u y mgraare.cnon ewinono m a.r-wi ADDRESS WOMELSOORF PA 19967-0038 PM t.E l GATES FRklGlHTRATE CURWENSUILLE CONStGNED TO 440RTH MERICM REENACTORIE9 CO ROUTE 079 DESTINATION _gg; gg pg 6633 em Es VIA Ward Truckina Corp.

CAR No.

O O-CU$1 R1 Oua CUR MECES HI TUTAL Ng-TOTAL BtfG.NO.

SHIPPED MECE InfEIGHT PIEEE 9" EDUlv.

Nuusul MUMBER RELEASE #:

CUST. REQ 9:

BOLS:

THRU:

CONSISTS OF ITEt1 927 050063 NONE 1.00 927.00 ZETTRAL 65S TUNDISH NOZZLE 93-039-1 ZlRCON OUTER SHELL CONSISTS OF ITEM 927 050064 NONE 1.00 927.00 ZETTRAL 95S NOZZLE 93-039-2/14.9 INSERT 36" X 49" - DOUBLE' FACE 1

77 NOTES:

TOTAL 9 IN EQUIU:

2926.0 TOTAL QTY:

1885 TO 4S:

2.261 TOTAL PALLET WT. (LB):

308 TOT 4L TA7E WT.

CLB):

0 B/L NO. APPLYING ON ABOVE:

960020-09-042

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